Easi Pacer 00100-Up MM Pdmm-0089b

Maintenance Manual
EASi Pacer™ Lift Truck
Model Serial No.

R30, R35, R40, R50 00100 and Up
PDMM-0089 Issued: 6/24/02

PDMM-0089B Revised: 5/3/04
This publication, PDMM-0089B, applies to the EASi Pacer™, Models R30, R35, R40, R50, S/N 00100 and up,
and to all subsequent releases of this product until otherwise indicated in new editions or bulletins. Changes
occur periodically to the information in this publication.
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.
© 2004 The Raymond Corporation.

The following terms are trademarks of The Raymond Corporation: EASi, intellidrive, Maintenance Minder,
Raymond, Pacer, and SMARTi. All other brand and product names are trademarks or registered trademarks of
their respective companies.
EASi Pacer™ Lift Truck Maintenance Manual
Table of Contents
Table of Contents
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Abbreviations & Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Minder™ Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Operator’s Daily Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Initial 90 Day Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Every 180 Days or 500 Deadman Hours (HD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Every 360 Days or 1500 Deadman Hours (HD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Motor Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Shorts to Frame Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
CAN Bus Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Electrical Connector Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Symptom Tables: Electrical Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
PDMM-0089 Issued: 6/24/02 iii

Table of Contents
Messages, Codes and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Messages, Codes and Tests Summary List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Message and Code Summary Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Power Amplifier LED Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Analog Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Digital Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Digital Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-115
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Navigation Instructions for the Pin-Out Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Pin-Out Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
Travel Circuit Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
PC Loader Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Component Specific Torque/Information Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Torque Chart - Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Decimal Equivalent Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20
Attachment Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
iv PDMM-0089 Issued: 6/24/02

Page Revision Record

0:
This page is a record of the revision of all pages in this manual. Whenever a page is revised, this
section is updated and included in the revision.
This manual supersedes EASi Pacer™ Maintenance Manual PDMM-0068.
• PDMM-0089 Original Issue Date - 6/24/02
• PDMM-0089B Revision Date - 5/3/04
Page Revised
Cover ......................... 5/3/04
iii ............................. 6/24/02
iv ............................. 6/24/02
v ................................ 5/3/04
vi ............................. 6/24/02
1-1 thru 1-6 ............. 6/24/02
2-1 thru 2-18 ........... 6/24/02
3-1 thru 3-18 ........... 6/24/02
4-1 thru 4-8 ............. 6/24/02
4-9 ............................. 5/3/04
4-10 thru 4-14 ......... 6/24/02
5-1 thru 5-9 ............. 6/24/02
5-10 ........................... 5/3/04
5-11 thru 5-34 ......... 6/24/02
6-1 thru 6-77 ........... 6/24/02
6-78 ........................... 5/3/04
6-79 thru 6-81 ......... 6/24/02
6-82 ........................... 5/3/04
6-83 thru 6-135 ....... 6/24/02
6-136 ......................... 5/3/04
6-137 thru 6-140 ..... 6/24/02
7-1 thru 7-30 ........... 6/24/02
7-31 ........................... 5/3/04
7-32 thru 7-41 ......... 6/24/02
7-42 ........................... 5/3/04
7-43 ......................... 6/24/02
7-44 ........................... 5/3/04
7-45 ........................... 5/3/04
7-46 thru 7-100 ....... 6/24/02
8-1 thru 8-74 ........... 6/24/02
9-1 thru 9-16 ........... 6/24/02
A-1 thru A-3............. 6/24/02
A-4............................. 5/3/04
A-5 thru A-14........... 6/24/02
A-15........................... 5/3/04
A-16 thru A-30......... 6/24/02
I-1 thru I-6............... 6/24/02
PDMM-0089 Issued: 6/24/02 Revised: 5/3/04 v

vi PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual How to Use This Manual
How to Use This Manual 1:
PDMM-0089 Issued: 6/24/02 1-1

How to Use This Manual EASi Pacer™ Lift Truck Maintenance Manual
Map of the Manual
Map of the Manual
Table of
Contents Page Revision Record
How To Use This

Manual Map of the Manual
Manual Design
Safety
Abbreviations and
Systems Symbols
Overview Vehicle Specifications
Scheduled
Maintenance
Troubleshooting
Messages, Codes
And Tests
Go to Chart
MAP2
1-2 PDMM-0089 Issued: 6/24/02

Map of the Manual
MAP2: Map of the Manual (Continued)
Component Alphabetical List of

Procedures Component
Procedures
Component Location
Theory of Photos
Operation
PC Loader
Program
Appendix Lubrication
Equivalency Chart
Torque Charts
Index
Decimal Equivalent
Chart
Standard/Metric
Conversions
Electrical and
Hydraulic Schematics
PDMM-0089 Issued: 6/24/02 1-3

Manual Design
Manual Design
This manual is designed with the following • Component Procedures gives step-by-step
objectives in mind: procedures for testing, removal,
installation, and adjustment of individual
• Provide technical coverage for expected
truck components. Components are
levels of user expertise.
grouped by truck system.
• Anticipate your needs and reduce your
decisions regarding maintenance. To find a component procedure, you may
use one of three methods:
• Reduce page flipping through a “one-stop
shopping” approach. • Look up the component name in the
List of Component Procedures.
The two-line running page header at the top of
each page tells you: • Find the component in the Component
Locator Photos.
• Name of the manual
• Look up the component name in the
(EASi Pacer™ Lift Truck Maintenance
maintenance manual Index.
Manual)
• Theory of Operation contains a detailed
• Current Chapter Title
connection point table (Pin-Out Matrix)
(for example, this page; How to Use This
designed to assist in testing and
Manual)
troubleshooting the truck. This chapter
• Current topic also explains signal flow within the
(for example, this page; Manual Design) hydraulic and electrical schematics for
This manual consists of the following sections: various conditions of lift truck operation.
• Appendix contains reference information
• How to Use This Manual explains the
such as torque values, lubricants,
manual format and design as well as
standard/metric conversions, and electrical
abbreviations and symbols used.
and hydraulic schematics.
• Safety explains warning and caution notes,
• PC Loader Program contains information
general safety rules and safety rules for
on how to update software, set factory
batteries, static, jacking, and welding.
defaults, and configure options on your
• Systems Overview includes lift truck EASi Pacer™ Lift Truck.
specifications and theory of operation
• Index lists subjects alphabetically.
information.
• Scheduled Maintenance outlines the
recommended schedule of preventive
services to keep your lift truck working
most efficiently.
• Troubleshooting is designed to take you
from a symptom to a specific sequence of
tests in order to isolate a failing component.
• Messages, Codes, and Tests lists the
electrical fault codes and procedures for
running firmware electrical tests.
1-4 PDMM-0089 Issued: 6/24/02

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

A ampere gm gram
approx approximately Gnd ground
amp ampere or amplifier
Attach. Card Attachment Card HD hours on deadman
aux auxiliary Ht height
AWG American Wire Gauge in. inch, inches
ITA International Truck
BSOC battery state-of-charge Association
BWI Brush Wear Indicator
kg kilogram(s)
CAN Controller Area Network km/h kilometers per hour
CCW counterclockwise kPa kilo Pascal
CFP Contactor Fuse Panel
cm centimeter LA Left Traction Power Amplifier
COP Computer Operating lb pound, pounds
Program LED Light Emitting Diode
CW clockwise LPC Lift Power Control
C/S cold storage
mA milliampere
Dgnd digital ground max maximum
DTIC Dealer/Technician min minute or minimum
intellidrive® Control System mm millimeter
Configuration Program MM Maintenance Minder™
DVM Digital Volt Meter mph miles per hour
MS steer motor
EASi Ergonomically Advanced
System with intellidrive®
No. number
EE UL Electric Truck Type
NV non-volatile
Certification Rating where
electrical equipment is N•m newton meter
completely enclosed
EPO Emergency Power Off OACH Overall Collapsed Height
EPROM Erasable Programmable Read OD Operator Display
Only Memory ODC Operator Display Card
ESD Electrostatic Discharge ODI Operator Display Interface
OSHA Occupational Safety and
ft foot Health Association
oz ounce
gal gallon or gallons
PDMM-0089 Issued: 6/24/02 1-5

Abbreviations & Symbols
Term/Symbol Definition Term/Symbol Definition

PA Lift Power Amplifier °F degrees Fahrenheit
PC personal computer °C degrees Centigrade
PCR Pacer™ < less than
pot potentiometer > greater than
psi pounds per square inch % percent
PWM pulse width modulation = equals
P/N part number
qt. quart or quarts
RA Right Traction Power

Amplifier
RAM random access memory
ref reference
ROM read only memory
Regen regenerative braking
SAE Society of Automotive

Engineers
SG specific gravity
SOL solenoid
spec specification
STR Steer Contactor
TPC Traction Power Control
UL Underwriter’s Laboratories
V volt
VDC volts direct current
VM Vehicle Manager
wrt with respect to

w/ with
w/o without
@ at
™ trademark
© copyright
® registered
+ plus or positive
– minus or negative
± plus or minus
° degrees
1-6 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual Safety
Safety 2:
PDMM-0089 Issued: 6/24/02 2-1

Safety EASi Pacer™ Lift Truck Maintenance Manual
Definitions
Definitions
Throughout this manual, you will see two kinds

of safety reminders:
! WARNING
A Warning indicates a potentially
hazardous situation that, if not
avoided, could result in serious
bodily injury or death.
! CAUTION
A Caution indicates a potentially
hazardous situation that, if not
avoided, could result in minor or
moderate bodily injury or damage to
the lift truck or nearby objects. It also
can be used to alert personnel
against unsafe practices.
2-2 PDMM-0089 Issued: 6/24/02

General Safety
General Safety
Do NOT attempt to operate this lift truck until

you have been trained to do so, and until you
have thoroughly studied the Owner/Operator
Manual.
28B15004D.EPS
Know the truck’s controls and what they do.

?
27J27009S.EPS
Do NOT operate this truck if it needs repair or if

it is in any way unsafe.
27J27010S.EPS
PDMM-0089 Issued: 6/24/02 2-3

General Safety
Operate this truck only from the operator’s

position.
27J27011S.EPS
Before working on this truck, always turn the

key switch to OFF and disconnect the truck’s
battery connector (unless this manual tells you
otherwise).
27J27012S.EPS
Do NOT wear watches, rings, or jewelry when

working on the truck.
2JEWELRY.EPS
Follow the scheduled lubrication, maintenance,

and inspection steps.
2SCHEDMNT.EPS
2-4 PDMM-0089 Issued: 6/24/02

General Safety
Follow the safety and repair instructions exactly

as they are written in this manual. Do NOT take
“shortcuts.”
28B15008D.EPS
Do NOT use an open flame near the truck.
27J27013S.EPS
Do NOT use gasoline or other flammable liquids

for cleaning parts.
22823 008.eps
Clean up any hydraulic fluid, oil, or grease that

has leaked or spilled on the floor.
2SPILLS.EPS
PDMM-0089 Issued: 6/24/02 2-5

General Safety
.
Use and park this truck indoors. Do NOT

operate outdoors (except for dock or ramp
operation, if permitted).
27J27014S.EPS
Do NOT wash this truck with a hose. Do NOT

steam clean inside compartments.
22823 008.eps
Do NOT add to or modify this truck without

written approval from The Raymond
Corporation.
27J27015S.EPS
2-6 PDMM-0089 Issued: 6/24/02

Battery Safety
Battery Safety
Before working on or near a battery,

review the general safety rules.
Always follow these safety rules.
See the battery manufacturer’s
instruction manual for specific
instructions on battery maintenance.
The instructions found there take
precedence over the instructions
found in this truck manual.
Size and Type

When you install a battery in this truck, make
sure that it is the correct size and voltage.
! WARNING
DO NOT install a battery that weighs
less than the recommended minimum
weight. This could affect the truck’s
stability.
This illustration (Figure 2-1) of the truck’s

specification plate gives you important 4
information about the battery used in this
truck. 1
The following list explains the numbered items 7
in the figure: 5
6
1. Battery size (in inches) 2
2. Maximum allowable weight of the battery 3
(in pounds)
3. Minimum allowable weight of the battery (in
pounds)
4. Truck voltage
5. Maximum rating of the battery (in
amp-hours)
6. Truck weight without a battery
7. Truck weight with a maximum weight
battery 2412-645.eps
Figure 2-1: Typical Truck Specification Plate
PDMM-0089 Issued: 6/24/02 2-7

Size and Type
! 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. Make sure there are
no open flames or sparks in the
charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
! CAUTION
Battery electrolyte is a solution of
sulfuric acid and water. Battery acid
causes burns. Should any electrolyte
come in contact with your clothing or
skin, flush the area immediately with
cold water. Should the solution get
on your face or in your eyes, flush
the area with cold water and get
medical help immediately.
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
2-8 PDMM-0089 Issued: 6/24/02

Size and Type
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
Disconnect the battery from the truck at the

battery connector, after turning the key switch
OFF. Do NOT break live circuits at the battery
terminals. A spark often occurs at the point
where a live circuit is broken.
27J27012S.EPS
PDMM-0089 Issued: 6/24/02 2-9

Size and Type
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.
Keep plugs, terminals, cables, and receptacles

in good condition to avoid shorts and sparks.
28D14127S.TIF
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 certain that the vent holes in the filler
plugs are open to allow the gas to escape from
the cells.
209G6S047.TIF
2-10 PDMM-0089 Issued: 6/24/02

Size and Type
Do NOT allow cleaning solution, dirt, or any

foreign matter to enter the cells.
Make sure the battery you are installing is the

correct size. A smaller or lighter weight battery
can seriously affect truck stability. See the
truck’s specification plate for more information.
27J27016S.EPS
NEVER plug a battery charger into the truck’s

battery connector. Plug the battery charger only
into the battery connector from the battery.
27J27017S.EPS
Follow the charging procedures in the Battery

Instruction Manual and in the Battery Charger
Instruction Manual.
225L6S014.EPS
PDMM-0089 Issued: 6/24/02 2-11

Static Precautions
Static Precautions
Electronic circuit boards and devices used on
the EASi Pacer™ Lift Truck can be damaged by
the discharge of static electricity, called
electrostatic discharge (ESD).
Static charges can accumulate from normal
operation of the lift truck as well as movement
or contact between non-conductive materials
such as plastic bags, synthetic clothing,
synthetic soles on shoes, and styrofoam coffee
cups.
Accumulated static can be discharged through
human skin to a circuit board or component by
touching the parts. Static discharge is also
possible through the air, when a charged object
is placed close to another surface at a different
electrical potential. Static discharge can occur
without seeing or feeling it.
Whenever working on or near static-sensitive
electronics, always follow these ESD
precautions:
1. Wear an ESD wrist strap.
2. Connect the ground plug to the ESD
ground jack on the lift truck. The ESD
ground jack is located on the tractor frame
near the steer tiller. If you cannot use the
ground jack, connect the ground clamp to
an unpainted, grounded surface on the lift
truck frame.
28D14130S.TIF
3. Handle circuit boards by the edges only. Figure 2-2: ESD Wrist Strap and Ground Jack
Avoid touching the edge connectors.
4. If you will be removing or installing
static-sensitive components, place them on
a properly grounded antistatic mat.
5. To transport static sensitive components,
including failed components being
returned, place the components in an
antistatic bag or box (available from your
local authorized Raymond Dealer).
The wrist strap and associated accessories
should be tested monthly to verify they are
working properly.
2-12 PDMM-0089 Issued: 6/24/02

Static Precautions
2MAT2.TIF
Figure 2-3: Anti-Static Kit (P/N 1-187-059) with Wrist Strap and Mat
Figure 2-3 shows the components of the

Raymond antistatic field service kit
(P/N 1-187-059). The kit includes a wrist strap,
ground cord, and static-dissipative work
surface (mat). Follow the instructions packaged
with the 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.
Contact your local authorized Raymond Dealer
for information.
PDMM-0089 Issued: 6/24/02 2-13

Jacking Safety
Jacking Safety
Sometimes you may need to jack the truck off
the floor to perform maintenance procedures.
When doing so, observe the proper safety
precautions.
1. Lower the carriage and forks completely to
the floor. Remove any load.
2. Place all controls in neutral.
3. Block the wheels to prevent movement of
the vehicle.
4. Turn the key switch OFF and disconnect
the battery connector.
5. Place the jack under the designated jacking
points. See Figures 2-4 and 2-5.
! WARNING
Use extreme care whenever the
truck is jacked up. Never block the
truck between the telescopic and the
floor. Keep hands and feet clear from 28D14044S.TIF
vehicle while jacking the truck. After Figure 2-4: Jacking Drive Wheel
the truck is jacked, place solid blocks
beneath it to support it. DO NOT rely
on the jack alone to support the
truck.
6. To jack the drive wheel: Place the jack in

the designated jacking position. See
Figure 2-4. Jack the truck up just high
enough to raise the drive wheel off the floor.
Place a block under the frame as shown.
7. To jack the tractor: Place the jack in the
designated jacking position near the
steerable wheel. See Figure 2-5. Jack the
truck so that the steerable wheel is off the
floor no more than 1 in. (25 mm). Block
under the frame as shown.
NOTE: After working on vehicle, test all controls
and functions to assure proper
operation. 28D14047S.TIF
Figure 2-5: Jacking Tractor
2-14 PDMM-0089 Issued: 6/24/02

Towing
Towing
To safely tow an EASi Pacer™ Lift Truck:
1. Lower the carriage and remove any load
from the forks.
3. Install the brake release bolts.
4. Using a suitable towing vehicle, lift the
truck until the steer tire is no more than
1 in. (25 mm) off the floor.
5. Tow the truck slowly in the tractor-first
direction.
! WARNING
When towing is complete, remove
the brake release bolts. Failure to do
so can cause serious injury.
PDMM-0089 Issued: 6/24/02 2-15

Welding Safety
Welding Safety
! CAUTION
Flame cutting or welding on painted
surfaces can produce potentially
harmful fumes, smoke, and vapors.
Before performing a flame cutting or
welding operation, remove the paint
from the area where the work will
be performed. Removal can be by
mechanical or chemical methods, or
a combination of both.
Flame cutting and/or welding

operations should be carried out
only in well ventilated areas using
local exhaust if necessary.
Before working on this truck, make sure that:

• Fire protection equipment is nearby.
• You know where the nearest eyewash
station is.
204G6S059.EPS
! CAUTION
Disconnect the battery before you
attempt to inspect, service, or repair
the lift truck.
• Check for shorts to frame as described on

page 5-6. If any shorts are detected, remove
them before you proceed with the welding 27j27012.eps
operation.
• Clean the area to be welded.
• Remove the Vehicle Manager, lift power
amplifier, and traction power amplifiers
from the lift truck.
• Protect all truck components from heat,
weld spatter, and debris.
2-16 PDMM-0089 Issued: 6/24/02

Welding Safety
• Attach the ground cable as close to the weld

area as possible.
• Do not perform any welding operations
near the electrical components.
• If welding must be done near the battery
compartment, remove the battery from the
lift truck.
PDMM-0089 Issued: 6/24/02 2-17

Welding Safety
2-18 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual Systems Overview
Systems Overview 3:
PDMM-0089 Issued: 6/24/02 3-1

Systems Overview EASi Pacer™ Lift Truck Maintenance Manual
Lift Truck Specifications
Lift Truck Specifications
Specification Plate
This lift truck is rated for performance by load
center and load weight. Review the specification
plate, located in the battery compartment, for
detailed load capacity and load center
information. See Figure 3-1.
Due to continuous product enhancement,
specifications are subject to change without
notice or obligation.
Serial number
Nominal battery
voltage
Raymond model designation

Power rating
of battery
Approximate weight
of lift truck with
Maximum battery
maximum battery
weight for this lift
installed, minus load
truck
and operator
Minimum battery
Approximate weight
weight for this
of lift truck minus
lift truck
battery, load, and
operator
Battery weight must
be between the
Maximum load
minimum and
capacity for this lift
maximum weight
truck
3412-645.wmf
Figure 3-1: Lift Truck Specification Plate
See Table 3-1 for lift truck specifications.
3-2 PDMM-0089 Issued: 6/24/02

Specification Plate
Table 3-1: Lift Truck Specifications

Model
Category
R30 R35 R40 R50
Max Load @ 24 in.

3,000 3,500 4,000 5,000
(610 mm) Ld Ctr
(1362 (1590) (1816) (2268)
lbs (kg)
Overall Collapsed Ht* 83 - 107 83 - 107 83 - 107 83 - 107

(OACH) in. (mm) (2108 - 2718) (2108 - 2718) (2108 - 2718) (2108 - 2718)
Elevated Ht* 127 - 251 127 - 258 188 - 258 188 - 251
in. (mm) (3226 - 6375) (3226 - 6553) (4775 - 6553) (4775 - 6375)
Extended Ht
175 - 299 175 - 306 236 - 306 236 - 299
w/Load Backrest*
(4445 - 7594) (4446 - 7772) (5994 - 7772) (5994 - 7594)
in. (mm)
Wheelbase 50.4 50.4 53.1 55.6

in. (mm) (1280) (1280) (1349) (1412)
Head Length
68.5 68.5 71.2 73.7
w/o Sideshift*
(1740) (1740) (1808) (1872)
in. (mm)
Head Length
70.9 70.9 73.6 76.1
w/Sideshift*
(1801) (1801) (1869) (1933)
in. (mm)
Battery Compartment 38.5x18.5x32.3 38.5x18.5x32.3 38.5x21.25x32.3 38.5x23.75x32.3

in. (mm) (978x470x820) (978x470x820) (978x540x820) (978x603x820)
Battery Voltage 36V
Min Battery Weight 2,000 2,300 2,600 2,700

lbs (kg) (908) (1044) (1180) (1226)
Max Battery Weight 2,600 2,600 2,900 3,250

lbs (kg) (1180) (1180) (1317) (1475)
Lift Truck Wt 6,190 6,190 6,200 6,900

w/o Battery lbs (kg) (2808) (2808) (2815) (3133)
*
Specifications will vary according to mast type
PDMM-0089 Issued: 6/24/02 3-3

Modes of Operation
Modes of Operation
There are several different modes of operation
for this truck. The main distinction is between
Run, Configure and Maintenance Modes. Run
Mode is the normal working mode for the truck.
The Configure Mode allows you to enter the
truck’s software and change parameters. The
Maintenance Mode allows you to access Learn
Mode and the various tests for troubleshooting.
Run Mode
When the truck is powered ON normally, the
onboard firmware performs a number of
internal selftests and enters the default mode of
operation, Run Mode. Run Mode is the normal
working mode.
Run Mode is also entered when the truck exits
Program Mode.
Configure Mode
Configure Mode is used to adjust various truck
performance parameters to specific customer
requirements.
See Table 3-2 for Configure Mode menu items
that can be changed and the selections that are
available.
Maintenance Mode
Maintenance Mode is used to test, cycle, and
troubleshoot functions on the truck.
Maintenance Mode is divided into two
categories; Static and Active. See Table 3-5 for
Maintenance Mode menu.
Static Maintenance Mode

This mode allows one function to be tested at a
time while in Maintenance Mode.
Active Maintenance Mode

This mode allows all input and analog tests to
be active in Run Mode. Enter Maintenance
Mode to select the tests to be active. Press the
up/down buttons on the operator display to
toggle between the selected tests.
3-4 PDMM-0089 Issued: 6/24/02

Passwords
! WARNING
Before placing the lift truck in
Maintenance Mode:
1. Jack the lift truck so that the drive

tires are off the floor.
2. Make sure the controls are in
neutral.
3. Make sure the lift truck is blocked
to keep it from moving.
4. Lower the forks all the way to the
floor.
To enter Maintenance Mode, you must enter the
maintenance password. See “Entering a
Password” on page 3-6.
Learn Mode
Learn mode for the lift and travel pots is
selected automatically when Maintenance Mode
is entered.
If the potentiometer value differs from the last
learned value, the display will prompt you to
return the control to neutral. Then, follow the
display instructions to learn the new neutral
value. If the VM, handle, or firmware is
changed, this will have to be done.
Passwords
Electronic Operator Key
Electronic Operator Key is a configurable
software feature which permits the customer to
establish an operator electronic key (password).
When the key switch is turned ON, the operator
is prompted to enter the electronic key
(password). The truck will not enter Run Mode
unless the proper electronic key is entered.
PDMM-0089 Issued: 6/24/02 3-5

Password
Password
Two levels of passwords can be used on this
truck; Configuration and Maintenance.
Configuration Password
The Configuration Password allows you to enter
Configure Mode. This is intended for customer
use in setting performance parameters within
those features purchased with the truck.
Maintenance Password
The Maintenance Password allows you enter the
Maintenance Mode. This is intended to be used
by qualified service technicians only.
It is strongly recommended that the
Maintenance Password be changed during
installation from the factory. This is to ensure
that access to Maintenance Mode is restricted
to qualified personnel. If the password is lost,
changed and/or forgotten, an authorized
Raymond dealer representative is required to
reset it to the original factory password. In this
case, all settings are reset to the factory default
parameters. Consequently, all variable settings
will require reconfiguration. Configuration
settings should be documented before a reset is
performed.
Entering a Password
1. The Operator Display (OD) will show Ray40
(or similar message depending on the truck
model).
NOTE: Press the ENTER key to access
Maintenance or Configure Mode after an
error code is displayed.
2. Press the ENTER key. The OD will show an
eight character field of underscores.
3. Enter the password as follows:
NOTE: The default Maintenance Password is
“_2_ _ _”. The default Configuration
Password is “1 _ _ _ _”.
3-6 PDMM-0089 Issued: 6/24/02

Entering a Password
To illustrate this procedure, assume you

are entering the default Maintenance
Password (“_2_ _ _”). Look at the OD. The
flashing underscore is the active character
position. To move the active character
position to the right, press the ENTER key.
To move the active character position to the
left, hold down the ENTER key and press
the DOWN button.
When the character position you want to
change is active, stop pressing the button.
4. Press the UP button. You will scroll up
through the numbers (0, 1, 2, 3 — 7, 8, 9) and
letters (a, b, c, — x, y, z).
If you press the DOWN button, you will
scroll down through the letters (z, y, x, — c, b,
a) and numbers (9, 8, 7 — 2, 1, 0).
NOTE: If you push and hold the button, you will

scroll very quickly.
Stop pressing the button when the letter or
number you want appears in the character
position.
5. Move to the next character position you
want to change by:
• Pressing the ENTER key to move the
active character position to the right.
• Holding down the ENTER key and
pressing the DOWN button to move the
active character position to the left.
6. Repeat steps 4 and 5 to change the letter or
number in this character position. Repeat
steps 3, 4 and 5 to enter the remaining
characters of the password.
7. When the OD shows the correct password,
press the ENTER key. If the password was
correct, you are now in Maintenance Mode.
8. If you make a mistake while entering a
character, repeat steps 3 through 7.
PDMM-0089 Issued: 6/24/02 3-7

Changing a Password
Changing a Password
NOTE: When entering the Configuration
password, you must enter the password
in the beginning space. For the
Maintenance password, you leave the
beginning space blank.
1. After entering either the Configuration or
Maintenance password, the screen will
scroll and ask if you want to change the
password.
Example: ENTER NEW MAINT PASSWORD
Press the ENTER key. The screen will stop
scrolling. Enter a new password.
2. Press the ENTER key to cursor all the way
to the right until you are asked to enter a
new password again.
3. Scroll up or down, selecting QUIT until you
get to a SAVE prompt. Select YES.
3-8 PDMM-0089 Issued: 6/24/02

Attachment Control
Attachment Control
Adjusting Clamp Pressure
1. Press the top attachment button
momentarily to activate the clamp. See
Figure 3-2.
2. The clamp pressure is shown on the OD.
3. To select another clamp pressure, use the
UP/DOWN keys on the OD. See Figure 3-3.
The clamp pressure you select remains
active until another is selected; even if the
lift truck is turned OFF.
Figure 3-2: Top Attachment Button

NOTE: Four clamp pressure settings are
available: Low, Med, High, and Max
(Max is the auxiliary relief pressure
setting).
4. Press the top attachment button to activate
the clamp.
Figure 3-3: UP/DOWN Keys on Operator’s Display
PDMM-0089 Issued: 6/24/02 3-9

Attachment Control
Table 3-2: Configure Mode Menu

CONFIGURE MODE MENU
Item Values Description
Quit Exit Configuration Mode

Save? Yes Save changes and leave Configure Mode;
Save? No Abandon changes and leave Configure Mode
Default Restore Factory Defaults

Yes Restore to Factory Defaults
No Do not restore to Factory Defaults
Speed (Forward) @ 7.0 mph Set Forward Maximum Speed

2.0 to 7.0 mph (0.1 mph Increments)/
3.0 - 11.0 Km/h (0.2 Km/h Increments)
Speed (Reverse) @ 7.0 mph Set Reverse Maximum Speed

2.0 to 7.0 mph (0.1 mph Increments)/
3.0 - 11.0 Km/h (0.2 Km/h Increments)
Accel Soft Set Travel Acceleration

@ Medium
Hard
Coast @ Long Set Coast Distance

Medium
Short
Lift/Lower Soft Set Lift/Lower Acceleration

@ Medium
Hard
Lift Cutout @ 20% Set Lift Cutout Point

0% to 50% (5% increments)
1_____ @ 1_____ Enter New Configuration Password

Current Configuration Default Password = ‘1_____’
English @ English Set Units for Messages (For Display Messages)

Metric
BWI-Trac Set Traction Brush Wear Indicator Action

1/2Speed 1/2 Top Travel Speed After 200 Additional Traction Miles
or
@ Icon Illuminated Icon ONLY
BWI-Lift Set Lift Brush Wear Indicator Action

No Lift Lift Motor Inoperative After 10 Additional Lift Hours
or
@ Icon Illuminated Icon ONLY
NOTE: @ Indicates Factory Default; * Indicates Optional Item
3-10 PDMM-0089 Issued: 6/24/02

Attachment Control
CONFIGURE MODE MENU
Mnt Mind Setup for Maintenance Minder

Quit MM Quit Maintenance Minder Menu
Enable Turn on MM
Reset Update MM to the Current Interval
Disable Turn off MM
Setup Setup the MM Interval (See Table 3-3, “Maintenance Minder
Menu (after Enable is Activated)” )
APOFF Enter the Automatic Power-Off Time

@ Disabled Disable the Automatic Power OFF Device
1 Min or
2 Min Automatic Power Off After 1 Min; 2 Min; etc., Without Any
3 Min Truck Activity
4 Min
5 Min
10 Min
Clock Set Time and Date

Quit Quit
24 Hour? Y Select 12 or 24-Hour Clock
24 Hour? N
DayLtS? Y Daylight Savings Time?
DayLtS? N
Set Time Set Time: 10:41PM = 10:41 PM or
2241 = 10:41 PM (24-Hour Clock)
08/27/01 Set Date: Month/Day/Year
VM X.XX Vehicle Manager Software Version
LPTAXXXX Left Traction Power Amp Software Version
RTPAXXXX Right Traction Power Amp Software Version
LPA XXXX Lift Power Amp Software Version
3 * Enter New Electronic Key Password

Current Password Default = 3
English* Select Language for Messages

@English
French
Spanish
Travel Alarm* Select the Alarm To Sound For Travel

Forks Forks First Direction Of Travel
Tractor Tractor First Direction Of Travel
@ Both Both Directions Of Travel
None Neither Direction of Travel
PDMM-0089 Issued: 6/24/02 3-11

Attachment Control
CONFIGURE MODE MENU
Lift/Lower Alarm* Select the Alarm To Sound For Lift/Lower

Lift Lift Direction Only
Lower Lower Direction Only
@ Both Both Lift and Lower Directions
None Neither Lift nor Lower
Sideshft* Select Sideshift Option (non-high speed attachment)

On Turn sideshift ON
Off Turn sideshift OFF
HydOpt* Select Optional Hydraulic Attachment

See Table 3-4, “Hydraulic Attachment Menu”
3.0 mph* Set the Speed Limit Switch Speed

OFF Turn Speed Limit Switch OFF
@ 3.0 mph
2.0 to 6.0 mph 0.1 mph Increments
3.0 to 10.0 Km/h 0.2 Km/h Increments
LftLimit Set the Lift Limit with Bypass Switch

@On Turn on this switch function
Off Disable this switch function
Bat Gate* Set the Battery Gate Switch Action

Off Turn Battery Gate Switch OFF
@Shutdown Complete Vehicle Shutdown
Weight* Select the Weight Sensor

On Turn Weight Sensor ON
Off Turn Weight Sensor OFF
SMARTi* Select SMARTi

On Turn SMARTi ON
Off Turn SMARTi OFF
OffDMlft Allow Lift/Lower Off Deadman

@Off No lift off Deadman
On Allows approximately five feet of lift. Return control to neutral
to repeat
3-12 PDMM-0089 Issued: 6/24/02

Attachment Control
Table 3-3: Maintenance Minder Menu (after Enable is Activated)

MAINTENANCE MINDER MENU
Setup See MNT MIND in Table 3-2, “Configure Mode Menu”

50 to 500 Hours of use (Deadman Pedal)
(in 50 Hr Factory Set (FS) at 200
increments)
Msg Only Message Only
L Cutout Cut-Out Lift Function and Message
Table 3-4: Hydraulic Attachment Menu

HYDRAULIC ATTACHMENT MENU
Attach 1 Attachment 1 (Setup)

Type Select Flow Type
A 2.0-3.3 GPM
B 3.3-4.5 GPM
C 4.5-5.8 GPM
D 5.8-7.0 GPM
E 7.0-10.0 GPM
NONE
Clamp? Is Attachment #1 a Clamp?
Y Yes - Attachment #1 is a Clamp
Low Set Low Clamp Pressure Setting (see below)
Med Set Medium Clamp Pressure Setting (see below)
Hi Set Hi Clamp Pressure Setting (see below)
QuitPsi Exit Pressure Selection
N No - Attachment #1 is not a Clamp
Attachment 1 Clamp Pressure Settings

Clamp Type
Pressure A B C D E
LOW 1-20 1-29 1-29 1 1-29
MED 20-29 1-29 1-29 1-29 29
HI 20-29 29 1-29 29 29
PDMM-0089 Issued: 6/24/02 3-13

Attachment Control
Table 3-4: Hydraulic Attachment Menu
HYDRAULIC ATTACHMENT MENU
Attach 2 Attachment 2 Setup

Type Select Flow Type
A 2.0-3.3 GPM
B 3.3-4.5 GPM
C 4.5-5.8 GPM
D 5.8-7.0 GPM
E 7.0-10.0 GPM
NONE
SideSh? Is Attachment #2 a Sideshifter?
Y Yes - Attachment #2 a Sideshifter
1 Speed Single Speed Sideshift (uses switches on thumb disc)
2 Speed Two Speed Sideshift (uses buttons on handle grip)
N No - Attachment #2 is not a Sideshifter
QuitAtt Exit Attachment Selection
Table 3-5: Maintenance Mode Menu

MAINTENANCE MODE MENU
Quit Exit Maintenance Mode
_2_____ @ _2_____ Enter New Maintenance Password. Default Password = ‘_2_____’
Learn Controls Learn the Control Handles

Return Travel Control to Neutral, Press ENTER key
Return Lift Control to Neutral, Press ENTER key
Weight Learn the Weight Sensor
A Inputs See Table 3-6, “Maintenance Mode Menu - Analog Input Tests”
D Inputs See Table 3-7, “Maintenance Mode Menu - Digital Input Tests”
Outputs See Table 3-8, “Maintenance Mode Menu - Digital Output Tests”
# of Errors Error Codes Logged

Logged 0-20 System Will Store Up To 20 Error Codes
Quit Exit Error Log Menu
Enter If not zero, Press to Scroll Through Logged Error Codes
Clear Press ENTER key to Clear all errors from log
A Maint Select Active Maintenance

On Display Active Maintenance
Off Do Not Display Active Maintenance
3-14 PDMM-0089 Issued: 6/24/02

Attachment Control
Table 3-6: Maintenance Mode Menu - Analog Input Tests

MAINTENANCE MODE MENU Analog Input Tests
A Inputs Analog Inputs
Quit AI Quit Analog Inputs
A00 Traction Motor #1 (left) Armature Current
A01 Traction Motor #2 (right) Armature Current
A02 Traction Motor #1 (left) Field Current
A03 Traction Motor #2 (right) Field Current
A04 Traction Motor #1 (left) Temperature
A05 Traction Motor #2 (right) Temperature
A06 Unassigned
A07 Traction Power Amplifier #1 Temperature
A08 Traction Power Amplifier #2 Temperature
A09 Battery Discharge Indicator Voltage
A10 Throttle Potentiometer Voltage
A11 Lift/Lower Potentiometer
A12 Lift Motor Current
A13 Lift Motor Temperature
A14 Lift Power Amplifier Temperature
A15 Unassigned
A16 Power Supply +12VDC
A18 Unassigned
A19* Pressure Sensor Voltage (weight)
A20 Unassigned
PDMM-0089 Issued: 6/24/02 3-15

Attachment Control
Table 3-7: Maintenance Mode Menu - Digital Input Tests

MAINTENANCE MODE MENU Digital Input Tests
D Inputs Digital Inputs
Quit DI Quit Digital Inputs
I00 Deadman Switch
I01 EPO Switch
I02* High Speed/Mast Limit Switch
I03 Tilt Up Switch
I04 Tilt Down Switch
I05* Sideshift Right Switch
I06* Sideshift Left Switch
I07* Lift Limit Mast Switch
I08 Unassigned
I09 Unassigned
I10 Unassigned
I11 FU1 Steering Fuse
I12 Unassigned
I13 Traction Motor #1 Brush Wear Indicators
I14 Traction Motor #2 Brush Wear Indicators
I15 Lift Motor Brush Wear Indicators
I16 Traction Motor #1 Speed Sensor
I17 Traction Motor #2 Speed Sensor
I18 Steer Position Sensor
I19* Battery Gate Switches
I20* Control Handle Option A Switch
I21* Control Handle Option B Switch
I22 Horn Switch
3-16 PDMM-0089 Issued: 6/24/02

Attachment Control
Table 3-8: Maintenance Mode Menu - Digital Output Tests
MAINTENANCE MODE MENU Digital Output Tests
Outputs Digital Outputs
Ready? Jack Up the Drive Wheels
Quit DO Quit Digital Outputs
O00 Toggle the TPC Contactor
O01 Toggle the LPC Contactor
O02 Toggle the STR Contactor
O03 Toggle the Load Hold (SOL 1) Solenoid
O04* Toggle the Sideshift (SOL 2) Solenoid
O05 Ramp the Proportional Lower (SOL 3) Solenoid
O06 Toggle the Tilt (SOL 4) Solenoid
O07 Toggle the P2-Dump (SOL 5) Solenoid
O08 Toggle the Auxiliary Direction (SOL 6) Solenoid
O09 Toggle the Lift/Auxiliary 1 (SOL 7) Solenoid
O10 Toggle the Lift/Auxiliary 2 (SOL 8) Solenoid
O11* Ramp the Proportional Relief (SOL 9) Solenoid
O12* Toggle the High Speed Auxiliary 1 (SOL 10) Solenoid
O13* Toggle the High Speed Auxiliary 2 (SOL 11) Solenoid
O14 Ramp the #1 (left) Traction Power Amplifier
O15 Ramp the #2 (right) Traction Power Amplifier
O16 Ramp the Lift Power Amplifier
O17 Toggle Traction Motor Brake #1 (left)
O18 Toggle Traction Motor Brake #2 (right)
O19 Ramp the Frequency to the Operator Display Alarm
O20 Toggle the Horn
O21* Toggle the Travel/Lift Alarm (Light)
O22* Toggle the Aux Dump (SOL 12) Solenoid
PDMM-0089 Issued: 6/24/02 3-17

Attachment Control
3-18 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual Scheduled Maintenance
Scheduled Maintenance 4:
PDMM-0089 Issued: 6/24/02 4-1

Scheduled Maintenance EASi Pacer™ Lift Truck Maintenance Manual
Maintenance Guidelines
Maintenance Guidelines
Following a regularly scheduled maintenance

program:
• promotes maximum truck performance
• prolongs truck life
• reduces costly down time
• avoids unnecessary repairs
Scheduled maintenance includes:
• Lubrication
• Cleaning
• Inspection
• Service
Perform all of the scheduled checks and
maintenance during the suggested intervals.
The time intervals given in this guide are based
on deadman hours under normal operating
conditions. When operating under severe or
extreme conditions, perform these services
more often as indicated in the chart below.
Type of Service
Working Environment
Service Frequency
180 days or
500 hours,
Normal An eight hour day of basic material handling
whichever
comes first
Severe Extended operating hours or constant use 250 hours
All UL Type EE rated lift trucks
Dusty or sandy conditions such as in cement plants, lumber or
flour mills, coal dust or stone-crushing areas
High temperature areas such as in steel mills, foundries,
Extreme enclosed (Type EE) applications 175 hours
Sudden temperature changes such as going from freezer to room
temperature
Corrosive atmosphere such as in chlorine or salt-sea air
environments
4-2 PDMM-0089 Issued: 6/24/02

Maintenance Minder™ Tool
Maintenance Minder™
Tool
Maintenance Minder Tool is a feature which
allows a customer to be prompted when the
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 is 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 the 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 PC
Loader program. The factory default is OFF.
Enabling
Once installed in the configuration options via
PC Loader, 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
Operations, see “Modes of Operation” on
page 3-4.
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
with the options QUIT MM and ENABLE. Use the
PDMM-0089 Issued: 6/24/02 4-3

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 Factory Suggested setting, followed by the
letters FS is displayed. Subsequently, when you
enter the time interval menu, the last used
setting is displayed. 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 desired value displayed, press
the horn button.
Use the tilt control to select the desired action
option. Then press the horn button.
• MSG ONLY causes the Operator Display to
show SCHEDULED MAINTENANCE DUE when the
scheduled maintenance time interval is
exceeded.
• L CUTOUT causes the Operator Display to
show LIFT CUT OUT, SCHEDULED MAINTENANCE
DUE when the scheduled maintenance time
interval is exceeded. Lift is disabled the
next time the power circuits are cycled
when this option is selected.
Use the tilt control to select QUIT MM from the
submenu. If the status has changed, a prompt
to save changes appears. Press the horn
button.
NOTE: From the Config Menu, exit by selecting
QUIT CFG. You will not receive additional
prompts 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
wish to change the time interval or action
option, enter Configure Mode.
horn button. When entered from an enabled
state, Maintenance Minder will offer a submenu
with the options QUIT MM, RESET, DISABLE and
SETUP. Use the tilt control to select SETUP, then
press the horn button. The current time
interval is displayed (hours). Proceed as
4-4 PDMM-0089 Issued: 6/24/02

described under "Setting Time Interval and

Action Option" on page 4-4.
Resetting Maintenance Minder

When Maintenance Minder is active, and, after
you have performed scheduled maintenance,
you wish to reset the reminder prompt, enter
Configure Mode.
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
wish to disable it, enter Configure Mode.
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-0089 Issued: 6/24/02 4-5

Operator’s Daily Checklist
Visual Inspection/Key Switch Turned OFF
Component What to Check Mark
TIRES/WHEEL
Tires No gouges, cracks, chunking, or flat spots

No bond failures
Excessive wear
Adequate tread (if applicable)
Wheel No cracks or excessive corrosion
No excessive wear in the bolt holes (loose mounting bolts)
Tightness of mounting bolts
BATTERY
Battery Fully charged/correct water level/correct voltage, no leakage

Properly installed
Battery Gates Gates properly installed/securely in place/not bent or cracked
LIFT/LOWER SYSTEM
Cables/Hoses No damage to chains or hoses
CONTROLS
Function Move smoothly without binding

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

Report any warning decals that are unreadable or damaged.
Check floor under truck for any dripping that might indicate a
leak
No ice or water accumulation in tractor end; no ice or water on
operator compartment floor
OVERHEAD GUARD
Inspect the overhead guard for broken welds, damaged, broken,

missing or bent struts or bars, excessive corrosion, loose
fasteners
HORN
Sounds when button is depressed
4-6 PDMM-0089 Issued: 6/24/02

Visual Inspection/Key Switch Turned OFF
Component What to Check Mark
STEERING
Smooth steering, without binding or excess play
DIRECTIONAL/SPEED CONTROL
Moves smoothly without binding

Returns to neutral when released
Controls speed and direction properly
Plugging functions properly
Speed limits function properly
LIFT/LOWER SYSTEM
Lift/lower and reach controls move smoothly and return to

neutral when released
All controls perform their functions as indicated
OPERATOR DISPLAY
Displays correct information and is easily readable
BRAKES
Pedal moves freely without binding

Lift truck stops in specified distance
Deadman brake functions properly (travel circuits disabled)
EMERGENCY POWER OFF BUTTON
Shuts down travel and lift functions when depressed
SAFETY
All warning and working lights (optional) are functional

All limit switches function properly
Travel alarm (optional) functions
PDMM-0089 Issued: 6/24/02 4-7

Initial 90 Day Maintenance
Initial 90 Day Maintenance
After the truck has been in service for 90 days, perform the following:
Component What To Do Refer to
Drive Units Change fluid. page A-2
Mounting Check torque of mounting hardware for major truck page A-4
Hardware components (lift motor and pump, aux. motor and pump,
brake assembly, drive motor and drive unit, hydraulic
manifolds, and mast-to-drive unit mounting bolts). Tighten or
replace any loose, broken, or missing hardware.
Check the torque of the overhead guard mounting bolts.
Lift Pump Separate pump and motor. Apply Molybdenum Anti-Seize page 7-75
Compound (P/N 990-638) to the splines.
4-8 PDMM-0089 Issued: 6/24/02

Every 180 Days or 500 Deadman Hours (HD)
Battery Check the weight stamped on the battery in the truck against page 3-2
the minimum and maximum allowable weights on the
specification tag for the truck. Report any trucks that are
running with batteries under the minimum, or over the
maximum allowable weight.
Make sure the battery has no more than 0.5 in. (13 mm) free
play in any direction.
Battery Inspect all battery connectors and leads for damage and cuts page 5-6
Connector in protective coatings.
Check for voltage and shorts to frame.
Battery Gates Make sure the battery gates are in place and not damaged.
Brakes/Brake In the tractor first direction, check brakes for proper stopping page 7-44
Pads distance. If brakes are applied while traveling at full speed
with full load, the lift truck should stop within 7 - 10 ft
(2.1 - 3.048 meters) after applying the brakes. This distance
will vary depending on floor conditions.
Visually inspect the friction disc and plates with the brakes
released. Minimum thickness of the friction disc is 0.207 in.
(5 mm).
The air gap between the armature disc and the brake coil
must be 0.008 - 0.018 in. (0.20 - 0.45 mm). Failure to keep
the brake shimmed will cause premature wear on the
friction disc and plates and excessive motor heat.
Electrical Cables Inspect all cables for nicks or cuts. Replace any cable that is
damaged or shows signs of excessive heat.
Inspect over-the-mast cables for proper tension.
Make sure over-the-mast pulley’s spin freely and show no
signs of wear.
PDMM-0089 Issued: 6/24/02 Revised: 5/3/04 4-9

Control Handle Operate the lift/lower function. Verify the response is smooth page 7-27
Functions and controllable.
Operate the travel function. Verify that the full range of
acceleration is smooth and responsive. Make sure that
plugging/Regen is functioning properly.
Look for any play in the center position of the lift or travel. page 7-27
Operate the Tilt, Sideshift and Optional attachment switches.
Verify they operate the function smoothly and do not stick.
Enter Maintenance Mode and test the lift/lower and travel
pots, A11 and A10. Make sure the voltage for both pots is
stable with no fluctuations in the neutral position. If the
voltage fluctuates by more than 0.2 volts in 10 seconds,
replace the pot to avoid unscheduled down time. Run the
pots all the way up and down the scale to verify smooth
voltage changes. This is especially important for the
lift/lower pot as an improper function can result in
unrequested load movement.
Deadman Pedal The Deadman Pedal must operate smoothly with no binding.
Check for proper activation and deactivation of the deadman
switch under the pedal.
Horn Make sure the horn sounds loudly when activated.

Make sure the horn is insulated from the frame.
Hydraulic Hoses Inspect all hydraulic hoses for leaks, nicks, cuts, chafing and
bulges. Replace damaged hoses as soon as possible.
Inspect all fittings for leaks. Repair any leaks immediately.
Inspect over the mast hoses for proper tension.
Make sure over-the-mast pulleys spin freely and show no
signs of wear
Hydraulic Check for proper fluid level and the proper fluid for the page 7-70
Reservoir working environment.
Optional Lights All lights are functional and securely mounted.
Overhead Guard Look for any physical damage to the guard. If the overhead
guard is structurally damaged, replace the guard.
Switches Check mast and optional switches for proper operation.
Chassis and Mast Inspect the mast bearings and rollers for damage or wear. page 7-84
Inspect the outside of the main frame for wear, especially if
the truck is used in drive-in racks.
Inspect the grease for contamination, then remove and
re-apply as required.
4-10 PDMM-0089 Issued: 6/24/02

Contactors Inspect contact tips for burnt or pitted surfaces. Failure to page 7-55
replace the tips may cause surfaces to weld together,
causing unscheduled down time.
Check the plunger for smooth operation with no binding. If
binding occurs, the truck may exhibit intermittent fault
codes.
Drain Holes Make sure the drain holes are not blocked by any debris.
(beneath
deadman pedal
and in battery
compartment)
Drive Unit Check for proper fluid level in the drive unit. If the fluid level page 7-34
is low, investigate for leaks and determine causes.
Forks Inspect forks for modifications, bends, cracks or wear. Check

for welding arcs and signs of excessive heat.
Tool P/N 922-369 is available for measuring the thickness
of the fork heels.
NOTE: If any of the above are found, replace the fork
immediately.
Hardware Check the tightness of wire and cable connections. This is page A-4
(bolts, nuts, and done by physically trying to move the connection with your
screws) hand.
Lift Chains Check for proper adjustment of the chains. Lubricate as

required.
Inspect the chains for excessive stretch or wear. Tool
(P/N 950-350/CG) is available to determine when lift chains
must be replaced.
NOTE: On Quad masts, adjust the lift chains on each section
of the mast so that the top of any section is within
1/4 in. (6.35 mm) of the top of the adjacent mast
section when fully lowered.
Make sure there is adequate clearance between the
cross-ties and the “thru mast” hoses.
PDMM-0089 Issued: 6/24/02 4-11

Motors Visually inspect brushes for excessive heat (discoloration of

the pigtails). If excessive heat is evident, inspect the
armature circuit for loose connections.
Find the shortest brush in the holder.
Remove the brush and check the overall dimension. Inspect
the brush for even wear over the full surface of the brush. If
the brush is not contacting the complete surface, replace
the brushes.
Inspect the brush rigging for damage or loose brush holders.
Ensure that the connections on the brush leads are tight.
Check brush spring tension.
Motor Minimum Brush Length Spring Tension
Drive 0.62 in. (16 mm) 40-65 oz (1134-1843 gm)

Lift 0.62 in. (16 mm) 40-65 oz (1134-1843 gm)
Steer 0.60 in. (15 mm) 35-55 oz (995-1559 gm)
Blow out the inside of the motor with compressed air.

Check the cable lugs to make sure they are tight to the
terminal studs. Torque both the inside and outside nut to page A-4
the proper values. Replace any cable that shows signs of
excessive heat.
Wheel and Tires Inspect all wheels and tires for chunking, bond failure, and page 7-15
excessive or uneven wear. Replace any tire exhibiting any of
these symptoms.
Steerable Wheel Lubricate the steer axle assembly.

Assembly Inspect the steer chain for proper adjustment. Chain should page 7-24
flex approximately 1/8 in. (3.175 mm).
Inspect the caster wheel axle and bearings for excessive wear.
Check caster wheel bearing for binding or excessive play.
Inspect drive axle for excessive play.
Lift Cylinders Inspect the condition of the rams for leaking seals, scored page 7-77
pistons, and secure mounting.
Side Shift and Tilt Inspect the condition of the rams for leaking seals, scored
Cylinders pistons, and secure mounting.
Shorts and Using a non-flammable cleaner, clean any dirt and oil buildup page 5-6
Voltage Leaks to inside the tractor compartment. This reduces the chance of
Frame intermittent error codes caused by shorts between
maintenance intervals. It also extends the life of cables and
harnesses.
NOTE: Do not use any cleaners or solvents inside motors.
Unplug the battery and check for voltage leaks to frame. Run page 5-6
ground tests.
4-12 PDMM-0089 Issued: 6/24/02

Sideshift Carriage Make sure the cap screws securing the lower mounting hooks
to the carriage bar are tight.
Check lower hook nut torque. Grease lower bearing surface. page A-4
Warning Decals Replace any warning decals that have become unreadable or
are damaged.

Hydraulic Change the fluid in the main hydraulic reservoir and install a page 7-70
Reservoir new fluid filter. page A-2
Drive Unit Change the fluid. page A-2
Pump Remove, clean, inspect, and repack.

Couplings On lift pump, apply Molybdenum Anti-Seize Compound
(P/N 990-638) to the splines
PDMM-0089 Issued: 6/24/02 4-13

4-14 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual Troubleshooting
Troubleshooting 5:
PDMM-0089 Issued: 6/24/02 5-1

Troubleshooting EASi Pacer™ Lift Truck Maintenance Manual
Electrical Troubleshooting Guidelines
Electrical
Troubleshooting
Guidelines
! WARNING
Block the lift truck so that the drive
tire is off the floor whenever a
troubleshooting procedure requires
turning key switch S1 ON. This will
avoid accidents caused by
unexpected lift truck travel.
! CAUTION
Unless otherwise directed, disconnect
the battery connector when you
check electrical circuits or
components with an ohmmeter.
Electrical current can damage the
ohmmeter.
Many problems are caused by a faulty or dirty

battery. Make sure the battery is clean.
• Save time and trouble by looking for simple
causes first.
• For information on electrical connector
location and function, see “Electrical
Connector Locator Chart” on page 5-15.
• Use a digital multimeter such as a Fluke
meter for all measurements. Analog meters
can give inaccurate readings and load down
sensitive electronic circuits enough to
cause failure. Ensure meter cables are
connected to the proper meter jacks and
that the proper function and scale are
selected.
5-2 PDMM-0089 Issued: 6/24/02

Electrostatic Discharge
• Printed circuit boards are conformal

coated. Clean test points in order to obtain
accurate readings.
• 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.
Electrostatic Discharge
Electrostatic charges introduced to the lift
truck’s electronics through the operator
controls can cause malfunctioning of the
Operator Display, such as flickering and
lockup. Electrostatic discharge can also cause
certain fault codes, such as F4, F5, and F6.
Over time, electrostatic discharge can damage
circuit cards. Static tends to be higher in
environments with low relative humidity, such
as freezers. See “Static Precautions” on
page 2-12.
Make sure static straps (P/N 600-974/001) are
installed on the truck and work properly.
PDMM-0089 Issued: 6/24/02 5-3

Motor Overheating
Motor Overheating
Motor overheating can be caused by any one of

the causes listed below.
Lack of Ventilation
Make sure that the ventilating holes or slots in
the motor housing are not obstructed. Also
make sure that the ventilation slots in the lift
truck covers are free of obstructions.
Dirt
See “Motor Cleaning” on page 7-60.
Bad Bearings
To check a motor for bad bearings:
1. Remove the motor from the lift truck.
2. Remove the brushes from the motor.
3. Rotate the armature shaft by hand. It
should rotate smoothly without any
binding. If there is binding, the motor
bearings are probably bad and the motor
assembly should be replaced.
4. Check for end play on the armature shaft.
There should be no noticeable end play.
Low Battery Voltage

Check battery voltage. If it is too low, replace or
recharge the battery.
Heavy Loads
Do not try to lift loads that are beyond the lift
truck’s capacity. Heavy loads may cause the lift
truck to become unstable. (See the specification
plate on the lift truck for maximum allowable
loads.)
Open or Short Circuit in Motor

See “Electric Motor Tests” on page 7-61.
5-4 PDMM-0089 Issued: 6/24/02

Open or Short Circuit in Motor
! CAUTION
Do not breathe any fumes from a
motor that has been severely
overheated. Burning insulation can
create noxious fumes.
Before trying to find the cause of the

problem:
• Disconnect all power to the motor.

• Let the motor cool.
• Thoroughly ventilate the area to
clear away any fumes.
PDMM-0089 Issued: 6/24/02 5-5

Shorts to Frame Test

“Shorts to frame” is an industry term for
unintentional current leakage paths between
normally isolated electrical circuits and their
metal enclosures.
Shorts to frame may 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 may result in improper
operation.
Shorts to frame are 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
• Improper 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
5-6 PDMM-0089 Issued: 6/24/02

To test for shorts to frame:

2. To test the battery for shorts to case,
connect a 12V test light to the battery case
from battery B+, and then to the battery
case from battery B–. If the light illuminates
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.
The meter may 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 illuminate,
continue to the next step.
3. Use a Digital Volt Meter (DVM) set 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. A reading
of more than 0.001A (1mA) indicates a
serious short. DO NOT continue until this
condition is corrected. The meter may 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 0.0002A (0.2mA),
go to step 4. If the current is greater than
0.0002A (0.2mA) and less than 0.001A
(1mA), 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.
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 indicates a serious short. DO NOT
continue until this condition is corrected.
The meter may be damaged if you proceed
before correcting this condition.
PDMM-0089 Issued: 6/24/02 5-7

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 the lift truck frame or
other conductive surfaces.
b. The most likely areas to check are:
• Motors
• Heat sinks
• Power cables
• Power circuit components
• Control circuit components
c. Repair or replace the component
causing the low resistance condition.
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 faulty; 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 and turn
the key switch ON. If the battery was
previously removed, make sure the battery
case does not touch the lift truck frame.
NOTE: The functions being checked must be
energized. Example; to check for shorts
to frame in the travel circuit, travel must
be requested.
6. Use a DVM set to the current function to
measure current leakage to the lift truck
frame from B+, B–, and all fuses and motor
terminals. Begin measuring at the highest
ampere scale and work toward the lowest. If
the current is less than 0.001A (1mA), go to
step 7. If the current is more than 0.001A
(1mA), continue to the following steps.
5-8 PDMM-0089 Issued: 6/24/02

a. To identify the cause of the short to

frame, disconnect circuit components
until the leakage current reads less than
0.001A (1mA). Do not reconnect
components one at a time, but leave
them disconnected until the leakage
current reads less than 0.001A (1mA).
Prevent disconnected terminals or
connectors from touching the lift truck
frame or other conductive surfaces.
b. The most likely areas to check are:
• Motors
• 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 (1mA) when
reconnecting a component, that
component or its wiring is faulty.
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.
PDMM-0089 Issued: 6/24/02 5-9

CAN Bus Troubleshooting
CAN Bus
Troubleshooting
The Vehicle Manager (VM) uses digital
communication lines (Controller Area Network
(CAN) Bus) to transmit data to and from the
power amplifiers (and SMARTi™ if installed).
These communication lines are labeled Bus+
and Bus–. If these lines become open or
shorted, fault codes such as 59, 5A, 5D, 5F, 5G,
or 5J is displayed. Use the steps that follow to
troubleshoot the CAN bus.
Traction Amplifier Related

Codes
If the fault code is specific to a traction power
amplifier (5F or 5G), the connectors between the
two amplifiers can be switched for
troubleshooting purposes only.
1. Check for pinched cables or wires which
can cause shorts to frame.
2. If the power amplifier light is not ON, verify
B+K2 and B– to the amplifier and relays.
3. Verify that the power amplifier is the correct
part number (traction versus lift).
4. Turn the key switch OFF. Switch the J1
and J2 connectors between the traction
amplifiers. Turn the key switch ON.
If the code changes, the problem is in the
power amplifier. If the code remains the
same, a problem with the harness may
exist.
5. Code 5F will be displayed if the signal at
JPTR1-21 (J1-1 of right amplifier) is lost.
This is the node select line which identifies
to the VM which amplifier is right and
which amplifier is left.
Check for battery voltage at JPTR1-21 with
respect to (wrt) TP4. If battery voltage is not
present, perform a continuity check from
JPTR1-21 to JPF5-2 of the Fuse/Relay
Card. If continuity is present there, check
for battery voltage at the tips of the K2
relay.
5-10 Revised: 5/3/04 PDMM-0089 Issued: 6/24/02

VM and Power Amplifier CAN Connectors
VM and Power Amplifier CAN

Connectors
Probe the CAN Bus connectors of all four
devices.
1. Unplug JPC4 (VM) and J2 of all three power
amplifiers.
2. Use an ohmmeter and measure the
resistance between BUS+ (JPC4-9) and
BUS– (JPC4-10) of the VM. The value
should be 135 to 155 ohms.
NOTE: JPC4 is a 19 pin connector. Pin 10 is in
the upper right corner and pin 9 is in
the lower left corner.
resistance between BUS+ (J2-3) and BUS–
(J2-6) of all three power amplifiers. The
meter should read an open circuit.
NOTE: Pin 6 is in the upper left corner and pin
3 is in the lower left corner.
terminating resistor of the lift amp between
J2-3 (lower left) and J2-5 (upper center).
The value should be 110 to 130 ohms.
5. Use an ohmmeter and measure the internal
shunt of the lift amp between J2-6 (upper
left) and J2-4 (upper right). The value
should be zero ohms. (This allows the
external jumper wire between pin JC2-4
and JC2-5 to enable the terminating
resistor between BUS+ and BUS–).
Wiring Harness
Probe the CAN Bus harness for shorts.
1. With all four devices unplugged, check for
shorts between BUS+ and BUS– of the
harness.
shorts between BUS+ of the harness and
truck frame and TP4 (B–).
shorts between BUS– of the harness and
truck frame and TP4 (B–).
PDMM-0089 Issued: 6/24/02 5-11

Pin to Socket Contact and Internal Devices
Pin to Socket Contact and

Internal Devices
Probe combinations of the CAN Bus harness
and devices to verify continuity of crimps and
pin to socket contact as well as internal
terminating resistors.
1. With only the VM plugged in, probe the
unplugged lift connector between BUS+
(JPL2-3) and BUS– (JPL2-6). This tests all
crimps in the harness and pin to socket
contact at the VM. The value should be 135
to 155 ohms. Wiggle the connector at the
VM as an additional test of the pin to socket
connections.
Visually examine each wire for a proper
crimp. Gently pull on each wire in the
harness to ensure a strong crimp.
2. With only the Lift Amplifier plugged in,
probe the unplugged VM connector between
BUS+ (JPC4-9) and BUS– (JPC4-10). This
tests all crimps in the harness and pin to
socket contact at the Lift Amplifier as well
as the jumper wire which connects the
internal shunt and the terminating resistor.
The value should be 110 to 130 ohms.
Wiggle the connector at the Lift Amplifier as
an additional test of the pin to socket
connections.
3. Plug in the right traction power amplifier
only. Install a jumper wire between J2-4
(upper right) and J2-5 (upper center) of the
right traction power amplifier. This will
enable the internal terminating resistor
that is normally not used. Probe the
unplugged VM connector between BUS+
(JPC4-9) and BUS– (JPC4-10). The value
should measure 110 to 130 ohms. Wiggle
the connector at the right traction power
amplifier as an additional test of the pin to
socket connections.
5-12 PDMM-0089 Issued: 6/24/02

Troubleshooting using a Replacement Power
4. Plug in the left traction power amplifier

only. Install a jumper wire between J2-4
(upper right) and J2-5 (upper center) of the
left traction power amplifier. This enables
the internal terminating resistor that is
normally not used. Probe the unplugged
VM connector between BUS+ (JPC4-9) and
BUS– (JPC4-10). The value should measure
110 to 130 ohms. Wiggle the connector at
the left traction power amplifier as an
additional test of the pin to socket
connections.
Troubleshooting using a
Replacement Power Amplifier
Before removing a suspected faulty power
amplifier, use a replacement power amplifier to
troubleshoot a truck that is experiencing
non-intermittent CAN Bus problems.
2. Unplug the J1 and J2 connectors from the
suspected power amplifier.
3. Place a piece of cardboard on top of the
suspected power amplifier to insulate the
replacement power amplifier from shorts to
B+, B–, M–, and so on.
4. Place the replacement power amplifier on
the cardboard and plug J1 and J2 in.
5. Install a jumper wire from TP4 (B–) to the
B– lug of the replacement power amplifier.
the key switch ON. Verify that the truck
passes SelfTest.
PDMM-0089 Issued: 6/24/02 5-13

Wiring
Wiring
Visually inspect all wiring and electrical
components for:
• Loose connections or connectors
• Loose or broken terminals
• Damaged terminals, blocks, or strips
• Exposed wire at terminations
• Abrasions, scrapes, nicks in the wire,
damage from overheating or burns, or other
general insulation damage
• Broken wiring and shorted conditions
(especially those that are close to metal
edges or surfaces)
During troubleshooting and repairs, it is
sometimes necessary to disconnect a connector,
move a harness, cut a cable tie, or remove the
wire from a bracket. Note the location of the
wire and all protective or securing attachments
before moving the harness.
After repair, return or replace all protective
and/or securing hardware to its original
condition. Protective materials are necessary to
provide reliable performance of the interconnect
system.
Examine and maintain any added materials
used to dress or protect the wire. This includes
spiral wrap, brackets, cable ties, fasteners, and
flexible conduit.
Do not attach tie wraps so tight that they pinch
cable harnesses. Avoid tie wrapping to
hydraulic hoses, that expand with pressure,
causing extra pinching of tie wrapped electrical
cables.
Use a digital ohmmeter to check for wiring
continuity.
5-14 PDMM-0089 Issued: 6/24/02

Electrical Connector Locator Chart
Electrical Connector
Locator Chart
Terminology
The term “connector JPx” means a mated
connector consisting of two connector halves.
One half contains male connectors, or pins (P); Pin Identifier Lines
the other half contains female connectors, or
jacks (J).
When you disconnect a mated JP connector,
you will have two connector halves. The
individual connector halves are designated by
“Jx” and “Px.” If you cannot locate a connector
designated “Jx” or “Px,” look for “JPx,” and vice
versa. Jack Pins
Molex connectors have ridges on the sides to
58C04013S.TIF
help locate pin number 1. Molex female sockets
have a single ridge on the short side at pin Figure 5-1: Molex Jack and Pin Connector
number 1. Male plugs have 1, 2, and 3 raised
ridges on the long side at pin numbers 1, 2,
and 3. See Figure 5-1.
See Table 5-1 to locate electrical connectors on
the lift truck.
NOTE: Some connector names may apply to
more than one connector.
Table 5-1: Electrical Connector Locator Chart
Connector Function or Routing Location

JPA1 Attachment Card connector to VM Attachment Card
JPA2 Attachment Card connector to pressure Attachment Card
sensor solenoids
JPA3 Attachment Card connector to battery gate Attachment Card
switches
JPB+ (+) Battery connector Battery
JPB– (–) Battery connector Battery
JPB1 Bump Detector connector to VM Bump Detector
JPB2 Right Brake connector to VM Right Brake
JPB3 Left Brake connector to VM Left Brake
JPD1 Operator Display connector to VM Operator Display
JPD2 Operator Display connector to overlay Operator Display
PDMM-0089 Issued: 6/24/02 5-15

Terminology

JPC1 VM connector to loader module/SMARTi™ VM
option
JPC2 NOT USED NOT USED
JPC3 NOT USED NOT USED
JPC4 VM connector to left traction power amplifier VM
JPC5 VM connector to operator display VM
JPC6 VM connector to multifunction control handle VM
JPC7 VM connector to deadman switch and steer VM
position sensor
JPC8 VM connector to contactor fuse panel and VM
horn
JPC9 VM connector to hydraulic manifold VM
JPC10 VM connector to brakes and motor sensors VM
JPC11 VM connector to weight sensor VM
JPC12 VM connector to lift limit and speed limit VM
switches
JPF1 Fuse/Relay Card connector to B(+) and B(–) Fuse/Relay Card
JPF2 Fuse/Relay Card connector to VM Fuse/Relay Card
JPF3 Fuse/Relay Card connector to key switch (S1) Fuse/Relay Card
and EPO switch
JPF4 Fuse/Relay Card connector to Attachment Fuse/Relay Card
Card
JPF5 Fuse/Relay Card connector to traction and lift Fuse/Relay Card
power amplifiers
JPH1 Sideshift connector to VM SOL2
JPH2 Over-the-mast cable connector to Attachment Over-the-mast Cable
Card Assembly
JPL1 Lift Power Amplifier connector Lift Power Amplifier
JPL2 Lift Power Amplifier connector Lift Power Amplifier
JPTL1 Left Traction Power Amplifier connector Left Traction Power Amplifier
JPTL2 Left Traction Power Amplifier connector Left Traction Power Amplifier
JPTR1 Right Traction Power Amplifier connector Right Traction Power Amplifier
JPTR2 Right Traction Power Amplifier connector Right Traction Power Amplifier
JPS1 NOT USED NOT USED
JPS2 Steer Position Sensor connector to VM Steer position sensor
5-16 PDMM-0089 Issued: 6/24/02

Terminology

JPS3 Left Traction Motor Speed Sensor connector to Left Traction Motor Speed
VM Sensor
JPS4 Right Traction Motor Speed Sensor connector Right Traction Motor Speed
to VM Sensor
JPS5 High Speed Limit Switch connector to VM High Speed Limit Switch
JPS6 Lift Limit Switch connector to VM Lift Limit Switch
JPS7 NOT USED NOT USED
JPS8 Lift Motor Brush Wear Indicator and Temp Lift Motor Brush Wear
Sensor connector to VM Indicator and Temperature
Sensors
JPS10 Battery Gate Switch connector to Attachment Battery Gate Switch
Card
JPS11 Left Traction Motor Brush Wear Indicator and Left Traction Motor Brush
Temperature Sensor connector to VM Wear Indicator and
Temperature Sensor
JPS12 Right Traction Motor Brush Wear Indicator Right Traction Motor Brush
and Temperature Sensor connector to VM Wear Indicator and
Temperature Sensor
JPWL1 Right Working Light connector to switch S15 Right Working Light
JPWL2 Left Working Light connector to switch S15 Left Working Light
JPWL3 Reverse Working Light connector to switch Reverse Working Light
S10
JPWL4 Interconnection to JPL2
JPWL5 Interconnection to JPL1
JP3 Strobe Lights connection
JP48 Over-the-mast Cable connection
PDMM-0089 Issued: 6/24/02 5-17

Hydraulics
Hydraulics
! CAUTION
Use extreme care when blocking the
forks or mast for any reason. Never
remove a block when it is supporting
the forks or mast.
Lower the forks fully and tilt the mast forward.

If the truck is equipped with sideshift, center
the forks horizontally.
When you check voltage at solenoids, make
sure all hydraulic lines and components are
fully installed.
Use an ohmmeter to check for wiring continuity
to the solenoids. Use an ammeter to check for
proper current to the solenoids and contactor
coils (refer to specific component tests).
! CAUTION
Unless otherwise directed, disconnect
the battery connector when you
check electrical circuits or
components with an ohmmeter.
Electrical current can damage the
ohmmeter.
Whenever possible, keep the key switch OFF

and the battery connector disconnected.
Visually inspect all hydraulic lines and
components for:
• Leaking connections or connectors
• Loose or broken fittings
• Damaged tubing, hoses, vents, or seals
5-18 PDMM-0089 Issued: 6/24/02

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.
NOTE: Reference electrical schematics
beginning on page A-13 and hydraulic
schematics beginning on page A-20.
Auxiliary Functions
Multiple Functions Affected
No Auxiliary Functions Work (Tilt, Sideshift)
Possible Cause Action

SOL8 binding Check for excessive torque on solenoid
valve.
Fuse FU3 blown Test fuse FU3 and replace if bad.
LPC contactor bad Run Test O01 - Toggle the LPC Contactor
(Page 6-117).
SOL8 not energized or not working Run Test O10 - Toggle the Lift/Aux2
properly Solenoid (Page 6-126)
Bad VM, VFC, or software Run Tests O01, O04, and O06. Follow
recommendations in test.
Bad aux pump Replace aux pump.
Bad aux motor Test aux motor. See “Electric Motor Tests”
on page 7-61.
PDMM-0089 Issued: 6/24/02 5-19

Auxiliary Functions
All Auxiliary Functions are Slow

Binding solenoid(s) Check for excessive torque on solenoid
valve(s).
Contamination Flush, refill, and bleed hydraulic system.
Hydraulic fluid viscosity too high or too Replace hydraulic fluid with correct fluid.
low See “Lubrication Equivalency Chart” on
page A-2.
Bad aux dir solenoid (SOL6) Run Test O08 - Toggle the Auxiliary
Direction Solenoid (Page 6-124)
Bad lift/aux solenoid 1 (SOL7) Run Test O09 - Toggle the Lift/Aux1
Solenoid (Page 6-125). Follow
Bad lift/aux solenoid 2 (SOL8) Run Test O10 - Toggle the Lift/Aux2
Solenoid (Page 6-126)
Bad VM, VFC, or software Run Tests O01, O04, and O06. Follow
Bad aux pump Replace aux pump.
Bad aux motor Test aux motor. See “Electric Motor Tests”
on page 7-61.
Aux system relief pressure too low Adjust aux system pressure.
5-20 PDMM-0089 Issued: 6/24/02

Auxiliary Functions
Tilt
No Tilt; Other Aux Functions OK

valve.
Bad tilt switch (S8 and/or S9) Run Test I03 - Tilt Up Switch (Page 6-93)
and Test I04 - Tilt Down Switch
(Page 6-94)
Bad tilt solenoid valve, coil, or wiring. Run Test I06 - Sideshift Left Switch
Check for contamination (optional) (Page 6-96) and Test O06 -
Toggle the Tilt Solenoid (Page 6-122). If
contamination is found, flush, refill, and
bleed hydraulic system.
SOL4 not energized or not working Run Test O06 - Toggle the Tilt Solenoid
properly (Page 6-122).
Bad VM or software Run Test I03 - Tilt Up Switch (Page 6-93)
and Test I04 - Tilt Down Switch
(Page 6-94)
Bad CB1 and CB2 Check for contamination. Repair or
replace as necessary.
Mechanical binding in tilt cylinder or Repair/replace cylinder or other binding
carriage components.
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.
Bad Tilt Solenoid Run Test O06 - Toggle the Tilt Solenoid
(Page 6-122)
Bad CB1 and CB2 Check for contamination. Repair or
replace as necessary.
Bad tilt cylinder Repair or replace as necessary.
PDMM-0089 Issued: 6/24/02 5-21

Sideshift
Sideshift
No Sideshift or One Direction Only; Other

Aux Functions OK

valve.
Bad sideshift switch (S6 and/or S7) Run Test I05 - Sideshift Right Switch
(optional) (Page 6-95) and/or Test I06 -
Sideshift Left Switch (optional)
(Page 6-96)
SOL2 not energized or bad Run Test O04 - Toggle the Sideshift
Solenoid (Optional) (Page 6-120)
Bad VM, or software Run Tests I05, I06, and O04. Follow
Mechanical binding in sideshift cylinder Repair/replace cylinder or other binding
or carriage components.
Contamination in hydraulic fluid Flush, refill, and bleed hydraulic system.
Sideshift - Slow Operation; Other Aux

Functions OK

Mechanical binding in sideshift cylinder Repair/replace cylinder or other binding
or carriage components.
Bad sideshift solenoid Run Test O04 - Toggle the Sideshift
Solenoid (Optional) (Page 6-120)
Bad sideshift cylinder Repair or replace as necessary.
5-22 PDMM-0089 Issued: 6/24/02

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

valve(s).
Bad lift/lower potentiometer Run Test A11 - Lift/Lower Potentiometer
(Page 6-80) or Test A11 - Lift/Lower
Potentiometer (solid state control
handle) (Page 6-82)
SOL7 or SOL3 not energized or bad Run Test O05 - Ramp the Proportional
Lower Solenoid (Page 6-121), or Test
O09 - Toggle the Lift/Aux1 Solenoid
(Page 6-125)
Hydraulic contamination (can cause Replace damaged component and flush,
binding proportional valve or fill, and bleed the hydraulic system.
load-holding solenoid)
PDMM-0089 Issued: 6/24/02 5-23

Lift/Lower System
Lift Function
No Lift

Lift cutout Make sure lift cutout is set correctly and
the battery is sufficiently charged.
LPC Contactor not energized or bad Run Test O01 - Toggle the LPC Contactor
(Page 6-117)
Bad lift/lower potentiometer VR2 or Run Test A11 - Lift/Lower Potentiometer
associated wiring (Page 6-80) or Test A11 - Lift/Lower
handle) (Page 6-82)
Relief valve REL1 stuck open Check 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, replace REL1.
Bad VM or software Run Test O01 - Toggle the LPC Contactor
(Page 6-117), Test O09 - Toggle the
Lift/Aux1 Solenoid (Page 6-125), and
Test O10 - Toggle the Lift/Aux2
Solenoid (Page 6-126).
Bad lift pump Replace lift pump.
Lift motor not energized or bad Check for power to the lift motor during
lift. Test lift motor. See “Electric Motor
Tests” on page 7-61.
valve(s).
SOL5 and SOL7 not energized or bad Run Test O07 - Toggle the P2-Dump
Solenoid (Page 6-123) and Test O09 -
Toggle the Lift/Aux1 Solenoid
(Page 6-125).
5-24 PDMM-0089 Issued: 6/24/02

Lift/Lower System
Slow Lift

Battery problems Replace battery with fully-charged good
battery.
associated wiring (Page 6-80) or Test A11 - Lift/Lower
handle) (Page 6-82)
valve(s).
SOL3 (proportional lower) not energized Run Test O05 - Ramp the Proportional
or bad Lower Solenoid (Page 6-121)
Relief valve REL1 stuck open Check for contamination in hydraulic
Plugged or malfunctioning flow control Check for contamination in hydraulic
valve in lift cylinder fluid. If contamination is present, flush,
contamination is found, replace the flow
control valves in the main lift cylinders.
Binding in the mast Inspect the mast and bearings for signs of
binding.
Lift motor not energized or bad Check for power to the lift motor during
lift. Test lift motor. See “Electric Motor
Tests” on page 7-61.
Bad VM or software Run Test O01 - Toggle the LPC Contactor
(Page 6-117), Test O09 - Toggle the
Lift/Aux1 Solenoid (Page 6-125), and
SOL7 not energized or bad Run Test O09 - Toggle the Lift/Aux1
PDMM-0089 Issued: 6/24/02 5-25

Lift/Lower System
Unable to Pick Up a Load

battery.
Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Contaminated or bad relief valve REL1 Check for contamination in hydraulic
Bad lift motor Test lift motor. See “Electric Motor Tests”
on page 7-61.
Lower Function
Slow Lower

valve(s).
or bad Lower Solenoid (Page 6-121).
valve fluid. If contamination is present, flush,
Contamination in load-holding solenoid Inspect load-holding solenoid SOL1 for
valve SOL1 contamination or binding.
associated wiring (Page 6-80). Follow recommendations in
test.
Mechanical binding in bearings or Adjust or replace bearings. Check
telescopic shimming.
5-26 PDMM-0089 Issued: 6/24/02

Lift/Lower System
Intermittent Lower

valve fluid. If contamination is present, flush,
associated wiring (Page 6-80).
valve(s).
Contamination in load-holding solenoid Clean or replace load holding solenoid
valve SOL1 valve.
or bad Lower Solenoid (Page 6-121).
Load Drifting/Settling

Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Contaminated or bad relief valve REL1 Check for contamination in hydraulic
valve.
Leaking or contaminated load holding Check for contamination in hydraulic
solenoid SOL1 fluid. If contamination is present, flush,
clean the solenoid valve. If no
contamination is found, replace the
solenoid valve.
Load too large for lift truck capacity Check load weight. Check lift pressure
setting.
PDMM-0089 Issued: 6/24/02 5-27

Symptom Tables: Travel Functions
Symptom Tables: Travel

Functions
Slow or Sluggish Acceleration

NOTE: First determine if problem is See categories below.
mechanical or electrical.
Mechanical:
Binding drive unit Replace drive unit.
Bad drive motor Check for dirt, contamination, worn
brushes, bent shaft.
Worn load wheel bearings Replace load wheel.
Debris in load wheel axle or caster Remove debris.
Dragging brake Adjust brake.
Electrical:
battery.
Bad throttle potentiometer (VR1) Run Test A10 - Throttle Potentiometer
Voltage (Page 6-77)
Bad drive motor Run Test O14 - Ramp the #1 (left)
(may test OK with no load, but fail Traction Power Amplifier (Page 6-130)
under load) and Test O15 - Ramp the #2 (right)
Traction Power Amplifier (Page 6-132)
Run Tests A00, A01, A02 and A03
Current is limited due to drive motor or Run Test A04 - Traction Motor #1 (left)
power panel temperature or bad Temperature (Page 6-72) and Test A05 -
temperature sensor Traction Motor #2 (right) Temperature
(Page 6-73)
Bad drive motor encoder, encoder drive Run Test I16 - Traction Motor #1 Speed
belt, or pulley Sensor (Page 6-105) and Test I17 -
Traction Motor #2 Speed Sensor
(Page 6-107)
Bad drive motor brushes Test I13 - Traction Motor #1 Brush Wear
Indicators (Page 6-99) and Test I14 -
Traction Motor #2 Brush Wear
Indicators (Page 6-101). Replace motor
brushes.
5-28 PDMM-0089 Issued: 6/24/02

Symptom Tables: Travel Functions
Slow Travel

NOTE: First determine if problem is See categories below.
mechanical or electrical.
Mechanical:
Binding drive unit Replace drive unit.
Bad drive motor Check for dirt, contamination, worn
brushes, bent shaft.
Worn load wheel bearings Replace load wheel.
Debris in wheel axle Remove debris.
Electrical:
battery.
Bad throttle potentiometer (VR1) Run Test A11 - Lift/Lower Potentiometer
(Page 6-80). Follow recommendations in
test.
Incorrect configuration Reconfigure the lift truck.
Bad drive motor Run Tests O14 and O15. Follow
(may test OK with no load, but fail recommendations in tests.
under load) or worn brushes Run Tests A00, A01, A02 and A03. Follow
recommendations in tests.
Short circuit from traction heat sink to Check for shorts to frame.
frame
Speed limited due to drive motor or power Run Tests A04, A05, A07 and A08. Follow
panel temperature or bad temperature recommendations in test.
sensor
If equipped with high speed limit switch Run Test I02 - High Speed Limit Switch
option (optional) (Page 6-92).
Bad VM Run Tests O14, O15, A00, A01, A02 and
A03.
PDMM-0089 Issued: 6/24/02 5-29

Symptom Tables: Electrical Functions
Symptom Tables:
Electrical Functions
NOTE: Reference electrical schematics

beginning on page A-13 and hydraulic
schematics beginning on page A-20.
Electrical Motors
Motor Arcing

Worn brushes or incorrect brush tension Replace brushes and/or brush springs.
Incorrect Lift cutout value Check battery specific gravity at cutout,
after battery has stabilized. Compare to
battery manufacturer specifications for
discharged battery. Adjust Lift Cutout
as needed.
Partially shorted drive motor armature or Refer to motor rebuild facility. Replace
field drive motor.
Rough or pitted drive motor commutator Refer to motor rebuild facility. Replace
drive motor.
Motor Overheating

Application exceeds designed workload -- Check with Dealer Service Manager to
short runs with plugging/acceleration verify application.
or heavy-duty lifting cycles
Bad battery Check voltage, both open circuit and
under load. Replace if necessary with
fully-charged good battery.
Incorrect Lift Cutout value Check battery specific gravity at cutout,
after battery has stabilized. Compare to
battery manufacturer specifications for
discharged battery. Adjust Lift Cutout
as needed.
Clogged motor vents Check and clear motor vent openings.
Cable, terminal, or wiring problems. Look Repair/replace wiring or cables as
for discolored terminals, loose or needed.
damaged crimps.
5-30 PDMM-0089 Issued: 6/24/02

Symptom Tables: Electrical Functions

Improper use of deadman pedal, resulting Instruct operator in proper stopping
in dragging brake procedures.
Worn or pitted TPC Contactor or LPC Inspect the TPC Contactor and LPC
Contactor tips Contactor tips. Replace tips as
necessary.
Test TPC Contactor operation. Run Test
O00 - Toggle the TPC Contactor
(Page 6-116). Follow recommendations
in test. Inspect TPC Contactor tips.
Replace tips as necessary.
Test LPC Contactor operation. Run Test
O01 - Toggle the LPC Contactor
(Page 6-117). Follow recommendations
in test. Inspect Lift Contactor tips.
Replace tips as necessary.
Drive motor armature current problem Run Test A00 - Traction Motor #1 (left)
Armature Current (Page 6-68) and Test
A01 - Traction Motor #2 (right)
Armature Current (Page 6-69). Follow
Worn, damaged, or bad brushes or Inspect motor brushes.
springs Check brush spring tension.
Binding gearbox or pump Check gearbox or pump for binding.
Clean, repair, or replace as necessary.
Hot lift/aux motor caused by sticking Replace Tilt/Sideshift valve.
Tilt/Sideshift valve
Hydraulic fluid viscosity too high or too Replace hydraulic fluid with correct fluid.
low See “Lubrication Equivalency Chart” on
page A-2.
Pressure relief set too high Adjust pressure relief.
PDMM-0089 Issued: 6/24/02 5-31

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 JPC5 harness Reseat harness connections.
Intermittent wires or connectors in Test for continuity while flexing harness.
harness If discontinuity is found, replace wiring
harness.
Electrical noise in motors Check tightness of motor power cable
connections. Check motor brushes for
arcing; replace if necessary.
Bad Operator Display Replace Operator Display.
Electromagnetic interference from Route display cable away from power
improper cable routing cables.
Bad input keys Replace input keys.
Short to frame See “Shorts to Frame Test” on page 5-6.
5-32 PDMM-0089 Issued: 6/24/02

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

battery.
Bad battery cables or connector Repair or replace as necessary.
Problem in key switch circuit Disconnect JPF3. Turn key switch ON.
Measure continuity between JPF3-4 and
JPF3-2. If no continuity, either key
switch S1 or cable to key switch is bad.
Measure continuity across terminals of
S1. If no continuity, replace S1; if
continuity, replace cable. Turn key
switch OFF.
Fuse FU5 blown Remove fuse FU5 and test continuity. If
continuity is missing, replace fuse.
Fuse FU10 blown Remove fuse FU10, and test continuity. If
continuity is missing, replace fuse.
Missing B+ due to bad wiring from Reconnect JPF3. With key switch OFF,
battery positive through JPF1-8 to measure voltage between JPF1-8 and
JPF3-4 TP4 and between JPF3-4 and TP4. If
battery voltage is not present,
troubleshoot wiring problem between
JPF3-4 and TP1 or cable from battery
positive to TP1; if wiring is OK, look for
missing B–.
Missing B– due to bad wiring from Disconnect JPC8. Measure voltage from
JPC8-6 through TP4 to battery negative TP1 (+) to JPF1-5, JPF1-11, JPF1-12,
JPF2-4, and JPC8-6. If battery voltage is
not present, troubleshoot wiring
problem between JPC8 and TP4 or cable
from TP4 to battery negative; if wiring is
OK, recheck fuse FU10 and look for
missing B+.
Bad VM Reconnect JPC8. Turn key switch ON.
Measure voltage between JPC8-17 (B+
key) and JPC8-6 (DGND) on the VM. If
B+ voltage is present, check the 12V
power supplied by the VM. If the 12V is
low, look for possible causes of the
voltage being pulled down. If, after all
devices that use the power supply are
disconnected from the VM, the power
supply voltages are not within spec,
replace the VM.
PDMM-0089 Issued: 6/24/02 5-33

5-34 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual Messages, Codes and Tests
Messages, Codes and Tests 6:
PDMM-0089 Issued: 6/24/02 6-1

Messages, Codes and Tests EASi Pacer™ Lift Truck Maintenance Manual
Messages, Codes and Tests Summary List
Messages and Codes

Code 1H - Traction Power Amplifier #1 (left) Overheated . . . . . . . . . . . . . . . . . . 6-10
Code 1L - The Vehicle Manager Detected The Emergency Power Off
Switch As Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 1T - Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 1V - Lift Power Amplifier Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 20 - Temperature Sensor Circuits Not Responding Or Out-Of-Range,
Traction Motor #1 (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 21 - Short Detected in Armature Circuit #1 (left) . . . . . . . . . . . . . . . . . . . 6-15
Code 25 - Short Detected in Field Circuit, #1 (left) . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 26 - Open Detected in Field Circuit, #1 (left) . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 29 - No Movement Detected When Travel Is Requested. . . . . . . . . . . . . . . 6-18
Code 2A - Traction Motor #1 (left) Overheated. . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 2H - Failure Detected In Speed Feedback Circuit #1 (left). . . . . . . . . . . . . 6-20
Code 2M - Traction Power Amplifier #1 (left) Fault . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 2N - Brush Wear Indicator, Traction Motor #1 (left) . . . . . . . . . . . . . . . . . 6-22
Code 42 - LPC Contactor Detected Closed When Commanded Open . . . . . . . . . 6-23
Code 43 - LPC Contactor Detected Open When Commanded Closed . . . . . . . . . 6-24
Code 44 - TPC Contactor Detected Closed When Commanded Open . . . . . . . . . 6-25
Code 45 - TPC Contactor Detected Open When Commanded Closed . . . . . . . . . 6-26
Code 4B - Steer Contactor Detected Closed When Commanded Open . . . . . . . . 6-27
Code 4C - Steer Contactor Detected Open When Commanded Closed . . . . . . . . 6-28
Code 59 - Software Error - Cannot Transmit. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code 5A - CAN Bus Error/Vehicle Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code 5F - No Communications Received From
Traction Power Amplifier #2 (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Code 5G - No Communications Received From
Traction Power Amplifier #1 (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-32
Code 5J - No Communication from Lift Power Amplifier . . . . . . . . . . . . . . . . .. 6-33
Code 6D - Pressure Sensor Out-Of-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-34
Code 6F - Lift Motor Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-35
Code 6G - Lift Motor Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . . .. 6-36
Code 6Q - Lift Circuit Detected Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-37
Code 6R - Lift Circuit Detected Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-38
Code 6U - Brush Wear Indicator, Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-39
Code 6V - Lift Power Amplifier Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-40
Code 80 - Throttle Controller Reading Out-of-Range . . . . . . . . . . . . . . . . . . . .. 6-41
Code 81 - Lift Controller Reading Out-of-Range . . . . . . . . . . . . . . . . . . . . . . .. 6-42
Code A0 - Incorrect Software for Proper Vehicle Operation . . . . . . . . . . . . . . .. 6-43
Code AG - Communications To/From Operator’s Display Failed . . . . . . . . . . .. 6-44
Code AH - Bad Operator Display Checksum . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-45
Code AJ - Bad ROM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-46
Code AK - Bad RAM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-47
Code AL - Bad Battery Backed RAM Memory . . . . . . . . . . . . . . . . . . . . . . . . .. 6-48
Code EC - Operating System Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-49
Code F4 - COP Time-out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-50
Code F5 - Bad Op Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-51
6-2 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual Messages, Codes and Tests
Code F6 - Vehicle Manager Reset . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 6-52

Code F8 - COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 6-53
Code FG - +12V Power Supply Out-of-Range. . . . . . . . . . . . . . . . . .. . . . . . . . . 6-54
Code FH - Battery Voltage Out-of-Range . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 6-55
Code G2 - Faulty Steer Position Reference Input . . . . . . . . . . . . . . .. . . . . . . . . 6-56
Code G7 - Steer Sensor Signal Fault . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 6-57
Code H0 - Short Detected in Armature Circuit #2 (right) . . . . . . . . .. . . . . . . . . 6-58
Code H3 - Short Detected in Field Circuit #2 (right) . . . . . . . . . . . .. . . . . . . . . 6-59
Code H4 - Open Detected in Field Circuit #2 (right). . . . . . . . . . . . .. . . . . . . . . 6-60
Code H6 - Traction Motor #2 (right) Overheated . . . . . . . . . . . . . . .. . . . . . . . . 6-61
Code HB - Failure Detected In Speed Feedback Circuit #2 (right) . .. . . . . . . . . 6-62
Code HC - Temperature Sensor Circuits Not Responding or
Out-of-Range, Motor #2 (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Code HE - Brush Wear Indicator, Traction Motor #2 (right) . . . . . . . . . . . . . . . . 6-64
Code HF - Traction Power Amplifier #2 (right) Overheated . . . . . . . . . . . . . . . . . 6-65
Code HK - Traction Power Amplifier #2 (right) Fault . . . . . . . . . . . . . . . . . . . . . 6-66
Analog Tests
Test A00 - Traction Motor #1 (left) Armature Current . . . . . . . . . . . . .. . .. .. . 6-68
Test A01 - Traction Motor #2 (right) Armature Current . . . . . . . . . . . .. . .. .. . 6-69
Test A02 - Traction Motor #1 (left) Field Current . . . . . . . . . . . . . . . . .. . .. .. . 6-70
Test A03 - Traction Motor #2 (right) Field Current. . . . . . . . . . . . . . . .. . .. .. . 6-71
Test A04 - Traction Motor #1 (left) Temperature . . . . . . . . . . . . . . . . .. . .. .. . 6-72
Test A05 - Traction Motor #2 (right) Temperature . . . . . . . . . . . . . . . .. . .. .. . 6-73
Test A07 - Traction Power Amplifier #1 (left) Temperature . . . . . . . . . .. . .. .. . 6-74
Test A08 - Traction Power Amplifier #2 (right) Temperature. . . . . . . . .. . .. .. . 6-75
Test A09 - Battery Discharge Indicator Voltage . . . . . . . . . . . . . . . . . .. . .. .. . 6-76
Test A10 - Throttle Potentiometer Voltage . . . . . . . . . . . . . . . . . . . . . .. . .. .. . 6-77
Test A10 - Throttle Potentiometer Voltage (solid state control handle) .. . .. .. . 6-78
Test A11 - Lift/Lower Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . 6-80
Test A11 - Lift/Lower Potentiometer (solid state control handle) . . . . .. . .. .. . 6-82
Test A12 - Lift Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . 6-84
Test A13 - Lift Motor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . 6-85
Test A14 - Lift Power Amplifier Temperature . . . . . . . . . . . . . . . . . . . .. . .. .. . 6-86
Test A16 - Power Supply +12VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . 6-87
Test A19 - Pressure Sensor Voltage (optional) . . . . . . . . . . . . . . . . . . .. . .. .. . 6-88
Input Tests
Test I00 - Deadman Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-90
Test I01 - EPO Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-91
Test I02 - High Speed Limit Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . .. . 6-92
Test I03 - Tilt Up Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-93
Test I04 - Tilt Down Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-94
Test I05 - Sideshift Right Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-95
Test I06 - Sideshift Left Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-96
Test I07 - Lift Limit Mast Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-97
Test I11 - FU1 Steering Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-98
Test I13 - Traction Motor #1 Brush Wear Indicators . . . . . . . . . . . . . . . . . . .. . 6-99
Test I14 - Traction Motor #2 Brush Wear Indicators . . . . . . . . . . . . . . . . . . .. 6-101
Test I15 - Lift Motor Brush Wear Indicators . . . . . . . . . . . . . . . . . . . . . . . . .. 6-103
PDMM-0089 Issued: 6/24/02 6-3

Messages, Codes and Tests EASi Pacer™ Lift Truck Maintenance Manual
Test I16 - Traction Motor #1 Speed Sensor . . . . . . . . . . . . . . . . . . . . . .. .. . . 6-105

Test I17 - Traction Motor #2 Speed Sensor . . . . . . . . . . . . . . . . . . . . . .. .. . . 6-107
Test I18 - Steer Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . 6-109
Test I19 - Battery Gate Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . 6-111
Tests I20 and I21- Control Handle Option Switches
“A” (I20) and “B” (I21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112
Test I22 - Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
Output Tests
Test O00 - Toggle the TPC Contactor . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . 6-116
Test O01 - Toggle the LPC Contactor . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . 6-117
Test O02 - Toggle the STR Contactor . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . 6-118
Test O03 - Toggle the Load Hold Solenoid . . . . . . . . . . . . . . . . . . . .. . .. . . . . 6-119
Test O04 - Toggle the Sideshift Solenoid (Optional) . . . . . . . . . . . . .. . .. . . . . 6-120
Test O05 - Ramp the Proportional Lower Solenoid . . . . . . . . . . . . .. . .. . . . . 6-121
Test O06 - Toggle the Tilt Solenoid . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . 6-122
Test O07 - Toggle the P2-Dump Solenoid . . . . . . . . . . . . . . . . . . . .. . .. . . . . 6-123
Test O08 - Toggle the Auxiliary Direction Solenoid . . . . . . . . . . . . .. . .. . . . . 6-124
Test O09 - Toggle the Lift/Aux1 Solenoid . . . . . . . . . . . . . . . . . . . .. . .. . . . . 6-125
Test O10 - Toggle the Lift/Aux2 Solenoid . . . . . . . . . . . . . . . . . . . .. . .. . . . . 6-126
Test O11 - Ramp the Proportional Relief Solenoid . . . . . . . . . . . . . .. . .. . . . . 6-127
Test O12 - Toggle the High Speed Aux1 Solenoid (Optional) . . . . . .. . .. . . . . 6-128
Test O13 - Toggle the High Speed Aux2 Solenoid (Optional) . . . . . .. . .. . . . . 6-129
Test O14 - Ramp the #1 (left) Traction Power Amplifier . . . . . . . . . .. . .. . . . . 6-130
Test O15 - Ramp the #2 (right) Traction Power Amplifier. . . . . . . . .. . .. . . . . 6-132
Test O16 - Ramp the Lift Power Amplifier . . . . . . . . . . . . . . . . . . . .. . .. . . . . 6-134
Test O17 - Toggle Traction Motor Brake #1 (left) . . . . . . . . . . . . . . .. . .. . . . . 6-135
Test O18 - Toggle Traction Motor Brake #2 (right). . . . . . . . . . . . . .. . .. . . . . 6-136
Test O19 - Ramp the Frequency to the Operator Display Alarm . . .. . .. . . . . 6-137
Test O20 - Toggle the Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . 6-138
Test O22 - Toggle the Aux Dump Solenoid (Optional) . . . . . . . . . . .. . .. . . . . 6-139
6-4 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual Messages, Codes, and Tests
Message and Code Summary Tables
Message and Code

Messages, Codes, and Tests 6:
Summary Tables
The following tables summarize informational, performance limiting, and fault codes.
NOTE: The following “Effect” designations are used throughout these tables:
“Effect” Designations
0 0 mph speed limit (coasts) H Load Handler Shutdown R Top Speed Minus 2 mph
1 1 mph speed limit (coasts) I Informational S Steer system shutdown
Acquire speed, configurable Lift system shutdown Traction system shutdown
A from 1.0 mph to max. L T w/o applying brake
speed
Hard Plug until <1 mph then Main lift system shutdown Lowering system shutdown
B M W
dump brake
Traction system derating 2nd stage lift pump Total shutdown
D N X
(Configure) inhibited
Decelerate to config. speed Non-intellispeed™ Speed Total shutdown w/o
E NI Y
(0 or 1.5 mph) limit applying brake
Decelerate to 0 speed Minimum Power (Traction Height detection shutdown
F P Z
System)
G Guidance Disabled Q Maximum weight assumed 2.5 2.5 mph speed limit
.
Informational / Performance Limiting

Code Condition Effect Related Tests
10 Power ON, SelfTest 0
12 Bump detected exceeds preset level I/P A17
15 Bump detector out of range I
Traction power amplifier #1 (left) overheated A07, O14, A08, O15,
1H I/2.5
A04, A05
1L Emergency power off switch detected down X I01
1T Lift cutout point configured for BSOC has been reached L A09
1V Lift power amplifier overheated L/H A14, A13, O16, A09
Traction System Fault Codes (Apply to left traction motor and Power Amp #1)
20 Temperature sensor circuits not responding 2.5 A04
21 Short detected in armature circuit T A00, O14
25 Short detected in field circuit T A02, O14
26 Open detected in field circuit T A02, O14
29 No movement detected when travel is requested P I16, O14
2A Traction motor #1 overheated I/2.5 A04, A05
2H Failure detected in speed feedback circuit #1 P I16, A16
2N Brush wear indicator, motor #1 I/2.5 I13
2M Traction power amplifier #1 fault T O14
PDMM-0089 Issued: 6/24/02 6-5

Messages, Codes, and Tests EASi Pacer™ Lift Truck Maintenance Manual
Contactor Fault Codes

P (or LPC) contactor detected closed when commanded O01
42 L
open
P (or LPC) contactor detected open when commanded O01
43 I
closed
PC (or TPC) contactor detected closed when commanded O00
44 T
open
PC (or TPC) contactor detected open when commanded O00
45 T
closed.
4B Steer contactor detected closed when commanded open I O02, I11
4C Steer contactor detected open when commanded closed T O02, I11
Communications Fault Codes

59 Software problem - Can’t transmit Y I23
5A CAN bus error/Vehicle Manager Y I23
5D SMARTi Communication Failure 2, 5
5F No communications from Traction Power Amp #2 (right) T I23
5G No communications from Traction Power Amp#1 (left) T I23
5J No communications from Lift Power Amp L I23
Lift System Fault Codes

6D Pressure sensor out-of-range I A19, A16
6F Lift motor overheated L/H A13
6G Lift motor temperature sensor out-of-range L/H A13
6Q Lift circuit detected shorted L O16, A12
6R Lift circuit detected open L O16, A12
6U Brush wear indicator, lift motor I/L I15
6V Lift power amplifier fault L O16, A12
Operator Controls Fault Codes

Code Condition Effect Related Test
80 Throttle controller reading out-of-range Y A10, A16
81 Lift controller reading out-of-range Y A11, A16
System Fault Codes

A0 Incorrect software for proper vehicle operation Y
AG Communications to Operator Display failed 2.5 A16
AH Bad Operator Display checksum 2.5 A16
AJ Defective ROM memory Y A16
AK Defective RAM memory Y A16
AL Defective battery backed RAM memory Y A16
6-6 PDMM-0089 Issued: 6/24/02

MTX Fault Codes

EC Operating system error Y
Function Controller Fault Codes

F4 System Card COP Timeout (inside Vehicle Manager) Y
F5 Bad op code Y
F6 Device reset Y A16
F8 COP not enabled Y
FG +12 volt power supply out-of-range Y A16
FH Battery voltage out-of-range Y A09
Steering Fault Codes

G2 Faulty steer position reference input 2.5 I18
G7 Steer sensor signal fault while driving 2.5 I18, I16, I17
Traction System Fault Codes (Apply to Motor #2 and Power Amp #2)
H0 Short detected in armature circuit #2 T A01, O15
H3 Short detected in field circuit #2 T A03, O15
H4 Open detected in field circuit #2 T A03, O15
H6 Traction motor #2 overheated I/2.5 A05, A04
HB Motor #2 speed feedback error P I17, A16
HC Traction power amplifier #2 temp. sensor out-of-range 2.5 A05
HE Brush wear indicator, motor #2 I/2.5 I14
A08, A07, O15, O14,
HF Traction power amplifier #2 overheated I/2.5
A05, A04
HK Traction power amplifier #2 fault T O15
PDMM-0089 Issued: 6/24/02 6-7

Power Amplifier LED Diagnostics
Power Amplifier LED

Diagnostics
The power amplifiers in the EASi Pacer™ Lift
Truck also display fault codes by way of
blinking Light Emitting Diode (LED) messages.
During troubleshooting, it is helpful to observe
the blinking LED on the power amplifiers in
addition to using the operator display to
decipher fault code messages.
An internal microcontroller automatically
checks the function of the power amplifiers.
When the microcontroller detects a fault, it
signals the appropriate fault code through the
LED on the front of the power amplifier.
Under normal operation, the LED flashes a
single flash at approximately one flash per
second. Any other LED flash pattern indicates
the microcontroller has detected a fault. The
code continues flashing until the code is
corrected.
Power Amplifier Fault Code Explanation

LED off No power or faulty amplifier
Solid on Faulty power amplifier
Heartbeat flash z ¤ Amplifier operational, no faults
1, 2 ¤ ¤¤ Hardware fail-safe error, faulty power amplifier
1, 3 ¤ ¤¤¤ (M–) terminal fault or motor output short
2, 1 ¤¤ ¤ Throttle fault
3, 2 ¤¤¤ ¤¤ Welded main contactor
3, 4 ¤¤¤ ¤¤¤¤ Missing contactor or main contactor did not close

NOTE: This code is normal when the truck is first
turned on and will return to the normal
heartbeat flash when the operator steps on the
deadman pedal and the contactors close.
Code 3,4 will return when the contactors open
due to normal operation of the truck when it
reaches an idle state.
4, 1 ¤¤¤¤ ¤ Low battery voltage
4, 2 ¤¤¤¤ ¤¤ High battery voltage
4, 3 ¤¤¤¤ ¤¤¤ Thermal cutback (overtemperature/undertemperature)
6-8 PDMM-0089 Issued: 6/24/02

Messages and Codes
Messages and Codes
PDMM-0089 Issued: 6/24/02 6-9

Messages and Codes
Code 1H
Code 1H - Traction Power Amplifier #1 (left)

Code Title
Overheated
The temperature reading from power amplifier #1

Reason
indicates overheating.
System Response
Alarm Sounds Yes
Operator Display Code 1H. Panel overheated, allow time to cool.
Travel PC Contactor Energized
Lift PC Contactor Energized
Performance Limits
Travel System 1 mph limit
Lift/Lower System Operational
Attachments Operational
How To Clear Allow time for the power amplifier to cool. Self resetting.
Test A07 - Traction Power Amplifier #1 (left)

Temperature (Page 6-74)
Test O14 - Ramp the #1 (left) Traction Power Amplifier
(Page 6-130)
Test A08 - Traction Power Amplifier #2 (right)
Temperature (Page 6-75)
Tests to Run Test O15 - Ramp the #2 (right) Traction Power Amplifier
(Page 6-132)
Test A04 - Traction Motor #1 (left) Temperature
(Page 6-72)
Test A05 - Traction Motor #2 (right) Temperature
(Page 6-73)
NOTE: The VM cannot cause this code.
6-10 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 1L
Code 1L - The Vehicle Manager Detected The

Code Title
Emergency Power Off Switch As Down
Reason The emergency power off switch is depressed.
System Response
Alarm Sounds Yes
Operator Display Code 1L. Lift emergency stop button.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Performance Limits
Travel System Shutdown
Lift/Lower System Shutdown
Attachments Shutdown
Turn key switch OFF, limit emergency off button, then

How To Clear
turn key switch ON to resume operation.
Tests to Run Test I01 - EPO Switch (Page 6-91)
PDMM-0089 Issued: 6/24/02 6-11

Messages and Codes
Code 1T
Code Title Code 1T - Battery Low
Cutout point configured for Lift Cutout has been

Reason
reached.
System Response
Alarm Sounds Yes
Operator Display Code 1T. Battery low, no lift.
Performance Limits
Travel System Operational
Lift/Lower System No lift
How To Clear Change battery. Self resetting.
Test A09 - Battery Discharge Indicator Voltage

Tests to Run
(Page 6-76)
6-12 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 1V
Code Title Code 1V - Lift Power Amplifier Overheated
The temperature reading from the lift power amplifier

Reason
System Response
Alarm Sounds Yes
Operator Display Code 1V. Overheated, allow time to cool.
Performance Limits
How To Clear Allow time for power amplifier to cool. Self resetting.
Test A14 - Lift Power Amplifier Temperature (Page 6-86)

Test A13 - Lift Motor Temperature (Page 6-85)
Test O16 - Ramp the Lift Power Amplifier (Page 6-134)
Tests to Run Test A09 - Battery Discharge Indicator Voltage
(Page 6-76)
PDMM-0089 Issued: 6/24/02 6-13

Messages and Codes
Code 20
Code 20 - Temperature Sensor Circuits Not

Code Title Responding Or Out-Of-Range, Traction Motor #1
(left)
The temperature signal from power amplifier #1 is not

Reason
responding or is out-of-range.
System Response
Alarm Sounds Yes
Operator Display Code 20. Speed limited.
Performance Limits
Travel System 1 mph speed limit
How To Clear Cycle the deadman switch.

Tests to Run
(Page 6-72)
6-14 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 21
Code 21 - Short Detected in Armature Circuit #1

Code Title
(left)
Reason Short detected in armature circuit #1.
System Response
Alarm Sounds Yes
Operator Display Code 21. Short detected in armature circuit.
Performance Limits
How To Clear Cycle key switch OFF/ON.
Test A00 - Traction Motor #1 (left) Armature Current

(Page 6-68)
Tests to Run Test O14 - Ramp the #1 (left) Traction Power Amplifier
(Page 6-130)
PDMM-0089 Issued: 6/24/02 6-15

Messages and Codes
Code 25
Code Title Code 25 - Short Detected in Field Circuit, #1 (left)
Reason Short detected in field circuit.
System Response
Alarm Sounds Yes
Operator Display Code 25. Short detected in field circuit.
Performance Limits
Test A02 - Traction Motor #1 (left) Field Current

(Page 6-70)
(Page 6-130)
6-16 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 26
Code Title Code 26 - Open Detected in Field Circuit, #1 (left)
Reason Open detected in field circuit.
System Response
Alarm Sounds Yes
Operator Display Code 26. Open detected in field circuit.
Performance Limits
Test A02 - Traction Motor #1 (left) Field Current

(Page 6-70)
(Page 6-130)
PDMM-0089 Issued: 6/24/02 6-17

Messages and Codes
Code 29
Code 29 - No Movement Detected When Travel Is

Code Title
Requested
This code is detected if the following four conditions

occur at the same time for more than two seconds:
1. Speed request from throttle is greater than 25%.

Reason 2. Velocity from the left motor speed sensor is zero.
3. The PWM command to the left power amplifier is
greater than 50%.
4. No current limit detected from power amplifier #1.
System Response
Alarm Sounds Yes
Operator Display Code 29. Speed limited.
Performance Limits
Travel System Speed limited
How To Clear Cycle the deadman switch.
None
Tests to Run NOTE: This code results when the drive motors are
stalled by trying to push a heavy load or
immovable object.
6-18 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 2A
Code Title Code 2A - Traction Motor #1 (left) Overheated
The Vehicle Manager has detected the left traction motor

Reason
has overheated.
System Response
Alarm Sounds Yes
Operator Display Code 2A. Overheated, allow time to cool.
Performance Limits
How To Clear Allow time for the motor to cool. Self resetting.

Tests to Run
(Page 6-72)
PDMM-0089 Issued: 6/24/02 6-19

Messages and Codes
Code 2H
Code 2H - Failure Detected In Speed Feedback

Code Title
Circuit #1 (left)
The speed feedback circuit is not communicating,

Reason
inoperative, or not installed in the truck.
System Response
Alarm Sounds Yes
Operator Display Code 2H. Speed limited.
Performance Limits
Travel System 2 mph or less speed limit
How To Clear Cycle the Deadman switch.
Tests to Run Test I16 - Traction Motor #1 Speed Sensor (Page 6-105)
6-20 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 2M
Code Title Code 2M - Traction Power Amplifier #1 (left) Fault
Reason A fault has been detected by the power amplifier.
System Response
Alarm Sounds Yes
Operator Display Code 2M. Schedule service.
Performance Limits
Travel System 0 mph, Traction system shutdown
Test O14 - Ramp the #1 (left) Traction Power Amplifier

Tests to Run (Page 6-130)
PDMM-0089 Issued: 6/24/02 6-21

Messages and Codes
Code 2N
Code 2N - Brush Wear Indicator, Traction Motor #1

Code Title
(left)
The switch on the traction motor #1 brush wear

Reason
indicator is closed indicating service is required.
System Response
Alarm Sounds Yes - 2 seconds
Operator Display Code 2K. Schedule service.
Performance Limits
Travel System Half-speed after 200 additional hours (if selected)
How To Clear Replace brushes. Self resetting.
Test I13 - Traction Motor #1 Brush Wear Indicators

Tests to Run
(Page 6-99)
6-22 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 42
Code 42 - LPC Contactor Detected Closed When

Code Title
Commanded Open
A voltage is detected by lift power amplifier at B+ when it

Reason
was commanded open.
System Response
Alarm Sounds Yes
Operator Display Code 42. Lift shutdown.
Performance Limits
Cycle key switch OFF/ON.
How To Clear NOTE: If this code can be cleared by disconnecting and

reconnecting the battery, check the K2 relay tips
for welding.
Tests to Run Test O01 - Toggle the LPC Contactor (Page 6-117)
If Intermittent:
Cycling the key or deadman switches very
quickly can cause this code due to the lack of
time for the precharge circuit to discharge.
1. Make sure the contactor vendor P/N is
revision G or higher. These contactors have
a faster drop out time.
2. Make sure the power cables from the TPC
and LPC to the power amplifiers are
connected at the proper locations.
PDMM-0089 Issued: 6/24/02 6-23

Messages and Codes
Code 43
Code 43 - LPC Contactor Detected Open When

Code Title
Commanded Closed
The correct voltage was not detected by the lift power

Reason
amplifier at B+ when it was commanded closed.
System Response
Alarm Sounds Yes
Operator Display Code 43. Lift shutdown.
Performance Limits
Tests to Run Test O01 - Toggle the LPC Contactor (Page 6-117)
6-24 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 44
Code 44 - TPC Contactor Detected Closed When

Code Title
Commanded Open
A voltage is detected by one or both of the traction power

Reason
amplifiers at B+ when it was commanded open.
System Response
Alarm Sounds Yes
Operator Display Code 44. Drive shutdown.
Performance Limits
Cycle key switch OFF/ON.
How To Clear NOTE: If this code can be cleared by disconnecting and

reconnecting the battery, check the K2 relay tips
for welding.
Tests to Run Test O00 - Toggle the TPC Contactor (Page 6-116)
If Intermittent:
Cycling the key or deadman switches very
quickly can cause this code due to the lack of
time for the precharge circuit to discharge.
1. Make sure the contactor vendor P/N is
revision G or higher. These contactors have
a faster drop out time.
2. Make sure the power cables from the TPC
and LPC to the power amplifiers are
connected at the proper locations.
PDMM-0089 Issued: 6/24/02 6-25

Messages and Codes
Code 45
Code 45 - TPC Contactor Detected Open When

Code Title
Commanded Closed
The correct voltage was not detected by one or both

Reason traction power amplifiers at B+ when it was
commanded closed.
System Response
Alarm Sounds Yes
Operator Display Code 45. Drive shutdown.
Performance Limits
Tests to Run Test O00 - Toggle the TPC Contactor (Page 6-116)
6-26 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 4B
Code 4B - Steer Contactor Detected Closed When

Code Title
Commanded Open
A voltage is detected at FU1_Sense when it was

Reason
commanded open.
System Response
Alarm Sounds Yes
Operator Display Code 4B. Speed limited.
Performance Limits
Travel System Top speed minus 2 mph
How To Clear Self resetting.
Test O02 - Toggle the STR Contactor (Page 6-118). If

Tests to Run Test O02 passes then run:
Test I11 - FU1 Steering Fuse (Page 6-98)
PDMM-0089 Issued: 6/24/02 6-27

Messages and Codes
Code 4C
Code 4C - Steer Contactor Detected Open When

Code Title
Commanded Closed
The correct voltage was not detected at FU1_Sense after

Reason
the steer contactor was commanded closed.
System Response
Alarm Sounds Yes
Operator Display Code 4C. Drive shutdown.
Performance Limits
Test O02 - Toggle the STR Contactor (Page 6-118). If

Tests to Run Test O02 passes then run:
Test I11 - FU1 Steering Fuse (Page 6-98)
6-28 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 59
Code Title Code 59 - Software Error - Cannot Transmit
Reason There is a CAN Bus error.
System Response
Alarm Sounds Yes
Operator Display Code 59. Shutdown.
Performance Limits
How To Clear Cycle the key switch ON/OFF.
Tests to Run See “CAN Bus Troubleshooting” on page 5-10.
PDMM-0089 Issued: 6/24/02 6-29

Messages and Codes
Code 5A
Code Title Code 5A - CAN Bus Error/Vehicle Manager
Reason There is a CAN Bus error.
System Response
Alarm Sounds Yes
Operator Display Code 5A. Shutdown.
Performance Limits
How To Clear Cycle the key switch ON/OFF.
6-30 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 5F
Code 5F - No Communications Received From

Code Title
Traction Power Amplifier #2 (right)
No communication from the traction power

Reason
amplifier #2 (right).
System Response
Alarm Sounds Yes
Operator Display Code 5F. Drive shutdown.
Performance Limits
PDMM-0089 Issued: 6/24/02 6-31

Messages and Codes
Code 5G
Code 5G - No Communications Received From

Code Title
Traction Power Amplifier #1 (left)
No communication from traction power

Reason
amplifier #1 (left).
System Response
Alarm Sounds Yes
Operator Display Code 5G. Drive shutdown.
Performance Limits
6-32 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 5J
Code 5J - No Communication from Lift Power

Code Title
Amplifier
Reason No communication from lift power amplifier.
System Response
Alarm Sounds Yes
Operator Display Code 5G. Lift shutdown.
Performance Limits
Lift/Lower System Lift system shutdown, Lower only
Attachments Load handler shutdown, Lower only
PDMM-0089 Issued: 6/24/02 6-33

Messages and Codes
Code 6D
Code Title Code 6D - Pressure Sensor Out-Of-Range
Reason Pressure sensor is out-of-range.
System Response
Alarm Sounds Yes
Operator Display Code 6D. Schedule service.
Performance Limits
Tests to Run Test A19 - Pressure Sensor Voltage (optional) (Page 6-88)
6-34 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 6F
Code Title Code 6F - Lift Motor Overheated
The Vehicle Manager has detected the lift motor has

Reason
overheated.
System Response
Alarm Sounds Yes
Operator Display Code 6F. Lift shutdown.
Performance Limits
Attachments Load handler shutdown
How To Clear Allow time to cool. Self resetting.
Tests to Run Test A13 - Lift Motor Temperature (Page 6-85)
PDMM-0089 Issued: 6/24/02 6-35

Messages and Codes
Code 6G
Code 6G - Lift Motor Temperature Sensor Out-of-

Code Title
Range
The temperature signal from the lift motor is not within

Reason
acceptable limits.
System Response
Alarm Sounds Yes
Operator Display Code 6G. Lift shutdown.
Performance Limits
Attachments Load handler shutdown
Tests to Run Test A13 - Lift Motor Temperature (Page 6-85)
6-36 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 6Q
Code Title Code 6Q - Lift Circuit Detected Shorted
A short in the lift circuit is detected by the lift power

Reason
amplifier.
System Response
Alarm Sounds Yes
Operator Display Code 6Q. Lift shutdown.
Performance Limits
Lift/Lower System Lift system shutdown

Tests to Run Test A12 - Lift Motor Current (Page 6-84)
PDMM-0089 Issued: 6/24/02 6-37

Messages and Codes
Code 6R
Code Title Code 6R - Lift Circuit Detected Open
Reason Lift circuit is detected open.
System Response
Alarm Sounds Yes
Operator Display Code 6R. Lift circuit detected open.
Performance Limits

6-38 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 6U
Code Title Code 6U - Brush Wear Indicator, Lift Motor
The switch on the lift motor brush wear indicator is

Reason
closed, indicating service is required.
System Response
Alarm Sounds Yes, 2 seconds
Operator Display Code 6T. Schedule service.
Performance Limits
Lift system shutdown after 10 additional hours of use, if

Lift/Lower System
selected
Tests to Run Test I15 - Lift Motor Brush Wear Indicators (Page 6-103)
PDMM-0089 Issued: 6/24/02 6-39

Messages and Codes
Code 6V
Code Title Code 6V - Lift Power Amplifier Fault
Reason Lift power amplifier fault is detected.
System Response
Alarm Sounds Yes
Operator Display Code 6V. Lift shutdown.
Performance Limits
How To Clear Cycle the key switch OFF/ON.

6-40 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code 80
Code Title Code 80 - Throttle Controller Reading Out-of-Range
Throttle potentiometer voltage is out-of-range. Results in

Reason
total shutdown without applying the brake.
System Response
Alarm Sounds Yes
Performance Limits
Return the control potentiometer to within its limits. Self

How To Clear
resetting.
Test A10 - Throttle Potentiometer Voltage (Page 6-77)

Tests to Run
Test A10 - Throttle Potentiometer Voltage (Page 6-78)
PDMM-0089 Issued: 6/24/02 6-41

Messages and Codes
Code 81
Code Title Code 81 - Lift Controller Reading Out-of-Range
Lift potentiometer voltage is out-of-range. Results in

Reason
total shutdown without applying the brake.
System Response
Alarm Sounds Yes
Performance Limits
Return the control potentiometer to within its limits. Self

How To Clear
resetting.
Test A11 - Lift/Lower Potentiometer (Page 6-80)

Tests to Run Test A11 - Lift/Lower Potentiometer (solid state control
handle) (Page 6-82)
6-42 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code A0
Code A0 - Incorrect Software for Proper Vehicle

Code Title
Operation
Software detected is not correct for this vehicle or the

Reason
vehicle identification in memory is corrupted.
System Response
Alarm Sounds Yes
Operator Display Code A0. Shutdown.
Performance Limits
Tests to Run None
Corrective Action:
1. If the problem is intermittent, refer to
“Shorts to Frame Test” on page 5-6.
NOTE: A VM from an EZC may have been
inadvertently installed.
2. Verify the current software version. See
page 9-8.
a. If the current software version is
incorrect, replace the VM.
b. If the current software version is
correct, replace the Operator’s Display
with a preprogrammed one.
PDMM-0089 Issued: 6/24/02 6-43

Messages and Codes
Code AG
Code AG - Communications To/From Operator’s

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. Speed limited, or blank display
Performance Limits
Tests to Run None
Corrective Action:
2. If Program Mode can be entered, replace the
ODI.
3. Check continuity of the cable from the VM
(JC5) to the ODI (JD1). Repair/replace as
necessary. If cable is good, replace the ODI.
4. Replace the VM.
6-44 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code AH
Code Title Code AH - Bad Operator Display Checksum
The software checksum in the display does not match

Reason
the one in the Vehicle Manager.
System Response
Alarm Sounds Yes
Operator Display Code AH. Speed limited.
Performance Limits
Travel System 1 mph Speed Limit
How To Clear Self Resetting.
Tests to Run None
Corrective Action:
NOTE: A VM from an EZC may have been
inadvertently installed.
page 9-8.
incorrect, replace the VM.
correct, replace the Operator’s Display
with a preprogrammed one.
PDMM-0089 Issued: 6/24/02 6-45

Messages and Codes
Code AJ
Code Title Code AJ - Bad ROM Memory
Reason The ROM memory test during start-up has failed.
System Response
Alarm Sounds Yes
Operator Display Code AJ. ROM check failure.
Performance Limits
Tests to Run None
Corrective Action:
page 9-8.
incorrect, obtain new software.
correct, replace the VM.
6-46 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code AK
Code Title Code AK - Bad RAM Memory
Reason The RAM memory test during start-up has failed.
System Response
Alarm Sounds Yes
Operator Display Code AK. RAM check failure.
Performance Limits
Tests to Run None
Corrective Action:
page 9-8.
PDMM-0089 Issued: 6/24/02 6-47

Messages and Codes
Code AL
Code Title Code AL - Bad Battery Backed RAM Memory
The non-volatile RAM memory test during start-up has

Reason
failed.
System Response
Alarm Sounds Yes
Operator Display Code AL. NV RAM check failure.
Performance Limits
Tests to Run None
Corrective Action:
page 9-8.
6-48 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code EC
Code Title Code EC - Operating System Error
Reason A fault was detected in the operating system.
System Response
Alarm Sounds Yes
Operator Display Code EC. Shutdown.
Performance Limits
Tests to Run None
Corrective Action:
2. Reload new software regardless of version
on ODI.
3. Replace the VM.
PDMM-0089 Issued: 6/24/02 6-49

Messages and Codes
Code F4
Code Title Code F4 - COP Time-out
The COP circuit has timed out before a reset was

Reason
generated.
System Response
Alarm Sounds Yes
Operator Display Code F4. Shutdown.
Performance Limits
Tests to Run None
Corrective Action:
1. Test static straps.
on ODI.
4. Replace the VM.
6-50 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code F5
Code Title Code F5 - Bad Op Code
Reason Bad code was detected during SelfTest.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None
Corrective Action:
1. Test static straps.
2. If intermittent, see“Shorts to Frame Test”
on page 5-6.
on ODI.
4. Replace the VM.
PDMM-0089 Issued: 6/24/02 6-51

Messages and Codes
Code F6
Code Title Code F6 - Vehicle Manager Reset
Reason A Vehicle Manager reset has occurred.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None
Corrective Action:
on ODI.
3. Replace the VM.
6-52 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code F8
Code Title Code F8 - COP Not Enabled
Reason Vehicle Manager COP not enabled.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None
Corrective Action:
on ODI.
3. Replace the VM.
PDMM-0089 Issued: 6/24/02 6-53

Messages and Codes
Code FG
Code Title Code FG - +12V Power Supply Out-of-Range
Reason The +12V power supply voltage is out-of-range.
System Response
Alarm Sounds Yes
Operator Display Code FG. Shutdown.
Performance Limits
Tests to Run Test A16 - Power Supply +12VDC (Page 6-87)
6-54 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code FH
Code Title Code FH - Battery Voltage Out-of-Range
Reason Battery voltage out-of-range.
System Response
Alarm Sounds Yes
Operator Display Code FH. Check battery.
Performance Limits
Test A09 - Battery Discharge Indicator Voltage

Tests to Run
(Page 6-76)
PDMM-0089 Issued: 6/24/02 6-55

Messages and Codes
Code G2
Code Title Code G2 - Faulty Steer Position Reference Input
Reason Faulty steer position reference input.
System Response
Alarm Sounds Yes
Operator Display Code G2. Speed limited.
Performance Limits
Travel System 1 mph Speed limit
Tests to Run Test I18 - Steer Position Sensor (Page 6-109)
6-56 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code G7
Code Title Code G7 - Steer Sensor Signal Fault
Differences in motor speeds indicate turn, when steer

Reason
position sensor does not.
System Response
Alarm Sounds Yes
Operator Display Code G7. Speed limited.
Performance Limits
Test I18 - Steer Position Sensor (Page 6-109)

Test I17 - Traction Motor #2 Speed Sensor (Page 6-107)
PDMM-0089 Issued: 6/24/02 6-57

Messages and Codes
Code H0
Code H0 - Short Detected in Armature Circuit #2

Code Title
(right)
Reason Short detected in armature circuit #2.
System Response
Alarm Sounds Yes
Operator Display Code H0. Short detected in armature circuit #2.
Performance Limits
Test A01 - Traction Motor #2 (right) Armature Current

(Page 6-69)
(Page 6-132)
6-58 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code H3
Code Title Code H3 - Short Detected in Field Circuit #2 (right)
Reason Short detected in field circuit #2.
System Response
Alarm Sounds Yes
Operator Display Code H3. Short detected in field circuit #2.
Performance Limits
Test A03 - Traction Motor #2 (right) Field Current

(Page 6-71)
(Page 6-132)
PDMM-0089 Issued: 6/24/02 6-59

Messages and Codes
Code H4
Code Title Code H4 - Open Detected in Field Circuit #2 (right)
Reason Open detected in field circuit #2.
System Response
Alarm Sounds Yes
Operator Display Code H4. Open detected in field circuit #2.
Performance Limits
Test A03 - Traction Motor #2 (right) Field Current

(Page 6-71)
(Page 6-132)
6-60 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code H6
Code Title Code H6 - Traction Motor #2 (right) Overheated
The Vehicle Manager has detected the right traction

Reason
motor has overheated.
System Response
Alarm Sounds Yes
Operator Display Code H6. Overheated, allow time to cool.
Performance Limits
How To Clear Allow time to cool. Self resetting.

Tests to Run
(Page 6-73)
PDMM-0089 Issued: 6/24/02 6-61

Messages and Codes
Code HB
Code HB - Failure Detected In Speed Feedback

Code Title
Circuit #2 (right)
The speed feedback circuit is inoperative or not installed

Reason
in the truck.
System Response
Alarm Sounds Yes
Operator Display Code HB. Speed limited.
Performance Limits
Travel System 2 mph or less speed limit
6-62 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code HC
Code HC - Temperature Sensor Circuits Not

Code Title
Responding or Out-of-Range, Motor #2 (right)
The temperature signal from the power amplifier #2 is

Reason
not responding or is out-of-range.
System Response
Alarm Sounds Yes
Operator Display Code HC. Speed limited.
Performance Limits
Travel System 1 mph Speed Limit

Tests to Run
(Page 6-73)
PDMM-0089 Issued: 6/24/02 6-63

Messages and Codes
Code HE
Code HE - Brush Wear Indicator, Traction Motor #2

Code Title
(right)
The switch on Traction Motor #2 brush wear indicator is

Reason
closed indicating service is required.
System Response
Alarm Sounds Yes, 2 seconds
Operator Display Code HE. Schedule service.
Performance Limits
Travel System Half speed after 200 additional hours (if selected)
Test I14 - Traction Motor #2 Brush Wear Indicators

Tests to Run
(Page 6-101)
6-64 PDMM-0089 Issued: 6/24/02

Messages and Codes
Code HF
Code HF - Traction Power Amplifier #2 (right)

Code Title
Overheated
The temperature reading from power amplifier #2

Reason
System Response
Alarm Sounds Yes
Operator Display Code HF. Panel overheated, allow time to cool.
Performance Limits
How To Clear Allow time for the power amplifier to cool. Self resetting.

(Page 6-73)
Test A08 - Traction Power Amplifier #2 (right)
Tests to Run Temperature (Page 6-75)
Test O15 - Ramp the #2 (right) Traction Power Amplifier
(Page 6-132)
PDMM-0089 Issued: 6/24/02 6-65

Messages and Codes
Code HK
Code Title Code HK - Traction Power Amplifier #2 (right) Fault
Reason A fault was detected by the power amplifier.
System Response
Alarm Sounds Yes
Operator Display Code HK. Schedule service.
Performance Limits
Test O15 - Ramp the #2 (right) Traction Power Amplifier

Tests to Run (Page 6-132)
6-66 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual Electrical Tests
Analog Input Tests

Electrical Tests 6:
Analog Input Tests
PDMM-0089 Issued: 6/24/02 6-67

Electrical Tests EASi Pacer™ Lift Truck Maintenance Manual
Analog Input Tests
Test A00 - Traction Motor #1 Diagnosis and Repair

(left) Armature Current
This test measures the armature current in the
! CAUTION
left traction motor. Make sure proper precautions are
observed against electrostatic
NOTE: Press Enter to stop message from
scrolling. An asterisk will appear. Press discharge. See “Static Precautions”
Enter again to return to scrolling on page 2-12.
message.
1. Check all motor and power amplifier
Related messages, codes, and tests connections for tightness and corrosion.
• Test O14 - Ramp the #1 (left) Traction 2. Check for shorts to frame. See “Shorts to
Power Amplifier (Page 6-130) Frame Test” on page 5-6.
• Code 21 (Page 6-15) 3. The traction power amplifier may be bad.
Swap traction power amplifiers #1 and #2.
Limits: If the code changes, replace the traction
power amplifier. If the code does not
• 0 to 400A while driving, reverse polarity change, go to step 4.
during Regen.
4. The motor may need servicing. See “Motors,
General” on page 7-60.
Run test:
This test must be run in Active
Maintenance Mode (see page 3-4).
Forks first = positive (+) reading
Tractor first = negative (–) reading
NOTE:
1. At rest, the Operator Display (OD) should
show approximately 0 ±10A.
2. Driving forward with no load and with drive
wheel straight shows current up to current
limit of approximately 400A. This
measurement varies depending on the
motor load.
3. During regen, the armature current is a
negative value up to current limit of 400A.
4. The current level should begin high and
decrease as the lift truck accelerates.
5. Use a clamp-on current meter placed on the
M– cable near the amplifier. Make sure the
current measured is within ±10% of the
value displayed on the OD.
6. If these results are not seen, the test has
failed.
6-68 PDMM-0089 Issued: 6/24/02

Analog Input Tests

(right) Armature Current
This test measures the armature current in the
! CAUTION
right traction motor. Make sure proper precautions are
NOTE: Press Enter to stop message from
scrolling. An asterisk will appear. Press discharge. See “Static Precautions”
Enter again to return to scrolling on page 2-12.
message.
1. Check all motor and power amplifier
Related messages, codes, and tests connections for tightness and corrosion.
• Test O15 - Ramp the #2 (right) Traction 2. Check for shorts to frame. See “Shorts to
Power Amplifier (Page 6-132) Frame Test” on page 5-6.
• Code H0 (Page 6-58) 3. The traction power amplifier may be bad.
Swap traction power amplifiers #1 and #2.
Limits: If the code changes, replace the traction
• 0 to 400A while driving, reverse polarity change, go to step 4.
during Regen.
4. The motor may need servicing. See “Motors,
General” on page 7-60.
Run test:
This test must be run in Active
Maintenance Mode (see page 3-4).
Forks first = positive (+) reading
NOTE:
1. At rest, the OD should show approximately
0A ±10A.
2. Driving forward with no load and drive
wheel straight shows current up to the
current limit of 400A. This measurement
varies depending on the motor load.
3. During Regen, the armature current is a
negative value up to the current limit of
400A.
4. The current level should begin high and
decrease as the lift truck accelerates.
5. Use a clamp-on current meter placed on the
M– cable near the traction power amplifier.
Make sure the current measured is within
±10% of the value displayed on the OD.
failed.
PDMM-0089 Issued: 6/24/02 6-69

Analog Input Tests

(left) Field Current
This test measures the field current in the left
! CAUTION
traction motor. Make sure proper precautions are
Related messages, codes, and tests discharge. See “Static Precautions”
on page 2-12.
• Test O14 - Ramp the #1 (left) Traction
Power Amplifier (Page 6-130)
• Code 25 (Page 6-16) 1. Check all motor and power amplifier
connections for tightness and corrosion.
• Code 26 (Page 6-17))
2. Check for shorts to frame. See “Shorts to
Frame Test” on page 5-6.
Limits:
3. The traction power amplifier may be bad.
• 0 to 22A max. depending on direction of Swap traction power amplifiers #1 and #2.
travel. If the code changes, replace the traction
Run test: change, go to step 4.
NOTE: This test must be run in Active 4. The motor may need servicing. See “Motors,
Maintenance Mode (see page 3-4). General” on page 7-60.
Forks first = positive (+) reading NOTE: The VM cannot cause this code.
1. At rest, the OD should show 0A.
2. Driving tractor first will show a negative
value. Driving forks first will show a
positive value.
3. The current will begin high, up to 20A, as
the lift truck accelerates then decrease to 2
to 4A at top speed.
failed.
6-70 PDMM-0089 Issued: 6/24/02

Analog Input Tests

(right) Field Current
This test measures the field current in the right
! CAUTION
on page 2-12.
• Test O15 - Ramp the #2 (right) Traction
Power Amplifier (Page 6-132)
• Code H3 (Page 6-59) 1. Check all motor and power amplifier
connections for tightness and corrosion.
• Code H4 (Page 6-60)
2. Check for shorts to frame. See “Shorts to
Frame Test” on page 5-6.
Limits:
3. The traction power amplifier may be bad.
• 0 to 22A max. depending on direction of Swap traction power amplifiers #1 and #2.
travel. If the code changes, replace the traction
Run test: change, go to step 4.
NOTE: This test must be run in Active 4. The motor may need servicing. See “Motors,
Maintenance Mode (see page 3-4). General” on page 7-60.
Forks first = positive (+) reading NOTE: The VM cannot cause this code.
1. At rest, the OD should show 0A.
2. Driving tractor first will show a negative
value. Driving forks first will show a
positive value.
3. The current will begin high, up to 20A, as
the lift truck accelerates then decrease to 2
to 4A at top speed.
failed.
PDMM-0089 Issued: 6/24/02 6-71

Analog Input Tests

(left) Temperature
This test measures the temperature of the left
! CAUTION
Related messages, codes, and tests
discharge. See “Static Precautions”
• Code 20 (Page 6-14) on page 2-12.
• Code 2A (Page 6-19)
• Test A00 - Traction Motor #1 (left) NOTE: This test shows temperature increase
Armature Current (Page 6-68) with use in Active Maintenance Mode.
1. Disconnect JPS11 from the motor. Measure
Limits:
the resistance of the temperature sensor at
• Ambient to +150°C (302°F) normal PS11-3 and PS11-1. Use this table as a
operation guideline.
• Operation cutback at 151°C (304°F) to
175°C (347°F) Motor Temp Sensor
Temperature Resistance
Run Test: °C °F (approximate)
25 77 205K ohms
NOTE: The temperature of the traction motor is
updated on the operator display every 50 122 78K ohms
20 seconds. 75 167 30K ohms
It may be helpful to compare the left and 100 212 13.7K ohms
right drive motor temperatures while 125 257 6.8K ohms
driving in a straight line.
150 302 3.6K ohms
1. Observe the operator display with the lift
175 347 1.3K ohms
truck at rest and at ambient temperature.
After 24 hours, it should show room
temperature. • If the resistance measured does not
• If the displayed temperature is different match the values listed in the table,
than the ambient temperature, the test replace the temperature sensor.
has failed. • If the resistance measured matches the
• If the ambient temperature is displayed, values listed in the table, troubleshoot
proceed to the next step. the associated wiring.
2. Drive the lift truck. The motor temperature 2. If the temperature sensor and associated
should rise evenly from ambient wiring are good, replace the VM.
temperature.
3. Run tests A04, A05, A07, and A08. If all
four tests indicate high temperature, refer
to “Motor Overheating” on page 5-4. If only
test A04 indicates a high temperature, the
test has failed.
6-72 PDMM-0089 Issued: 6/24/02

Analog Input Tests

(right) Temperature
This test measures the temperature of the right
! CAUTION
on page 2-12.
• Code H6 (Page 6-61)
• Test A01 - Traction Motor #2 (right)
Armature Current (Page 6-69) NOTE: This test shows temperature increase
with use in Active Maintenance Mode.
Limits: 1. Disconnect JPS12 from the motor. Measure
• Ambient to +150°C (302°F) normal PS12-3 and PS12-1. Use this table as a
operation guideline.
• Operation cutback at 151°C (304°F) to
175°C (347°F) Motor Temp Sensor
Temperature Resistance
Run Test: °C °F (approximate)
NOTE: The temperature of the traction motor is 25 77 205K ohms
updated on the operator display every 50 122 78K ohms
20 seconds.
75 167 30K ohms
It may be helpful to compare the left and 100 212 13.7K ohms
right drive motor temperatures while
driving in a straight line. 125 257 6.8K ohms
150 302 3.6K ohms
truck at rest and at ambient temperature. 175 347 1.3K ohms
temperature.
• If the resistance measured does not
• If the displayed temperature is different match the values listed in the table,
than the ambient temperature, the test replace the temperature sensor.
has failed.
• If the resistance measured matches the
• If the ambient temperature is displayed, values listed in the table, troubleshoot
proceed to the next step. the associated wiring.
2. Drive the lift truck. The motor temperature 2. If the temperature sensor and associated
should rise evenly from ambient wiring are good, replace the VM.
temperature.
four tests indicate high temperature, refer
test has failed.
PDMM-0089 Issued: 6/24/02 6-73

Analog Input Tests
Test A07 - Traction Power Diagnosis and Repair

Amplifier #1 (left) Temperature NOTE: If the lift truck is driven in circles or
constantly to the left or right, the
This test measures the temperature in the left temperature between traction power
traction power amplifier. amplifier #1 and #2 may vary.
1. Verify cables, heatsink pad and torque.
2. Clean area around the power amplifiers and
• Code 1H (Page 6-10) air slots in truck covers to maximize air
• Code 20 (Page 6-14) flow.
3. Swap traction power amplifiers #1 and #2.
Limits: If the code changes, replace the power
amplifier.
• Normal operating range –25°C (–13°F) to
+85°C (185°F) NOTE: Do not change the VM. The VM cannot
cause this test to fail.
• Overtemperature cutback: >85°C (185°F)
• Undertemperature cutback: –25°C (–13°F)
to –40°C (–40°F)
Run Test:
NOTE: The temperature of the power amplifier
is displayed on the OD.
temperature.
• If the displayed temperature is different
than the ambient temperature, the test
has failed.
• If the ambient temperature is displayed,
proceed to the next step.
2. Drive the lift truck. The motor temperature
should rise evenly from ambient
temperature.
3. Run tests A04, A05, A07 and A08. If all four
tests indicate high temperatures, refer to
“Motor Overheating” on page 5-4. If only
test has failed.
6-74 PDMM-0089 Issued: 6/24/02

Analog Input Tests
Test A08 - Traction Power Diagnosis and Repair

Amplifier #2 (right) NOTE: If the lift truck is driven in circles or
Temperature constantly to the left or right, the
temperature between traction power
This test measures the temperature at traction amplifier #1 and #2 may vary.
power amplifier #2 (right). 1. Verify cables, heatsink pad and torque.
Related messages, codes, and tests air slots in truck covers to maximize air
• Code HC (Page 6-63) flow.
• Code HF (Page 6-65) 3. Swap traction power amplifiers #1 and #2.
If the code changes, replace the power
amplifier.
Limits:
NOTE: Do not change the VM. The VM cannot
• Normal operating range –25°C (–13°F) to cause this test to fail.
+85°C (185°F)
to –40°C (–40°F)
Run Test:
is displayed on the OD.
temperature.
• If the displayed temperature is different
than the ambient temperature, the test
has failed.
• If the ambient temperature is displayed,
proceed to the next step.
2. Drive the lift truck. The motor temperature
should rise evenly from ambient
temperature.
four tests indicate high temperatures, refer
test has failed.
PDMM-0089 Issued: 6/24/02 6-75

Analog Input Tests
Test A09 - Battery Discharge

Indicator Voltage
This test measures the voltage used to calculate
the battery state of charge.

• Code 1T - Battery Low (Page 6-12)
• Code FH - Battery Voltage Out-of-Range
(Page 6-55)
• “Shorts to Frame Test” on page 5-6
Run test:
Verify the battery voltage shown on the OD is
within ±5% of the voltmeter reading measured
between B+ and B–.
Min Max
Battery
32 44.88
Voltage
If the numbers displayed are not in this range,

the test has failed.
Diagnosis and Repair

1. With the lift truck idle, measure voltage at
PC8-7 of VM with reference to TP4 (B–).
Verify voltage is 1.5 to 2.0V lower than
battery voltage.
2. If the voltage is steady but out-of-range,
check the battery with a voltmeter. The
battery may need to be serviced.
3. Measure resistance from PC8-7 of VM to
TP1. The value should read 5.1K ±1%.
• If the resistance is not OK, replace the
Relay Fuse Card or repair/replace its
associated wiring as necessary.
• If the resistance is OK, proceed to the
next step.
4. The VM may be bad. Replace the VM.
6-76 PDMM-0089 Issued: 6/24/02

Analog Input Tests
Test A10 - Throttle Run test:.

Potentiometer Voltage
Control Handle Position Voltage Range
This test measures the voltage from the Full Forward (forks-first) 1.1 to 1.5V
forward/reverse throttle potentiometer in the
control handle. Full Reverse (tractor-first) 3.5 to 3.9V
Neutral 2.25 to 2.75V
• Code 80 (Page 6-41) Move the control handle into the different
positions listed in the table and check the
operator display for the correct voltage.
! WARNING When observing the voltage on the operator

display the values should change smoothly and
Jack the drive tires off the floor evenly as the control handle is moved from full
before conducting this test. The lift forward position to full reverse position.
truck may travel unexpectedly. See If the readings on the operator display are
“Jacking Safety” on page 2-14. outside of the voltage range listed in the table,
Limits:
• The operator display shows the voltage
present at corresponding control handle
positions. ! CAUTION
• When JPC6 is disconnected, 5.0V is present Make sure proper precautions are
on the operator display. observed against electrostatic
NOTE: Running Learn for the controls may discharge. See “Static Precautions”
make the code disappear. on page 2-12.
NOTE: If the throttle potentiometer is replaced,

run Learn on the lift truck for controls.
1. Check control handle connection JPC6. It
may be loose or disconnected from the
control handle.
2. The throttle potentiometer may be bad.
Using an ohmmeter, the potentiometer
should read approximately 2000 ohms from
PC6-15 to PC6-13 when the handle is in the
neutral position.
PDMM-0089 Issued: 6/24/02 6-77

Analog Input Tests
Test A10 - Throttle Run Test:

Potentiometer Voltage Control Handle
Voltage range
Position
This test measures the voltage from the
forward/reverse throttle potentiometer in the *Full forward 0.72 - 1.5V (low)
control handle. OR
*Full reverse 3.5 - 4.27V (high)
Related messages, codes, and tests Move handle to full
forward then let return 1.86 - 3.13V
• Code 80 (Page 6-41) slowly to neutral
Move handle to full
reverse then let return 1.86 - 3.13V
! WARNING slowly to neutral
Jack the drive tires off the floor Difference between the
0.12V max
before conducting this test. The lift two neutral voltages
truck may travel unexpectedly. See *If voltage is high in full forward (forks-first)
“Jacking Safety” on page 2-14. position, VM 223-003-023/XXX or
VM 1019580/XXX is present. If voltage is
high in full reverse (tractor-first) position,
Limits: VM 223-001-068/XXX is present.
The operator display shows the voltage present Move the control handle into the different
at corresponding control handle positions. positions listed in the table and check the
NOTE: Running Learn for the controls may operator display for the correct voltage.
make the code disappear. When observing the voltage on the operator
display, the values should change smoothly and
evenly as the control handle is moved from full
forward position to full reverse position.
If the readings on the operator display are
outside of the voltage range listed in the table,
! CAUTION
Make sure proper precautions are
on page 2-12.
NOTE: If the control handle is replaced, run

Learn on the lift truck for controls.
1. Check control handle connection JPS4.
Make sure it is not loose or disconnected
from the solid state module.

Analog Input Tests
2. Make sure: 10. Turn the key switch OFF and disconnect
• the control handle mount set screw is tight. the module cable from the VM at PC4.
See “Control Handle” on page 7-27. 11. Turn the key switch ON and re-run the test.
• the control handle cable exits the handle in The voltage should read 5.0V or lower.
the straightest, lowest path over the power 12. Turn the key switch OFF and jumper
amplifiers with a gentle curve to the frame PC4-10 to PC4-15.
wall. This will distribute the twisting action
13. Turn the key switch ON and re-run the test.
of the handle on the cable.
The voltage should read between 0 and
• the handle is not rubbing on covers for full 0.36V.
handle travel.
14. Measure the voltage at PC4-15 (+) wrt
3. For ease of troubleshooting, remove the PC4-14 (–). The voltage should read 4.5V or
solid state module from the back of the higher. Repeat for PC4-8 (+) wrt PC4-14 (–)
ODI. since the lift supply from the VM supplies
4. Turn key switch OFF and disconnect JPS4 both circuits on the module.
at the module. 15. If steps 12, 14, and 15 pass, the VM is
5. Turn the key switch ON and re-run the test. good. Proceed to step 17. If not, replace the
The voltage should be between 0 and 0.36V. VM.
6. Turn the key switch OFF and jumper NOTE: Before replacing the VM, use PC Loader
JPS4-10 to JPS4-14 on the module. to update to the latest software. See “PC
Loader Installation” on page 9-3.
The voltage should be 4.5V or higher. 16. Check continuity of the cable between the
module and VM.
8. Measure the voltage at JPS4-15 (+) wrt
JPS4-14 (–). The voltage should read 4.5V NOTE: Pins 12, 13 and shield are missing by
or higher. design.
9. If steps 6, 8, and 9 pass, the module, cable 17. If the cable checks good, replace the
and VM are good. Replace the handle. If module. If not, replace the cable.
not, proceed to step 11.
JPS4
J1 PC4 Vehicle
Handle Solid State
15 15 POT_SUP (TRAVEL)
10 TRAVEL_IN 10
VR TRAVEL_POT_INPUT
13 DGND 13 TRAVEL RETURN
N/C
9 N/C N/C 9 N/C
11 LIFT IN 11 LIFT_POT_INPUT
VR
8 8 POT_SUP (LIFT)
S3 7 7 HORN_INPUT
S8 3 3 TILT_UP_INPUT
S9 4 4 TILT_DN_INPUT
S6 6 6 S/S RIGHT_INPUT
S7 5 5
S/S_LEFT_INPUT
1 1
S4 OPTION_A_INPUT
S5 2 2 OPTION_B_INPUT
14 DGND 14 DGND
12 N/C 12
N/C N/C
Figure 6-1: Solid State Control Handle Interface Module - Throttle Pot
PDMM-0089 Issued: 6/24/02 6-79

Analog Input Tests
Test A11 - Lift/Lower Run Test:.

Potentiometer
Lift/Lower Knob
Voltage Range
This test measures the voltage from the Position
Lift/Lower potentiometer (VR2) in the control Full lower 0.4 to 0.9V
handle.
Neutral 2.0 to 2.5V
Related messages, codes, and tests Full lift 3.55 to 3.9V
• Code 81 (Page 6-42)

Move the lift/lower knob into the positions
listed in the table and check the operator
display for the correct voltage.
! WARNING
When observing the voltage on the operator
The lift carriage and forks may move display, the values should change smoothly and
during this test. evenly as the handle is moved from full lower to
full lift.
If the readings on the operator display are
! CAUTION outside the voltage range in the table, the test
Keep the area around the forks clear. has failed.
The ceiling clearance should allow
the highest lift. Diagnosis and Repair
Limits: ! CAUTION
• The OD shows the voltage that should be
present at various lift/lower knob positions.
• If JPC6 is disconnected, 5.0V is displayed
on the OD.
on page 2-12.
NOTE: Running Learn for the controls may
make the code disappear. NOTE: If the lift/lower potentiometer is
replaced, run Learn on the lift truck for
controls.
1. Check connection JPC6. It may be loose or
disconnected from the VM.
2. The lift/lower potentiometer may be bad or
out of adjustment.
With the lift/lower knob in the neutral
position, the resistance between PC6-13 to
PC6-8 should read approximately 2000
ohms.
To adjust VR2:
a. Loosen the lift knob set screws and
remove the lift knob.
b. Turn the shaft of VR2 until the display
reads 2.5V.
6-80 PDMM-0089 Issued: 6/24/02

Analog Input Tests
c. Reinstall the lift knob and tighten the

set screws to 8 to 12 in. lb
(0.9 to 1.4 Nm).
d. Verify that while in A11, the display
reads 2.5 ±0.15V. If not, repeat
previous steps until it does.
e. Move VR2 to full lift position and full
lower position. Verify that the voltages
stay between 0.5 and 4.5V on the
display.
f. Repeat steps as necessary.
g. Run Learn on the Control Handle.
h. Exit Maintenance mode.
PDMM-0089 Issued: 6/24/02 6-81

Analog Input Tests
Test A11 - Lift/Lower Run Test:

Potentiometer (solid state
Lift Knob Position Voltage Range
control handle)
Full Lower 3.50 to 4.66V
This test measures the voltage from the Full Lift 0.7 to 1.4V
Lift/Lower potentiometer (VR2) in control
Move knob to full lift then
handle. 1.86 to 3.13V
let return slowly to neutral
This test applies to lift trucks equipped with: Move knob to full lower
• a solid state control handle then let return slowly to 1.86 to 3.13V
P/N 828-006-161/005, /006, or /008 neutral
• and VM (P/N 223-001-068/001 or /002) Difference between the two
0.12V max
with control module neutral voltages
OR
Move the lift/lower knob into the positions
• VM P/N 223-003-023/001, /002 or /003
listed in the table and check the operator
display for the correct voltage.
When observing the voltage on the operator
• Code 81 (Page 6-42). display, the values should change smoothly and
evenly as the handle is moved from full lower to
full lift.
! WARNING If the readings on the operator display are
outside the voltage range in the table, the test
The lift carriage and forks may move
has failed.
during this test.
! CAUTION
Keep the area around the forks clear. ! CAUTION
The ceiling clearance should allow Make sure proper precautions are
the highest lift. observed against electrostatic
Limits: on page 2-12.
The OD shows the voltage present at various

NOTE: If the control handle is replaced, run
lift/lower knob positions.
Learn on the lift truck for controls.
NOTE: Running Learn for the controls may
1. Check connections JPS4 and PC4. See
make the code disappear.
Figure 6-2. They may be loose or
disconnected from the module or VM.

Analog Input Tests
2. Make sure: 9. If steps 6, 8, and 9 pass, the module, cable

• the lift knob is installed correctly. See “Lift and VM are good. Replace the handle. If
Knob Repair/Replacement” on page 7-30. not, proceed to step 11.
• the control handle cable exits the handle in 10. Turn the key switch OFF and disconnect
the straightest, lowest path over the power the module cable from the VM at PC4.
amplifiers with a gentle curve to the frame 11. Turn the key switch ON and re-run the test.
wall. This will distribute the twisting action The voltage should read 5.0V or higher.
of the handle on the cable.
12. Turn the key switch OFF and jumper
• the handle is not rubbing on covers for full PC4-11 to PC4-8.
handle travel.
3. For ease of troubleshooting, remove the The voltage should read between 0 and
solid state module from the back of the 0.36V.
Operator Display Interface (ODI).
14. Measure the voltage at PC4-8 (+) wrt
4. Turn key switch OFF and disconnect JPS4 PC4-14 (–). The voltage should read 4.5V or
at the module. higher.
5. Turn the key switch ON and re-run the test. 15. If steps 12, 14, and 15 pass, the VM is
The voltage should read between 0 and good. Proceed to step 17. If not, replace the
0.36V. VM.
6. Turn the key switch OFF and jumper 16. Check continuity of the cable between the
JPS4-11 to JPS4-14 on the module. module and VM.
7. Turn the key switch ON and re-run the test. NOTE: Pins 12, 13, and shield are missing by
The voltage should read 4.5V or higher. design.
8. Measure the voltage at JPS4-8 (+) wrt 17. If the cable checks good, replace the
JPS4-14 (–). The voltage should read 4.5V module. If not, replace the cable.
or higher.
JPS4
J1 PC4 Vehicle
Handle Solid State
15 15 POT_SUP (TRAVEL)
10 TRAVEL_IN 10
VR TRAVEL_POT_INPUT
13 DGND 13 TRAVEL RETURN
N/C
9 N/C N/C 9 N/C
11 LIFT IN 11 LIFT_POT_INPUT
VR
8 8 POT_SUP (LIFT)
S3 7 7 HORN_INPUT
S8 3 3 TILT_UP_INPUT
S9 4 4 TILT_DN_INPUT
S6 6 6 S/S RIGHT_INPUT
S7 5 5
S/S_LEFT_INPUT
1 1
S4 OPTION_A_INPUT
S5 2 2 OPTION_B_INPUT
14 DGND 14 DGND
12 N/C 12
N/C N/C
Figure 6-2: Solid State Control Handle Interface Module - Lift/Lower Pot
PDMM-0089 Issued: 6/24/02 6-83

Analog Input Tests
Test A12 - Lift Motor Current 2. Compare your test results with the
amperage readings located on the Quality
This test measures the lift motor current Assurance sheet for the lift truck.
through the power amplifier.
NOTE: The lift power amplifier and the traction
• Code 6V (Page 6-40) power amplifier are different and cannot
be swapped for troubleshooting.
1. If the operator display and the ammeter
! WARNING readings do not agree, the power amplifier
may be bad.
The lift carriage and forks may move
during this test. 2. If the operator display and the amperage
probe both show very high readings,
binding or a problem in the lift motor or
mast exists. Repair motor or reshim mast
! CAUTION as necessary.
Keep the area around the forks clear. NOTE: Do not change the VM. The VM cannot
The ceiling clearance should allow cause this test to fail.
the highest lift.
Limits:
• 0 to 500A
• The lift current will vary with the weight
being lifted. The display will show
approximately 250A when lifting full speed
with no load on the forks.
Run Test:
NOTE: This test may show better results in
Active Maintenance.
When starting this test, place a fully
charged battery in the vehicle.
! CAUTION
on page 2-12.
1. Compare the operator display readings with

that of an “accurate” clamp type ammeter
while lifting.
6-84 PDMM-0089 Issued: 6/24/02

Analog Input Tests
Test A13 - Lift Motor Diagnosis and Repair

Temperature
This test measures the temperature of the lift
! CAUTION
motor. Make sure proper precautions are
on page 2-12.
• Code 6F (Page 6-35)
• Code 6G (Page 6-36)
1. Disconnect JPS8 from the motor. Measure
Limits: PS8-1 and PS8-3. Use the table as a
• Ambient to +150°C (302°F) normal guideline.
operation
• Operation cutback at 151°C (304°F) to Motor Temp Sensor
175°C (347°F) Temperature Resistance
°C °F (approximate)
Run Test: 25 77 205K ohms
Observe the operator display with the lift truck 50 122 78K ohms
at rest and at ambient temperature. After 24 75 167 30K ohms
hours, it should show room temperature. 100 212 13.7K ohms
NOTE: It is helpful to compare the lift motor 125 252 6.8K ohms
temperature to the traction motor
150 302 3.6K ohms
temperatures when the lift truck is at
rest and at ambient temperature. 175 347 1.3K ohms
If the displayed temperature is different than
the ambient temperature, the test has failed. • If the resistance measured does not
match the values in the table above,
replace the temperature sensor.
• If the resistance measured matches the
values listed in the table, troubleshoot
the associated wiring.
2. If the temperature sensor and associated
wiring are good, replace the VM.
PDMM-0089 Issued: 6/24/02 6-85

Analog Input Tests
Test A14 - Lift Power Amplifier

Temperature
This test measures the temperature of the Lift
Power Amplifier.

• Code 1V (Page 6-13)
Limits:
• Normal operating range –25°C (–13°F) to
+85°C (185°F)
to –40°C (–40°F)
Run Test:
temperature.
2. At ambient temperature, compare the lift
power amplifier temperature with the
traction power amplifier temperature
(Tests A07 and A08). If only test A14
indicates a high temperature, the test has
failed.
will be displayed on the operator display.
As lift is initiated, the temperature
should increase over time.

1. Verify cables, heatsink pad and torque.
air slots in truck covers to maximize air
flow.
3. If the temperature reading on the operator
display does not increase or increases
erratically, the power amplifier may be bad.
NOTE: Do not change the VM. The VM cannot
cause this test to fail.
6-86 PDMM-0089 Issued: 6/24/02

Analog Input Tests
Test A16 - Power Supply 6. The power supply in the VM may be bad.
Replace the VM.
+12VDC
This test measures the +12VDC power supply
voltage.

• Code FG (Page 6-54)
Limits:
• +12VDC ±0.5V output.
Run test:
If the operator display does not read within
these limits or is not illuminated, the test has
failed.
! CAUTION
on page 2-12.
1. Disconnect JPC5 from the VM.

2. Connect the (+) lead of a voltmeter to PC5-1
and the (–) lead to TP4 (B–). With the key
switch ON, the meter should show
+12 ±0.5V.
3. Reconnect JPC5 and disconnect all other
connectors from the VM except the operator
display (JPC5) and B+ key (JPC8).
If the display illuminates, then one of the
disconnected components is dragging the
12V supply down.
4. Plug in one connector at a time to
determine which component is bad.
5. The cable from the VM to the OD may be
bad. Troubleshoot and repair or replace as
necessary.
PDMM-0089 Issued: 6/24/02 6-87

Analog Input Tests
Test A19 - Pressure Sensor Diagnosis and Repair

Voltage (optional)
This test measures the voltage from the
! CAUTION
pressure sensor used for load weight sensing. Make sure proper precautions are
on page 2-12.
• Code 6D (Page 6-34)
• Test A16 - Power Supply +12VDC
(Page 6-87) 1. Connect a voltmeter to JPC11-3 (+) and
JPC11-2 (–). With no weight on the forks,
NOTE: If Test A19 does not appear in the the voltmeter should indicate
Maintenance Mode menu, use PC Loader approximately 1.0V.
to enable the feature. See “Options” on
page 9-13. 2. As weight is added to the forks, the voltage
should increase and the value indicated on
the operator display should also increase. If
! CAUTION the voltage increases on the voltmeter but
not on the operator display, replace the VM.
Use extreme caution when working
near the elevated forks. 3. If neither the meter nor the display value
changes, replace the pressure sensor.
4. If the weight and voltage indicated are both
Limits: low, the 12V supply to the sensor is low.
Connect a voltmeter to JPC11-4 (+) and
• The operator display shows the voltage
JPC11-2 (–). If it is less than 11.0V, run
present with various load weights.
Test A16 - Power Supply +12VDC
(Page 6-87).
Load Weight Voltage
0 (no load) 1V
5000 lbs 5V
• If the weight sensor is disconnected at the

VM, the operator display will show 0V.
Run Test:
The voltage shown on the operator display
should increase and decrease linearly as the
load weight is either increased or decreased. If it
does not, the test has failed.
6-88 PDMM-0089 Issued: 6/24/02

Digital Input Tests

Electrical Tests 6:
Digital Input Tests
PDMM-0089 Issued: 6/24/02 6-89

Digital Input Tests
Test I00 - Deadman Switch

This test is to observe the ON/OFF signal from
the Deadman Switch (S2).

• None
! WARNING
Do not conduct this test on a ramp.
Run test:
NOTE: This test may show best results in Active
Maintenance.
The following table indicates the message that
should appear on the OD during this test.
Operator Operator
Action Display Message
Off deadman OFF
On deadman ON
If the display does not change when the pedal is

depressed, the test has failed.
! CAUTION
on page 2-12.
1. Disconnect JPC7 at the VM.

2. Use an ohmmeter and test switch (S2) for
proper operation.
3. Check continuity of the wires that go to the
switch. Repair or replace as necessary.
4. Jumper PC7-5 and PC7-16 on the VM. The
display should show a change of state. If
not, replace the VM.
6-90 PDMM-0089 Issued: 6/24/02

Digital Input Tests
Test I01 - EPO Switch 3. Check for battery voltage at JPF2-6 wrt
TP1 (–). If the meter does not show battery
This test is to observe the ON/OFF signal from voltage, repair/replace the Contactor Fuse
the EPO switch (S21). Panel.
4. Check for battery voltage at JPC8-11 wrt
Related messages, codes, and tests TP1 (–).
• Code 1L (Page 6-11) • If the meter does not show battery

voltage, repair wiring.
• If the meter shows battery voltage,
! CAUTION replace the VM.
Opening the EPO switch will open
the TPC and LPC contactors. All
traction and lift control will cease.
Run test:
Use the following table as a guideline for this
test.
Operator Switch EPO

EPO
Display S21 Switch
Button
Message Position Resistance
Out OFF Up <0.5 ohms
In ON Down Infinite
If the display does not change when the switch

is depressed, the test has failed.
! CAUTION
on page 2-12.
1. Check for battery voltage at JPF3-3 wrt

voltage, repair/replace the Contactor Fuse
Panel.
2. Check for battery voltage at JPF3-1 wrt
voltage, repair/replace S21 or associated
wiring.
PDMM-0089 Issued: 6/24/02 6-91

Digital Input Tests
Test I02 - High Speed Limit Diagnosis and Repair

Switch (optional)
This test is to observe ON/OFF signal from the
! CAUTION
high speed limit switch (S11) if installed. Make sure proper precautions are
on page 2-12.
• Test A16 - Power Supply +12VDC
(Page 6-87)
1. Check for +12VDC at JPS5-1 (+) and
NOTE: If Test I02 does not appear in the
JPS5-3 (–). If the meter does not show
Maintenance Mode menu, use PC Loader
+12VDC, go to step 4.
page 9-13. 2. Jumper JPS5-2 and JPS5-3. If the display
reads ON with the jumper in and OFF with
the jumper removed, replace the switch.
! WARNING 3. Measure the resistance between JPS5-2
and JPC12-6. If the resistance is not
Do not attempt high speeds during 0 ohms, repair/replace the cable.
this test. Speed limiting while
4. Jumper JPC12-6 and JPC12-3 on the VM.
elevated is defeated during this test. If the display does not read ON with the
jumper in and OFF with the jumper
removed, replace the VM.
! CAUTION
Use extreme caution when working
around an elevated mast.
Run test:
The following table indicates the messages on
the OD for this test.
Operator Display
Mast Position
Message
Lowered ON
Raised OFF
If the display does not change when the forks

are raised sufficiently to cause a change of state
on the switch, the test has failed.
6-92 PDMM-0089 Issued: 6/24/02

Digital Input Tests
Test I03 - Tilt Up Switch 4. Check the continuity of the cable between
the module and the VM. If the cable fails
This test is to observe the ON/OFF signal from the test, replace the cable.
the tilt up switch (S8) in the control handle. NOTE: The cable is “straight through” pin 4 to
pin 4 and pin 14 to pin 14, etc., except
Related messages, codes, and tests pin 12 and pin 13 are not connected.
• Test O06 - Toggle the Tilt Solenoid 5. Check the continuity of the module. If the
(Page 6-122) module does not pass the test, replace the
module.
• Code 6V - Lift Power Amplifier Fault
(Page 6-40) NOTE: The module is also “straight through”
• Code 5G - No Communications Received pin 4 to pin 4, pin 14 to pin 14, and so
From Traction Power Amplifier #1 (left) on.
(Page 6-32) 6. Jumper JC6-3 and JC6-14 on the VM. The
Run test: not, replace the VM.

Active Maintenance.
If the display does not change when the tilt up
switch is depressed, the test has failed.
! CAUTION
on page 2-12.
NOTE: If module P/N 154-012-569/001 and

cable P/N 223-003-012 are not
installed, go to step 5.
1. Turn the key switch to OFF, unplug the
handle from the module and the module
from the VM.
2. Plug the handle directly into the VM. Turn
the key switch to ON and re-run the test.
NOTE: A code 80 or 81 will appear during
SelfTest.
If the test now passes, go to step 6. If the
test fails, go to the next step.
proper operation.
PDMM-0089 Issued: 6/24/02 6-93

Digital Input Tests
Test I04 - Tilt Down Switch 4. Check the continuity of the cable between
the module and the VM. If the cable fails
This test is to observe the ON/OFF signal from the test, replace the cable.
the tilt down switch (S9) in the control handle. NOTE: The cable is “straight through” pin 4 to
pin 4 and pin 14 to pin 14, etc., except
Related messages, codes, and tests pin 12 and pin 13 are not connected.
• Test O06 - Toggle the Tilt Solenoid 5. Check the continuity of the module. If the
(Page 6-122) module does not pass the test, replace the
module.
Run test: NOTE: The module is also “straight through”
pin 4 to pin 4, pin 14 to pin 14, and so
NOTE: This test may show better results in on.
Active Maintenance.
6. Jumper JC6-4 and JC6-14 on the VM. The
If the display does not change when the tilt display should show a change of state. If
down switch is depressed, then the test has not, replace the VM.
failed.
! CAUTION
on page 2-12.

from the VM.
SelfTest.
proper operation.
6-94 PDMM-0089 Issued: 6/24/02

Digital Input Tests
Test I05 - Sideshift Right Switch 3. Use an ohmmeter and test switch (S6) for
proper operation.
(optional)
4. Check the continuity of the cable between
This test is to observe the ON/OFF signal from the module and the VM. If the cable fails
the sideshift right switch (S6) in the control the test, replace the cable.
handle (if the option is installed and configured NOTE: The cable is “straight through” pin 6 to
on the lift truck). pin 6 and pin 14 to pin 14, etc., except
pin 12 and pin 13 are not connected.
5. Check the continuity of the module. If the
• Test O06 - Toggle the Tilt Solenoid module does not pass the test, replace the
(Page 6-122) module.
NOTE: If Test I05 does not appear in the NOTE: The module is also “straight through”
Maintenance Mode menu, use PC Loader pin 6 to pin 6, pin 14 to pin 14 and so
to enable the feature. See “Options” on on.
page 9-13. 6. Jumper JC6-6 and JC6-14 on the VM. The

Active Maintenance.
If the display does not change when the
sideshift right switch is depressed, the test has
failed.
! CAUTION
on page 2-12.

from the VM.
SelfTest.
PDMM-0089 Issued: 6/24/02 6-95

Digital Input Tests
Test I06 - Sideshift Left Switch 3. Use an ohmmeter and test switch (S7) for
proper operation.
(optional)
This test is to observe the ON/OFF signal from the module and the VM. If the cable fails
the sideshift left switch (S7) in the control the test, replace the cable.
handle (if the option is installed and configured NOTE: The cable is “straight through” pin 5 to
on the lift truck). pin 5 and pin 14 to pin 14, etc., except
pin 12 and pin 13 are not connected.
• Test O06 - Toggle the Tilt Solenoid module does not pass the test, replace the
(Page 6-122) module.
NOTE: If Test I06 does not appear in the NOTE: The module is also “straight through”
Maintenance Mode menu, use PC Loader pin 5 to pin 5, pin 14 to pin 14 and so
to enable the feature. See “Options” on on.
page 9-13. 6. Jumper JC6-5 and JC6-14 on the VM. The

Active Maintenance.
If the display does not change when the
sideshift left switch is depressed, the test has
failed.
! CAUTION
on page 2-12.

cable P/N 223-003-012 are NOT
from the VM.
SelfTest.
6-96 PDMM-0089 Issued: 6/24/02

Digital Input Tests
Test I07 - Lift Limit Mast Switch Diagnosis and Repair

(optional)
This test is to observe the ON/OFF signal from
! CAUTION
the lift limit mast switch (S12) if installed. Make sure proper precautions are
on page 2-12.
• None
NOTE: If Test I07 does not appear in the
proper operation.
page 9-13. 2. Check continuity of the wires that go to the
3. Jumper PC12-5 and PC12-2 on the VM.
! CAUTION The display should show a change of state.
Use extreme caution when working If not, replace the VM.
around an elevated mast.
! WARNING
Do not lift in an area with a ceiling
height less than the lift truck’s
maximum elevated height.
Run test:
The following table indicates the correct
messages on the OD for this test.
Operator Display
Mast Position
Message
Lowered ON
Raised OFF
If the display does not change when the forks

are raised sufficiently to cause a change of state
on the switch, the test has failed.
NOTE: Under normal operation, when the
switch is open and the operator requests
Lift, the message “press UP key to
continue lifting” will appear. Press the
grey up arrow on the Operator Display.
PDMM-0089 Issued: 6/24/02 6-97

Digital Input Tests
Test I11 - FU1 Steering Fuse Diagnosis and Repair
This test is to measure the absence or presence

of B+ voltage at the Load Side of the Steer Motor ! CAUTION
(STR) contactor. Make sure proper precautions are
• Test O02 - Toggle the STR Contactor on page 2-12.
(Page 6-118)
• Code 4B - Steer Contactor Detected Closed Check for B+ at TP1 (+) and JC8-9 (–) when
When Commanded Open (Page 6-27) contactor is open and 0V when contactor is
• Code 4C - Steer Contactor Detected Open closed.
When Commanded Closed (Page 6-28) • If voltages are correct, replace the VM.
• If voltages are not correct, repair/replace
! CAUTION wiring as necessary.
When this test is activated and the
deadman pedal is depressed, the
steer motor/pump will activate.
Run test:
NOTE: Only run this test after Test O02 - Toggle
the STR Contactor (Page 6-118) has
passed.
The deadman pedal must be depressed
for the test to function.
Use the table as a guideline.
B+ Voltage Operator Display

Status Message
B+ present ON
B+ absent OFF
If the display message does not change when

the deadman pedal is depressed, the test is a
failure.
6-98 PDMM-0089 Issued: 6/24/02

Digital Input Tests
Test I13 - Traction Motor #1 Diagnosis and Repair

Brush Wear Indicators NOTE: It is possible for an uninsulated Brush
Wear Indicator to touch the brush spring
This test is used to observe the composite signal if not positioned correctly. If this occurs,
from the two brush wear indicator switches in carefully bend the terminal away from
traction motor #1 (left). the spring and insulate with heat-shrink
tubing.
Related messages, codes, and tests If the brushes are worn and the test will
• Code 2N (Page 6-22) not show ON, replace the brushes. If the
test still fails, go to step 1. If the brushes
• Motor Brush Inspection on page 4-12.
are not worn and the test will not show
NOTE: Code 2N will only occur upon the first OFF, go to step 4.
drive request after power-up.
! CAUTION
! CAUTION Make sure proper precautions are
When working around the motors, observed against electrostatic
use extreme caution to prevent small discharge. See “Static Precautions”
parts from falling into them. on page 2-12.
Run Test: 1. For each of the four stations, carefully

attach a short jumper from the brush wear
Use the table as a guideline. indicator spade connector to the brush
spring of the motor. If the display shows ON
Operator now, clean the brush wear indicator
Brush Status
Display Message connection and repeat at the other three
stations. If any of the four stations do not
Worn, needs
ON show ON, go to step 2.
replacing
OK OFF
! CAUTION
When any of the eight brush springs touch any Do NOT jumper from one brush pair
of the four wear indicator T-bars, the OD to another brush pair 90o away
should show ON. since they are opposite polarity and
NOTE: Test requires B+ at the brushes. different voltages. Brush pairs 180o
Therefore, depress the deadman pedal to apart (across from each other) are
close the travel contactor. the same polarity at the same
voltage.
2. Disconnect JPS11 at the motor. Depending

on which station failed step 1, attach the
jumper from JPS11-2 or JPS11-4 to the
brush spring. If it shows ON now, repair or
replace the wiring inside the motor. If it
does not show ON, go to step 3.
PDMM-0089 Issued: 6/24/02 6-99

Digital Input Tests
3. Disconnect JPS10 at the VM. Depending on

which station failed steps 1 or 2, attach the
jumper from JPC10-8 or JPC10-9 to the
brush spring. If the display shows ON,
repair or replace the wiring. Check
continuity from JPC10-8 to JPS11-2 and
JPC10-9 to JPS11-4. If it does not show ON
with the jumper in place, replace the VM.
NOTE: A dirty motor or battery may make the
brush wear indicator always show ON.
4. Remove the wire from the brush wear
indicator at the brush rigging. If it shows
OFF now, clean the motor or adjust the
T-bar. If it does not show OFF, go to step 5.
5. Unplug JS11. If the OD shows OFF, locate
which wire is shorted to the vehicle. If it
does not show OFF, go to step 6.
6. Remove JC10-8 and JC10-9 from the VM. If
the display shows OFF now, look for a wire
shorted to the vehicle. If it still will not show
OFF, replace the VM.
6-100 PDMM-0089 Issued: 6/24/02

Digital Input Tests
Test I14 - Traction Motor #2 Diagnosis and Repair

Brush Wear Indicators NOTE: It is possible for an uninsulated brush
wear indicator to touch the brush spring
This test is used to observe the composite signal if not positioned correctly, causing this
from the two brush wear indicator switches in code to appear. If this occurs, carefully
traction motor #2 (right). bend the terminal away from the spring
and insulate with heat-shrink tubing.
• Code HE (Page 6-64) not show ON, replace the brushes. If the
NOTE: Code HE will only occur upon the first OFF, go to step 4.
drive request after power-up.
! CAUTION

Use the table as a guideline. indicator spade connector to the brush
Brush Status
Worn, needs
replacing
OK OFF
! CAUTION
of the four brush wear indicator T-bars, the OD to another brush pair 90o away
NOTE: Test requires B+ at the brushes. different voltages. Brush pairs 180o
Therefore, depress the deadman pedal to apart (across from each other) are
close the travel contactor. the same polarity at the same
voltage.

jumper from JPS12-2 or JPS12-4 to the
brush spring. If it shows ON now, repair or
replace the wiring inside the motor. If it
does not show ON, go to step 3.
PDMM-0089 Issued: 6/24/02 6-101

Digital Input Tests
3. Disconnect JPS10 at the VM. Depending on

JPC10-10 to JPS12-4. If it does not show
ON with the jumper in place, replace the
VM.
5. Remove JS12-2 and JS12-4 from the
connector. If the OD shows OFF, locate
doesn’t show OFF, go to step 6.
6. Remove JC10-13 and JC10-10 from the
VM. If the display shows OFF now, look for
a wire shorted to the vehicle. If it still will
not show OFF, replace the VM.
6-102 PDMM-0089 Issued: 6/24/02

Digital Input Tests
Test I15 - Lift Motor Brush Wear Diagnosis and Repair

Indicators NOTE: It is possible for an uninsulated Brush
Wear Indicator to touch the brush spring
This test is used to observe the composite signal if not positioned correctly, causing this
from the two brush wear indicator switches in code to appear. If this occurs, carefully
lift motor. bend the terminal away from the spring
and insulate with heat-shrink tubing.
• Code 6U (Page 6-39) not show ON, replace the brushes. If the
NOTE: Code 6U will only occur upon the first OFF, go to step 4.
lift request after power-up.
! CAUTION

Use the following table as a guideline. indicator spade connector to the brush
Brush Status
Worn, needs
replacing
OK OFF
! CAUTION
of the four brush wear indicator T-bars, the OD to another brush pair 90o away
different voltages. Brush pairs 180o
apart (across from each other) are
the same polarity at the same
voltage.

jumper from JPS8-2 or JPS8-4 to the brush
spring. If it shows ON now, repair or replace
the wiring inside the motor. If it does not
show ON, go to step 3.
PDMM-0089 Issued: 6/24/02 6-103

Digital Input Tests
3. Disconnect JPC10 at the VM. Depending on

JPC10-15 to JPS8-4. If it does not show ON
with the jumper in place, replace the VM.
5. Remove JS8-2 and JS8-4 from the
connector. If the OD shows OFF, locate
doesn’t show OFF, got to step 6.
6. Remove JC10-14 and JC10-15 from the
VM. If the display shows OFF now, look for
a wire shorted to the vehicle. If it still will
not show OFF, replace the VM.
6-104 PDMM-0089 Issued: 6/24/02

Digital Input Tests
Test I16 - Traction Motor #1 Run test:

Speed Sensor NOTE: This test will show best results in Active
Maintenance.
This test is to observe the signal from the speed
sensor on traction motor #1 (left) in mph. 1. Use the table as a guideline.
Related messages, codes, and tests Sensor Signal Operator Display

Status Message
• Code 2H (Page 6-20)
Present 0-7 MPH
• Code 29 (Page 6-18)
Absent OFF
! WARNING The OD will show speed as seen by the

velocity sensor. Desired travel speed is set
Perform this test in an area free of in Configure for best accuracy. See
obstructions with ample room for Table 3-2, “Configure Mode Menu,” on
maneuvering, or with both drive page 10.
wheels jacked up. 2. The speed and direction of each drive motor
depends on the position of the steer tire.
Use extreme caution whenever the Forks first is negative, tractor first is
lift truck is jacked up. Never block positive. For best results, position the steer
the lift truck between the telescopic tire straight ahead.
and the floor. Use a suitable hoist to 3. Compare results with “Test I17 - Traction
stabilize the mast. Keep hands and Motor #2 Speed Sensor” on page 6-107.
feet clear from beneath vehicle while
jacking the lift truck. After the lift Diagnosis and Repair
truck is jacked up, place solid blocks
1. Check for shorts to frame (–) at all three
or jack stands beneath it to support
wires (+), JPS3-1, JPS3-2, JPS3-3 and
it. DO NOT rely on the jack alone to repair as necessary. Install edge guard, if
support the lift truck. See “Jacking needed, where wires drop through the lift
Safety” on page 2-14. truck frame.
2. The cable from JPS3 to the VM may be bad.
Check continuity from:
• JPC10-4 to JPS3-1
Repair or replace as necessary.
3. Measure the voltage from JPS3-1 (+) to
JPS3-3 (–). The meter should show
approximately 11.5V.
PDMM-0089 Issued: 6/24/02 6-105

Digital Input Tests
4. Connect a voltmeter from JPS3-2 (+) to

JPS3-3 (–) with no metal over the sensor.
The meter should show approximately 5V.
With a flat iron or steel object over the
sensor, the meter should show
approximately 0V. (Note: a magnet will stick
to iron or steel.) If these figures are not
seen, replace the speed sensor.
The clearance from the sensor to the
impeller is 0.050 to 0.080 in. (1.27 to
2.03 mm).
6-106 PDMM-0089 Issued: 6/24/02

Digital Input Tests
Test I17 - Traction Motor #2 Run test:

Speed Sensor NOTE: This test will show best results in Active
Maintenance.
This test is to observe the signal from the speed
sensor on traction motor #2 (right) in mph. 1. Use the table as a guideline.
Related messages, codes, and tests Sensor Signal Operator Display

Status Message
• Code HB (Page 6-62)
Present 0-7 MPH
Absent OFF
! WARNING
The OD will show speed as seen by the
Perform this test in an area free of velocity sensor. Desired travel speed is set
obstructions with ample room for in Configure for best accuracy. See
maneuvering, or with both drive Table 3-2, “Configure Mode Menu,” on
wheels jacked up. page 10.
Use extreme caution whenever the 2. The speed and direction of each drive motor
lift truck is jacked up. Never block depends on the position of the steer tire.
Forks first is negative, tractor first is
the lift truck between the telescopic positive. For best results, position the steer
and the floor. Use a suitable hoist to tire straight ahead.
stabilize the mast. Keep hands and
3. Compare results with “Test I16 - Traction
feet clear from beneath vehicle while Motor #1 Speed Sensor” on page 6-105.
jacking the lift truck. After the lift
truck is jacked up, place solid blocks Diagnosis and Repair
it. DO NOT rely on the jack alone to 1. The cable from JPS4 to the VM may be bad.
Check for continuity from:
support the lift truck. See “Jacking
Safety” on page 2-14. • JPC10-5 to JPS4-1
Repair or replace as necessary.
2. Measure the voltage from JPS4-1 (+) to
JPS4-3 (–). The meter should show
approximately 11.5V. If it does not, run
Test A16 - Power Supply +12VDC
(Page 6-87).
3. Check for shorts to frame (–) at all three
wires (+), JPS4-1, JPS4-2, JPS4-3 and
repair as necessary. Install edge guard, if
needed, where wires drop through the lift
truck frame.
PDMM-0089 Issued: 6/24/02 6-107

Digital Input Tests
4. Connect a voltmeter from JPS4-2 (+) to

JPS4-3 (–) with no metal over the sensor.
The meter should show approximately 5V.
With a flat iron or steel object over the
sensor, the meter should show
approximately 0V. (Note: A magnet will
stick to iron or steel.) If these figures are
not seen, replace the speed sensor.
The clearance from the sensor to the
impeller is 0.050 to 0.080 in. (1.27 to
2.03 mm).
6-108 PDMM-0089 Issued: 6/24/02

Digital Input Tests
Test I18 - Steer Position Sensor Diagnosis and Repair
This test is to observe the feedback from the

Steer Position sensor. ! CAUTION
Related messages, codes, and tests observed against electrostatic
• Code G2 (Page 6-56)
on page 2-12.
• Code G7 (Page 6-57)
1. Make sure the steer position prox switch is

! WARNING not damaged. Replace any damaged
components as necessary.
Perform this test in an area free of
NOTE: Adjust the prox switch position if the
obstructions with ample room for results are erratic. The gap between the
maneuvering. bottom face of the sensor and the upper
surface of the steer plate should
measure 0.080 ±.020 in. (2 ±0.005 mm).
! CAUTION 2. The cable from the VM to the steer position
Steer tire rotation is opposite that of sensor (JC7 to JS2) may be bad. Check for
the steer tiller. continuity from:
Run test: • JPC7-17 to JP2-2
• JPC7-18 to JP2-3
As the steer tire rotates, the numbers listed in
the table appear on the display. If they do not • JPC7-8 to JP2-4
change or are erratic, the test has failed. Repair or replace the cable as necessary.
3. Check for +12V at JPS2-1 wrt TP4 (B–).
Steer Operator
Steer Tire 4. Connect the (+) lead of a voltmeter to
Tiller Display
Position JPC7-17, steer channel A, and the (–) lead
Position Message
to TP4 (B–).
90° (full clockwise)
Left 101 NOTE: Steer channels A, B, and C are displayed
to 67°
in Test I18 as A B C where A is the outer
67° to 41° Left 100 ring and C is the inner ring on the
41° to 18° Left 000 encoder.
18° to –18° 5. Place a steel object, such as a screwdriver,
Centered 001
(wheels centered) over the bottom of the prox switch.
–18° to –41° Right 011 When the metal object is over the bottom of
–41° to –67° Right 010 the prox switch, the voltmeter should read
–90° less than 2V. Display = 1.
(counterclockwise) Right 110 When the metal object is taken away from
to –67° the bottom of the prox switch, the voltmeter
Error Condition 111 should read more than 7V. Display = 0.
If the above two conditions are not met,
replace the prox switch.
PDMM-0089 Issued: 6/24/02 6-109

Digital Input Tests
6. Connect the (+) lead of the voltmeter to

JPC7-18, steer channel B, and repeat
step 5. The results should be the same.
7. Connect the (+) lead of the voltmeter to
JPC7-8, steer channel C, and repeat step 5.
The results should be the same.
8. If steps 4 through 7 show the proper
voltages for the prox switch, but not the
proper display, replace the VM.
6-110 PDMM-0089 Issued: 6/24/02

Digital Input Tests
Test I19 - Battery Gate Switches 3. The switch is not receiving the proper
voltage. With a voltmeter, check for 12V at:
This test is to observe the signal from the
Battery Gate Switches (if installed). Meter Lead Position
(+) (–)
JPS13-1 to JPS13-3 (right gate (with left gate
Alarm Shutdown installed))
NOTE: If Test I19 does not appear in the JPS14-1 to JPS14-3 (left gate (with right gate
Maintenance Mode menu, use PC Loader installed))
to enable the feature. See “PC Loader JPA3-8 to JPA3-3 (Attachment Card input)
Installation” on page 9-3
JPA1-2 to JPA1-9 (Attachment Card output)
Run test: JPC7-4 to JPC7-7 (VM input)

Active Maintenance. 4. Check continuity of JP13-3 (Gnd) to JP14-2
(out). This wire is essential to ganging the
ON or OFF is indicated on the OD. two switches together in series.
If the display does not change when both 5. Check for proper operation of the circuit by
battery gates are installed and one gate is using jumpers in the following locations:
removed, the test has failed.
Diagnosis and Repair ! CAUTION

Unless otherwise specified,
disconnect the previous jumper
! CAUTION before continuing on to the next
Make sure proper precautions are location.
• JPS13-2 to JPS13-3 and
on page 2-12. JPS14-2 to JPS14-1 together
• JPA3-5 to JPA3-3 (Attachment Card
1. Make sure the battery gate setting is not set input)
to OFF in the config menu where options • JPA1-1 to JPA1-9 (Attachment Card
are: OFF, Alarm, Speed Limit, and output)
Shutdown.
• JPC7-15 to JPC7-7 (at VM)
2. Verify that both switches (S22A and S22B)
Repair or replace cables or Attachment
are engaged when the battery gates are
Card if faulty.
installed.
If, after jumpering these connections, the
display does not change, replace the VM.
PDMM-0089 Issued: 6/24/02 6-111

Digital Input Tests
Tests I20 and I21- Control 2. Plug the handle directly into the VM. Turn
the key to the ON position and re-run the
Handle Option Switches test.
“A” (I20) and “B” (I21) NOTE: Code 80 or 81 will appear during
SelfTest.
This test is to observe ON/OFF signal from the
Option “A” (S4) and “B” (S5) switches in the 3. If the test now passes, go to step 6. It the
operator’s control handle. These switches are test fails, go to step 8.
normally used in conjunction with a high speed 4. Check the continuity of the cable between
attachment option. the module and the VM. If the cable checks
bad, replace the cable.
NOTE: The cable is “straight through”; pin 1 to
None pin1, pin 14 to pin 14 and so on. Pins 12
and 13 are not connected.
NOTE: If Test I20 or I21 does not appear in the
Maintenance Mode menu, use PC Loader 5. Check the continuity of the module. If the
to enable the feature. See “Options” on module checks bad, replace the module.
page 9-13. NOTE: The module is “straight through”; pin 1
to pin1, pin 14 to pin 14 and so on.
Run test:
6. Use an ohmmeter and test switch (S4 or S5)
Use the table as a guideline. for proper operation.
Option “A” or “B” Operator switch. Repair or replace as necessary.
Switch Position Display Message
8. Jumper JC6-1 (S4) or JC6-2 (S5) and
Depressed ON JC6-14 on the VM. The display should
Released OFF show a change of state. If not, replace the
VM.

! CAUTION
on page 2-12.

1. Turn the key switch to the OFF position.
Unplug the handle from the module and the
module from the VM.
6-112 PDMM-0089 Issued: 6/24/02

Digital Input Tests
Test I22 - Horn Switch NOTE: The module is “straight through”; pin 7
to pin 7, pin 14 to pin 14 and so on.
This test is to observe ON/OFF signal from the 6. Use an ohmmeter and test switch (S3) for
Horn switch (S3) in the operator’s control proper operation.
handle.
8. Jumper JC6-7 and JC6-14 on the VM. The
None display should show a change of state. If
not, replace the VM.
Run test:
Use the following table as a guideline.
Horn Switch Operator

Position Display Message
Depressed ON
Released OFF


1. Turn the key switch to the OFF position.
Unplug the handle from the module and the
module from the VM.
the key to the ON position and re-run the
test.
NOTE: Code 80 or 81 will appear during
SelfTest.
3. If the test now passes, go to step 5. It the
test fails, go to step 6.
the module and the VM. If the cable checks
bad, replace the cable.
NOTE: The cable is “straight through”; pin 7 to
pin 7, pin 14 to pin 14 and so on. Pins
12 and 13 are not connected.
module checks bad, replace the module.
PDMM-0089 Issued: 6/24/02 6-113

Digital Input Tests
6-114 PDMM-0089 Issued: 6/24/02

Digital Output Tests

Electrical Tests 6:
PDMM-0089 Issued: 6/24/02 6-115

Test O00 - Toggle the TPC Diagnosis and Repair

Contactor
This test turns the TPC contactor ON and OFF.
! CAUTION
• Code 44 - TPC Contactor Detected Closed on page 2-12.
When Commanded Open (Page 6-25)
• Code 45 - TPC Contactor Detected Open
When Commanded Closed (Page 6-26) 1. Disconnect JPC8 from the VM.
• Test I11 - FU1 Steering Fuse (Page 6-98) 2. Measure the resistance between TPC-X and
TPC-Y. The resistance should read
approximately 100 ohms.
! CAUTION • If the resistance is not correct, replace
Jack the drive wheels off the floor the contactor.
for this test. • If the resistance is correct, proceed to
the next step.
Use extreme caution whenever the
lift truck is jacked up. Never block 3. Connect the (+) lead of a DVM to PC8-14
and the negative lead to PC8-20 on the VM.
the lift truck between the telescopic
and the floor. Use a suitable hoist to 4. Run the test. The meter should indicate
stabilize the mast. Keep hands and near battery voltage. With the test OFF, the
meter should read 0V.
jacking the lift truck. After the lift • If the voltages are correct, troubleshoot
the wiring in the TPC contactor circuit.
or jack stands beneath it to support • If the voltages are not correct, replace
the VM.
it. DO NOT rely on the jack alone to
Safety” on page 2-14.
! WARNING
The traction system may not act as
expected during this test. If the
traction power amplifier is shorted,
the lift truck may start to travel when
the contactor is toggled ON/OFF.
Run test:
NOTE: Toggle this test using the UP/DOWN
keys on the ODI. Make sure the TPC
toggles, not the LPC.
If the contactor does not cycle in/out when the
test is toggled, the test has failed.
6-116 PDMM-0089 Issued: 6/24/02

Test O01 - Toggle the LPC Diagnosis and Repair

Contactor
This test turns the LPC contactor ON and OFF.
! CAUTION
• Code 42 - LPC Contactor Detected Closed on page 2-12.
• Code 43 - LPC Contactor Detected Open
2. Measure the resistance between LPC-X and
LPC-Y. The resistance should read
! CAUTION approximately 100 ohms.
The ceiling height should be higher • If the resistance is not correct, replace
than maximum elevated height of the contactor.
the vehicle under test. • If the resistance is correct, proceed to
the next step.
3. Connect the (+) lead of a DVM to PC8-14
! WARNING and the negative lead to PC8-21 on the VM.
4. Run the test. The meter should indicate
The lift system may not act as
near battery voltage. With the test OFF, the
expected during this test. If the lift meter should read 0V.
power amplifier is shorted, the mast
• If the voltages are correct, troubleshoot
may lift when the contactor is the wiring in the LPC contactor circuit.
toggled ON/OFF.
• If the voltages are not correct, replace
the VM.
Run test:
keys on the ODI. Make sure the LPC
toggles, not the TPC.
PDMM-0089 Issued: 6/24/02 6-117

Test O02 - Toggle the STR Diagnosis and Repair

Contactor
This test turns the STR contactor ON and OFF.
! CAUTION
• Code 4B - Steer Contactor Detected Closed on page 2-12.
• Code 4C - Steer Contactor Detected Open
2. Measure the resistance between STR-X and
STR-Y. The resistance should read
! WARNING approximately 100 ohms.
• If the resistance is not correct, replace
DO NOT attempt to drive the lift truck
the contactor.
while conducting this test.
• If the resistance is correct, proceed to
the next step.
! CAUTION 3. Connect the (+) lead of a DVM to PC8-14

and the negative lead to PC8-18 on the VM.
The steer system may not act as
4. Run the test. The meter should indicate
expected during this test. The steer
near battery voltage. With the test OFF, the
motor will run when the contactor is meter should read 0V.
toggled ON and OFF.
• If the voltages are correct, troubleshoot
the wiring in the STR contactor circuit.
Run test: • If the voltages are not correct, replace
the VM.
keys on the OD.
6-118 PDMM-0089 Issued: 6/24/02

Test O03 - Toggle the Load Hold Diagnosis and Repair

Solenoid
This test turns the Load Hold solenoid (SOL1)
! CAUTION
ON and OFF. Make sure proper precautions are
on page 2-12.
• Test O05 - Ramp the Proportional Lower
Solenoid (Page 6-121)
NOTE: If the horn, aux functions and lift/lower
all do not function, troubleshoot B+
! WARNING circuit at JPC8-4 and JPC8-5.
Measure the resistance between JPC9-3 and
Make sure the forks are fully
JPC9-6. The resistance should read
lowered before performing this test. approximately 37 ohms.
1. If the resistance is not correct, troubleshoot
associated wiring and contactor coil.
! CAUTION
2. If the resistance is correct, replace the VM.
The lowering function normally uses
the proportional lower solenoid in
conjunction with the load hold
solenoid.
Run test:
Enter this test in Maintenance Mode. Toggle the
test ON and OFF with the UP/DOWN keys.
1. Disconnect wire SOL1-1 from solenoid 1.
See “Main Manifold Solenoid Layout” on
page 7-9.
2. Connect an ammeter between the
disconnected wire and terminal SOL1-1 on
the solenoid.
3. Toggle the test ON. When the OD shows
ON, the ammeter should read 900 to
1100 milliamps (0.9 to 1.1 amps). If not,
PDMM-0089 Issued: 6/24/02 6-119

Test O04 - Toggle the Sideshift 1. If the resistance is not correct, troubleshoot
associated wiring and solenoid coil.
Solenoid (Optional)
This test turns the Sideshift solenoid (SOL2) ON
and OFF.

None
NOTE: The sideshift option must be installed
before this test is available.
If Test O04 does not appear in the
page 9-13.
Run test:
page 7-9.
the solenoid.
! CAUTION
on page 2-12.

circuit at JPC8-4 and JPC8-5.
6-120 PDMM-0089 Issued: 6/24/02

Test O05 - Ramp the Diagnosis and Repair

Proportional Lower Solenoid
This test is used to turn ON the Proportional
! CAUTION
Lower solenoid (SOL3) by increasing the PWM Make sure proper precautions are
signal. observed against electrostatic
Related messages, codes, and tests on page 2-12.
• Test O03 - Toggle the Load Hold Solenoid
(Page 6-119) NOTE: If the horn, aux functions and lift/lower
! CAUTION
The lowering function normally uses JPC9-11. The resistance should read
the proportional lower solenoid in approximately 23 ohms.
conjunction with the load hold 1. If the resistance is not correct, troubleshoot
solenoid. associated wiring and solenoid coil.
Run test:
NOTE: The proportional solenoid is only used
for the lower functions.
1. 0 to 90% will appear on the OD. Use the
UP/DOWN arrows to increase or decrease
the percentage.
2. Use the table as a reference guide for
testing. All values are approximate.
Operator Amps On Voltage On

Display Message Meter Meter
0% 0 0
15% 0.3 4.5
30% 0.6 9.0
45% 1.0 15.0
60% 1.3 20.0
75% 1.6 26.0
90% 2.0 32.0
PDMM-0089 Issued: 6/24/02 6-121

Test O06 - Toggle the Tilt

Solenoid
This test turns the Tilt solenoid (SOL4) ON and
OFF.

None
Run test:
page 7-9.
the solenoid.
! CAUTION
on page 2-12.

6-122 PDMM-0089 Issued: 6/24/02

Test O07 - Toggle the P2-Dump

Solenoid
This test turns the P2-Dump solenoid (SOL5)
ON and OFF.

None.
Run test:
page 7-9.
the solenoid.
! CAUTION
on page 2-12.

PDMM-0089 Issued: 6/24/02 6-123

Test O08 - Toggle the Auxiliary

Direction Solenoid
This test turns the Auxiliary Direction solenoid
(SOL6) ON and OFF.

None
Run test:
page 7-9.
the solenoid.
! CAUTION
on page 2-12.

6-124 PDMM-0089 Issued: 6/24/02


Solenoid
This test turns the Lift/Aux1 solenoid (SOL7)
ON and OFF.

None
Run test:
page 7-9.
the solenoid.
! CAUTION
on page 2-12.

PDMM-0089 Issued: 6/24/02 6-125


Solenoid
This test turns the Lift/Aux2 solenoid (SOL8)
ON and OFF, if installed.

None
Run test:
page 7-9.
the solenoid.
! CAUTION
on page 2-12.

6-126 PDMM-0089 Issued: 6/24/02

Test O11 - Ramp the Measure the resistance between JPC9-3 and
Proportional Relief Solenoid approximately 33.7 ohms.
This test turns the Proportional Relief solenoid 1. If the resistance is not correct, troubleshoot
(SOL9) ON by increasing the PWM signal. associated wiring and solenoid coil.
NOTE: SOL9 is present only on trucks with
high speed auxiliary functions.
If Test O11 does not appear in the
page 9-13.
Run Test:
1. 0 to 90% will appear on the OD. Use the
UP/DOWN arrows to increase or decrease
the percentage.
2. Use the table as a reference guide for
testing. All values are approximate.
Operator Voltage On
Display Message Meter
0% 0.0
15% 4.5
30% 9.0
45% 15.0
60% 20.0
75% 26.0
90% 32.0
! CAUTION
on page 2-12.

PDMM-0089 Issued: 6/24/02 6-127

Test O12 - Toggle the High 2. Check for B+ at JPA2-8 wrt TP4. If voltage
is missing or incorrect, replace the VM.
Speed Aux1 Solenoid (Optional)
3. Check for B+ at JPA1-6 wrt TP4. If voltage
This test turns the High Speed Aux1 solenoid is missing or incorrect, replace the
(SOL10) ON and OFF (if the option is installed Attachment Card.
and configured on the lift truck). 4. Check for B+ at JPC7-9-6 wrt TP4.
• If voltage is missing or incorrect,
Related messages, codes, and tests troubleshoot wiring between the VM and
None the Attachment Card.
• If voltage is correct, replace the VM.
NOTE: If Test O12 does not appear in the
page 9-13.
Run test:
page 7-9.
disconnected wire and terminal SOL10-1
on the solenoid.
! CAUTION
on page 2-12.

1. Measure the resistance between JPC9-3
and JPA2-8. The resistance should read
approximately 33.7 ohms. If the resistance
is not correct, troubleshoot associated
wiring and solenoid coil.
6-128 PDMM-0089 Issued: 6/24/02

Test O13 - Toggle the High 3. Check for B+ at JPH2-3 wrt TP4. If voltage
is missing or incorrect, replace the
Speed Aux2 Solenoid (Optional) Attachment Card.
This test is used to turn the High Speed Aux2 4. Check for B+ at JP48-3 wrt TP4.
solenoid (SOL11) ON and OFF (if the option was • If voltage is missing or incorrect,
installed and configured on the lift truck). troubleshoot wiring between the VM and
the Attachment Card.
Related messages, codes, and tests • If voltage is correct, replace the VM.
None
NOTE: If Test O13 does not appear in the
page 9-13.
Run test:
page 7-9.
disconnected wire and terminal SOL11-1
on the solenoid.
! CAUTION
on page 2-12.
1. Measure the resistance between JPA2-3

and JPA2-10. The resistance should read
approximately 36 ohms. If the resistance is
not correct, troubleshoot associated wiring
and solenoid coil.
2. Check for B+ at JPA2-10 wrt TP4. If voltage
is missing or incorrect, replace the VM.
PDMM-0089 Issued: 6/24/02 6-129

Test O14 - Ramp the #1 (left) Run Test:

Traction Power Amplifier NOTE: Depress the deadman pedal to release
the brake. If the brakes do not release,
This test turns on the left Traction Power run Tests O17 and O18.
Amplifier (#1) by gradually increasing the
command to it through the CAN bus. 1. This test will ramp from 0 to 100% in 10%
increments when the UP/DOWN buttons
are pushed. To change directions, press the
Related messages, codes, and tests ENTER button. The voltage readings should
• Code 1H - Traction Power Amplifier #1 (left) change according to the table. The voltages
Overheated (Page 6-10) may vary slightly from those in the table,
depending on the battery voltage.
• Code 21 - Short Detected in Armature
Circuit #1 (left) (Page 6-15) Operator Approximate
• Code 26 - Open Detected in Field Circuit, Display Message Voltage
#1 (left) (Page 6-17) 0% 36.0V
• Code 29 - No Movement Detected When 10% 34.0V
Travel Is Requested (Page 6-18)
20% 30.0V
• Code 2M - Traction Power Amplifier #1 (left)
30% 26.0V
Fault (Page 6-21)
40% 22.0V
! CAUTION 50% 19.0V
DO NOT EXCEED a current level of 60% 15.0V
100A for 5 seconds or 50A for 10 70% 12.0V
seconds without wheel movement. 80% 8.0V
Prolonged applications of current to
90% 5.0V
the motor without movement will
damage the motor. 100% 0.0V
NOTE: Note: The (+) meter lead
connects to the M– hookup
! WARNING and the (–) lead connects to
The left traction motor will rotate the B– hookup on the power
amplifier.
during this test if it passes. Jack the
drive wheels up.
2. When this display shows FWD, press
Use extreme caution whenever the ENTER to toggle to REVERSE and repeat
lift truck is jacked up. Never block step 1.
and the floor. Use a suitable hoist to
6-130 PDMM-0089 Issued: 6/24/02

3. During this test, the field terminal F1 and

F2 will drop approximately 6V (while the
test is running).
Meter Lead Meter Lead

Connection Connection
(Forward) (Reverse)
(+) (–) (+) (–)
B+ F1 B+ F2
The meter will start at battery voltage and

drop approximately 6V when the test is
operating.
! CAUTION
on page 2-12.
1. If the percentage on the OD changes and

the voltage on the meter changes according
to the table, but the motor does not turn,
check the motor and repair or replace as
necessary. See “Electric Motor Tests” on
page 7-61.
2. If the percentage on the OD changes but
the voltage on the power amplifier does not,
swap the left and right power amplifiers. If
the problem changes to the right side,
replace the power amplifier.
PDMM-0089 Issued: 6/24/02 6-131

Test O15 - Ramp the #2 (right) Run Test:

Traction Power Amplifier NOTE: Depress the deadman pedal to release
the brake. If the brakes do not release,
This test turns on the right Traction Power run Tests O17 and O18.
Amplifier (#2) by gradually increasing the
command to it through the CAN bus. 1. This test will ramp from 0 to 100% in 10%
increments when the UP/DOWN buttons
are pushed. To change directions, press the
Related messages, codes, and tests ENTER button. The voltage readings should
• Code 29 - No Movement Detected When change according to the table. The voltages
Travel Is Requested (Page 6-18) may vary slightly from those in the table,
depending on the battery voltage.
• Code H0 - Short Detected in Armature
Circuit #2 (right) (Page 6-58) Operator Approximate
• Code H4 - Open Detected in Field Circuit #2 Display Message Voltage
(right) (Page 6-60) 0% 36.0V
• Code HK - Traction Power Amplifier #2 10% 34.0V
(right) Fault (Page 6-66)
20% 30.0V
30% 26.0V
! CAUTION 40% 22.0V
DO NOT EXCEED a current level of 50% 19.0V
100A for 5 seconds or 50A for 10
60% 15.0V
seconds without wheel movement.
70% 12.0V
Prolonged applications of current to
the motor without movement will 80% 8.0V
damage to the motor. 90% 5.0V
100% 0.0V
NOTE: Note: The (+) meter lead
! WARNING connects to the M– hookup
and the (–) lead connects to
The right traction motor will rotate the B– hookup on the power
during this test if it passes. Jack the amplifier.
drive wheels up.
Use extreme caution whenever the 2. When this display shows FWD, press
lift truck is jacked up. Never block ENTER to toggle to REVERSE and repeat
the lift truck between the telescopic step 1.
6-132 PDMM-0089 Issued: 6/24/02

3. During this test, the field terminal F1 and

F2 will drop approximately 6V (while the
test is running).
Meter Lead Meter Lead

Connection Connection
(Forward) (Reverse)
(+) (–) (+) (–)
B+ F2 B+ F1
The meter will start at battery voltage and

drop approximately 6V when the test is
operating.
! CAUTION
on page 2-12.

to the table but the motor does not turn,
page 7-61.
the voltage on the power amplifier does not
change, swap the left and right power
amplifiers. If the problem changes to the
left side, replace the power amplifier.
PDMM-0089 Issued: 6/24/02 6-133

Test O16 - Ramp the Lift Power This test will ramp from 0 to 100% in 10%
increments when the UP/DOWN buttons are
Amplifier pushed. The lift motor will spin faster as the
voltage increases. The voltage readings should
This test turns on the Lift Power Amplifier by
change according to the table.
gradually increasing the command to it through
the CAN bus. Operator
Voltage
Display Message
Related messages, codes, and tests 0% 0.0V
• Code 6V - Lift Power Amplifier Fault 10% 2.7V
(Page 6-40) 20% 6.3V
30% 9.7V
! WARNING 40% 13.0V

50% 16.5V
The lift motor will rotate and the load
60% 20.0V
handler will move during this test if it
passes. 70% 23.0V
80% 27.0V
90% 30.0V
The ceiling height must be greater
than the maximum elevated height 100% 34.0V
of the lift truck in the area where
testing is performed. Diagnosis and Repair
Run Test: ! CAUTION

Meter Lead Connections on
Power Amplifier observed against electrostatic
(+) (–)
on page 2-12.
B+ M–

to the table but the motor does not turn,
page 7-61.
the voltage on the power amplifier does not
change, replace the lift power amplifier.
6-134 PDMM-0089 Issued: 6/24/02

Test O17 - Toggle Traction 2. Using an ohmmeter, measure the

resistance of the brake coil. The resistance
Motor Brake #1 (left) should measure 21 to 27 ohms (resistance
value will increase with an increase in
This test turns the brake on Traction Motor #1
brake temperature but will still be within
(left) ON or OFF.
this range). Record the value for reference.
If it is not correct, replace the brake coil.
3. With the key switch ON, connect a
• Code 29 - No Movement Detected When voltmeter at JPB3-1 (+) and TP4 (B–). The
Travel Is Requested (Page 6-18) meter should show battery voltage. Record
the value for reference. If it does not show
• Code 2A - Traction Motor #1 (left)
battery voltage, move the meter lead to
Overheated (Page 6-19)
JPC10-20 (B+KB output from the VM), then
• Code H6 - Traction Motor #2 (right) JPC10-19 (B+KB input to the VM), then T1
Overheated (Page 6-61) (output of Fuse/Relay card). Repair or
replace wires as needed.
! CAUTION 4. Check for shorts to frame at JPB3-1 and

JPB3-2. Repair or replace wires as needed.
The left brake may not operate as Install edge guard, if needed, where wires
expected during this test. drop through the lift truck frame.
5. Connect JPB3 (left brake under test) and
Run Test: disconnect JPB2 (right brake). Disconnect
T1 at the Fuse/Relay card. Connect an
Toggle this test ON and OFF with the ammeter between T1 (+) of the Fuse/Relay
UP/DOWN keys. card and wire T1 (–). When test is Off (brake
energized), current should read 1.5 to 1.7A.
Two clicks should be heard when turning ON or
If test fails, go on to next step.
OFF due to the two stage design.
NOTE: Divide battery volts from step 3 by coil
If a double click is not heard, the test has failed.
resistance in step 2 for specific current
value.
6. Leave JPB3 connected at the brake. Unplug
JPC10 connector from the VM. Use an
! CAUTION ohmmeter to measure resistance between
JPC10-17 and JPC10-20. If the resistance
value does not match step 2, repair/replace
observed against electrostatic wires. If the resistance value does match
discharge. See “Static Precautions” step 2, replace the VM.
on page 2-12.
NOTE: In order to make the brakes operate,

depress the deadman pedal. See Test I00
on page 6-116 to troubleshoot the
deadman switch if necessary.
1. Disconnect connection JPB3 at the brake.
PDMM-0089 Issued: 6/24/02 6-135

Test O18 - Toggle Traction 2. Using an ohmmeter, measure the

resistance of the brake coil. The resistance
Motor Brake #2 (right) should read 21 to 27 ohms (resistance
value will increase with an increase in
This test turns the brake on Traction Motor #2
brake temperature but will still be within
(right) ON or OFF.
this range). Record the value for reference.
If it is not correct, replace the brake coil.
3. With the key switch ON, connect a
• Code 29 - No Movement Detected When voltmeter at JPB2-1 (+) and TP4 (B–). The
Travel Is Requested (Page 6-18) meter should show battery voltage. Record
the value for reference. If it does not show
• Code 2A - Traction Motor #1 (left)
battery voltage, move the meter lead to
Overheated (Page 6-19)
JPC10-21 (B+KB output from the VM), then
• Code H6 - Traction Motor #2 (right) JPC10-19 (B+KB input to the VM), then T1
Overheated (Page 6-61) (output of Fuse/Relay card). Repair or
replace wires as needed.
! CAUTION 4. Check for shorts to frame at JPB2-1 and

JPB2-2. Repair or replace wires as needed.
The right brake may not operate as Install edge guard, if needed, where wires
expected during this test. drop through the lift truck frame.
5. Connect JPB2 (right brake under test) and
Run Test: disconnect JPB3 (left brake). Disconnect T1
at the Fuse/Relay card. Connect an
Toggle this test ON and OFF with the ammeter between T1 (+) of the Fuse/Relay
UP/DOWN keys. card and wire T1 (–). When test is Off (brake
energized), current should read 1.5 to 1.7A.
Two clicks should be heard when turning ON or
If test fails, go on to next step.
OFF due to the two stage design.
NOTE: Divide battery volts from step 3 by coil
If a double click is not heard, the test has failed.
resistance in step 2 for specific current
value.
6. Leave JPB2 connected at the brake. Unplug
JPC10 connector from the VM. Use an
! CAUTION ohmmeter to measure resistance between
JPC10-16 and JPC10-21. If the resistance
value does not match step 2, repair/replace
observed against electrostatic wires. If the resistance value does match
discharge. See “Static Precautions” step 2, replace the VM.
on page 2-12.
NOTE: In order to make the brakes operate,

depress the deadman pedal. See Test I00
on page 6-116 to troubleshoot the
deadman switch if necessary.
1. Disconnect connection JPB2 at the brake.

Test O19 - Ramp the Frequency

to the Operator Display Alarm
This test turns the Operator Display Alarm
(Sonalert) ON, creating the “arcade” error
sound.

None
Run Test:
If the Sonalert does not sound when the ENTER
key is pushed, the test has failed.
! CAUTION
on page 2-12.
1. If the Sonalert does not work, the OD cable

may be bad. Use an ohmmeter to check
continuity from JPC5-5 of the VM to
JPD1-5 of the ODI. Repair or replace as
necessary.
2. Measure voltage at JPC5-1 (+) and
JPC5-8 (–). The voltage should read
approximately 12V. If not, replace the VM.
3. Measure voltage at JPC5-1 (+) and
JPC5-5 (–). The voltage should change (as
little as 0.5V) when the test is activated. If
not, replace the VM. If voltage changes,
replace the ODI.
PDMM-0089 Issued: 6/24/02 6-137

Test O20 - Toggle the Horn

This test turns the lift truck’s Horn ON and
OFF.

• Test I22 - Horn Switch (Page 6-113)
Run Test:
NOTE: ON/OFF will appear on the OD. Toggle
this test ON and OFF with the
UP/DOWN keys.
When the ENTER key is pressed the horn
should sound. If it does not sound, the test has
failed.
NOTE: Check hydraulic functions for operation.
They receive battery voltage from the
same source as the horn. If they work,
B+KA into the VM is present.
! CAUTION
on page 2-12.
1. Connect a meter to H1 (+) and H2 (–) and

run the test. The meter should indicate
near battery voltage.
• If the voltage is correct, replace the
horn.
• If the voltage is not correct, proceed to
the next step.
2. Connect the (+) lead of the meter to
JPC8-15 and the (–) lead to JPC8-16 and
run the test. The meter should indicate
near battery voltage.
• If battery voltage is present,
troubleshoot the wiring and components
in the horn circuit.
• If it does not, replace the VM.
6-138 PDMM-0089 Issued: 6/24/02

Test O22 - Toggle the Aux Dump 7. Connect the (+) lead of a voltmeter to wire
SOL12-1. Connect the (–) lead to wire
Solenoid (Optional) SOL12-2.
This test is used to turn the Aux Dump solenoid 8. Toggle the test ON. The voltmeter should
(SOL12) ON and OFF. read positive battery voltage. If it doesn’t, go
on to the next step.
Related messages, codes, and tests 9. Test for battery voltage at SOL12-1 (+) with
respect to TP4 (B–). If battery voltage is not
None found, work back through the following
NOTE: If Test O22 does not appear in the connection path until the open circuit is
Maintenance Mode menu, use PC Loader found:
to enable the feature. See “Options” on • SOL6-1
page 9-13.
• SOL4-1
• JPC9-3 (B+KA output of VM)
Run Test:
Repair or replace wires as necessary.
NOTE: ON/OFF will appear on the OD. Toggle
10. Turn the key switch OFF. Check for
this test ON and OFF with the
continuity, with respect to TP4 (B–), to trace
UP/DOWN keys.
back through the following B– path:
Check hydraulic functions for operation.
• JPF4-2 (B–F input to Aux card)
They receive battery voltage from the
same source as the horn. If they work, • JPF4-2 (B–F output from Fuse/Relay
B+KA into the VM is present. card)
1. Enter this test in the lift truck’s Repair or replace wires as necessary.
maintenance mode. 11. Toggle the test ON.
2. Disconnect wire SOL12-1 from solenoid 12. 12. Remove the wire from JPA2-3 (+) and
3. Connect an ammeter between this wire and JPA2-8 (–). Connect the voltmeter to those
terminal SOL12-1 on the solenoid. terminals on the Attachment card.
4. Toggle this test ON. When the OD shows 13. If the meter shows (+) voltage with the test
ON, the ammeter should read 900 to ON, repair or replace the wire from JPA2-8
1100mA (0.9 to 1.1A). If this reading is OK, to SOL12-2. If there was no voltage, remove
the test is a success. cable JPA1 from the Attachment Card and
JPC7 from the VM. Check it for continuity
and repair or replace as necessary.
14. Connect the voltmeter to JPA1-6 (+) and
1. Turn the key switch OFF. JPA1-9 (–). With the test ON, the meter
2. Disconnect both wires from the solenoid should read approximately 4.5V. If it does,
coil. replace the Attachment card. If it does not,
replace the VM.
3. Connect the leads of an ohmmeter to the
terminals on the solenoid coil.
4. Set the ohmmeter scale to R x 1.
5. The resistance should read approximately
36 ohms. If not, replace the solenoid coil. If
it is, go on to the next step.
6. Turn the key switch ON. Re-enter this test
in the lift truck’s maintenance mode.
PDMM-0089 Issued: 6/24/02 6-139

6-140 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual Component Procedures
Component Procedures 7:
PDMM-0089 Issued: 6/24/02 7-1

Component Procedures EASi Pacer™ Lift Truck Maintenance Manual
Component Locator Photos. 7-3 Cold Storage Conditioning. . . . . . . . . . . 7-58

Field Upgrade . . . . . . . . . . . . . . . . . 7-58
Remounting Attachment Module . . . 7-59
Steering and Controls . . . 7-11 Motors, General . . . . . . . . . . . . . . . . . . 7-60
Motor Cleaning . . . . . . . . . . . . . . . . 7-60
Steer Motor . . . . . . . . . . . . . . . . .. .. . . 7-12 Electric Motor Tests. . . . . . . . . . . . . 7-61
Location . . . . . . . . . . . . . . . . .. .. . 7-12 Drive Motor . . . . . . . . . . . . . . . . . . . . . . 7-63
Removal . . . . . . . . . . . . . . . . .. .. . 7-12 Removal . . . . . . . . . . . . . . . . . . . . . 7-63
Installation. . . . . . . . . . . . . . .. .. . 7-13 Installation . . . . . . . . . . . . . . . . . . . 7-65
Wheel/Tire Assemblies. . . . . . . . .. .. . . 7-15 Lift Motor . . . . . . . . . . . . . . . . . . . . . . . 7-67
Inspection . . . . . . . . . . . . . . .. .. . 7-15 Removal . . . . . . . . . . . . . . . . . . . . . 7-67
Drive Wheel/Tire . . . . . . . . . .. .. . 7-15 Installation . . . . . . . . . . . . . . . . . . . 7-68
Steerable Wheel/Tire . . . . . . .. .. . 7-16
Steerable Wheel Assembly . . .. .. . 7-19
Steer Chain Adjustment . . . . .. .. . 7-24
Hydraulic Components . . 7-69
Operator Display Card . . . . . . . . .. .. . . 7-25
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . 7-70
Removal . . . . . . . . . . . . . . . . .. .. . 7-25
Fluid Level. . . . . . . . . . . . . . . . . . . . 7-70
Installation. . . . . . . . . . . . . . .. .. . 7-25
Selecting Hydraulic Fluid Type . . . . 7-70
Control Handle . . . . . . . . . . . . . .. .. . . 7-27
Bleeding the Hydraulic System . . . . 7-70
Removal . . . . . . . . . . . . . . . . .. .. . 7-27
Pressure Adjustment. . . . . . . . . . . . . . . 7-72
Disassembly. . . . . . . . . . . . . .. .. . 7-27
Auxiliary System Pressure
Assembly . . . . . . . . . . . . . . . .. .. . 7-28
Adjustment . . . . . . . . . . . . . . . . . . 7-72
Installation. . . . . . . . . . . . . . .. .. . 7-28
Setting Lift System Pressure
Control Handle Replacement .. .. . 7-29
Relief Valve . . . . . . . . . . . . . . . . . . 7-73
Control Module Installation . .. .. . 7-31
Steer Pump . . . . . . . . . . . . . . . . . . . . . . 7-74
Removal . . . . . . . . . . . . . . . . . . . . . 7-74
Drive and Brake . . . . . . . 7-33 Installation . . . . . . . . . . . . . . . . . . . 7-74
Lift/Aux Pump . . . . . . . . . . . . . . . . . . . 7-75
Drive Units . . . . . . . . . . . . . . . . . . . . . . 7-34 Removal . . . . . . . . . . . . . . . . . . . . . 7-75
Adding Oil . . . . . . . . . . . . . . . . . . . 7-34 Installation . . . . . . . . . . . . . . . . . . . 7-75
Replacement . . . . . . . . . . . . . . . . . 7-35 Lift Cylinders . . . . . . . . . . . . . . . . . . . . 7-77
Axle Seal . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Replacement of Seals and Wipers . . 7-77
Removal . . . . . . . . . . . . . . . . . . . . . 7-38 Flow Control Valve . . . . . . . . . . . . . . . . 7-78
Installation. . . . . . . . . . . . . . . . . . . 7-41 Replacement . . . . . . . . . . . . . . . . . . 7-78
Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Quad Mast Hose Replacement. . . . . . . . 7-79
Inspection . . . . . . . . . . . . . . . . . . . 7-44 Installation . . . . . . . . . . . . . . . . . . . 7-79
Brake Air Gap Adjustment . . . . . . . 7-45 Hose and Bracket Adjustment . . . . . 7-81
Brake Assembly . . . . . . . . . . . . . . . 7-46
Mast Components . . . . . . 7-83
Electrical Components . . . 7-51
Mast Removal/Installation . . . . . . . . . . 7-84
Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52 Partial Removal . . . . . . . . . . . . . . . . 7-84
Contactor Fuse Panel. . . . . . . . . . . . . . . 7-53 Installation after Partial Removal . . . 7-85
Removal . . . . . . . . . . . . . . . . . . . . . 7-53 Complete Mast Removal . . . . . . . . . 7-86
Installation. . . . . . . . . . . . . . . . . . . 7-54 Installation after Complete
Contactors . . . . . . . . . . . . . . . . . . . . . . . 7-55 Removal . . . . . . . . . . . . . . . . . . . . 7-88
Testing Contactor . . . . . . . . . . . . . . 7-55 Mast Disassembly . . . . . . . . . . . . . . 7-90
Contactor Tip Inspection . . . . . . . . 7-55 Mast Shimming . . . . . . . . . . . . . . . . 7-99
Vehicle Manager . . . . . . . . . . . . . . . . . . 7-56
Removal . . . . . . . . . . . . . . . . . . . . . 7-56
Installation. . . . . . . . . . . . . . . . . . . 7-56
7-2 PDMM-0089 Issued: 6/24/02

Component Locator Photos

Main Lift Chain

Overhead Guard
Mast
page 7-84
Lift Cylinder
page 7-90
Hydraulic Filter
Free Lift Chain
Battery
Connector
Tilt Cylinder
Brake (2)
page 7-44 Forks
Drive Motor (2)

page 7-63
Drive Unit (2)
Drive Wheel (2)

page 7-15
78D14017s.TIF
Figure 7-1: Tractor Components (Front Covers Removed)
PDMM-0089 Issued: 6/24/02 7-3

Overhead Guard
Main Manifold
See Figure 7-7.
Steer Pump
page 7-74
Horn
Hydraulic Filter
Tilt Cylinder
Attachment Manifold
See Figure 7-8.
Hydraulic Reservoir
Steer Motor
page 7-12
Drive Motor
page 7-63
Lift Motor
page 7-67
Drive Unit
Drive Wheel Lift Pumps

page 7-15 page 7-75
78d14086s.TIF
Figure 7-2: Tractor Components, Mast Removed
7-4 PDMM-0089 Issued: 6/24/02

Overhead Guard
Operator Display
page 7-25
Power Amplifiers Control Handle

page 7-27
Contactor Fuse Panel

page 7-52
Steering Tiller
Steer Valve
Orbitrol
Steerable Wheel Deadman Pedal

page 7-19
78d14086s.TIF
Figure 7-3: Operator Compartment (Top Cover Removed)
PDMM-0089 Issued: 6/24/02 7-5

Right Traction Operator

Power Amplifier Display Main Manifold
See Figure 7-10. page 7-25 Key Switch EPO Switch page 7-72
(on panel)
Left Traction Fuse Panel

Power Amplifier page 7-52
See Figure 7-10.
FU1-FU3
Lift/Lower
Amplifier Contactors
See
Figure 7-9.
Steering Tiller Shaft Control Handle

page 7-27
Steer Valve (Orbitrol) Vehicle Manager
See Figure 7-6.
78d14023s.TIF
Figure 7-4: Top Console, Cover Removed
7-6 PDMM-0089 Issued: 6/24/02

Relay K2
Relay K1 Relay K3
FU7 FU5 FU9 Contactor Fuse Panel

FU6 FU10
FU8
FU1
FU2 Traction Lift Steer

Contactor FU3
Contactor Contactor
78d14113sTIF
Figure 7-5: Power Panel
PDMM-0089 Issued: 6/24/02 7-7

Key Switch
Drip Guard
(folded under for photo)
Vehicle Manager
Mounting Bolts (under bracket)
Vehicle Manager Connections

(Front View)
78d14121s.TIF
Figure 7-6: Vehicle Manager and Connections
7-8 PDMM-0089 Issued: 6/24/02

SOL4 SOL2 SOL1 SOL5 SOL8
SOL7
SOL6
SOL9
SOL3 Mast Side
SOL7
SOL6 SOL4
SOL5
SOL8
SOL1
SOL3 SOL9
SOL2 Operator Side
Figure 7-7: Main Manifold Solenoid Layout
Figure 7-8: Attachment Manifold Solenoid
PDMM-0089 Issued: 6/24/02 7-9

Connection
JPL1
Connection
JPL2
Connection
JPAB–
Connection
JPAB+
Connection
JPAM–
78D14131S.TIF
Figure 7-9: Lift Power Amplifier Connections (Top View)
JPTL2 LA-F2 RA-F1 JPTR1

JPTL1
JPTR2
LA-F1
LAB–
RAF2
RAB+
LAM– LAB+
RAB– RAM–
78D14133S.TIF
Figure 7-10: Traction Power Amplifier Connections (Overhead View)
7-10 PDMM-0089 Issued: 6/24/02

Steering and Controls

Steering and Controls
PDMM-0089 Issued: 6/24/02 7-11

Steer Motor Steering and Controls
Steer Motor
See “Motors, General” on page 7-60 for
instructions on: Supply Steer Steer Pump- Pressure
Hose Pump Mounting Bolt (2) Hose
• cleaning the motor
• testing the motor
• inspecting and changing the brushes
Location
The steer motor is located in the center of the
front of the truck, mounted to the frame, above
the lift motor. See Figure 7-11.
Steer Motor
Removal
Steer Motor
2. Remove the front covers. Mounting Bolt (4)
Drain Hose
(cable wrapped)
Power Cables (2) Impeller
Shroud
78d14050s
Figure 7-11: Steer Pump and Motor
3. Remove two steer pump mounting bolts
and lift the pump off the motor. You may
Coupling
need to cut the cable ties holding the drain
hose to the supply hose. See Figure 7-12.
4. Remove power cables from the steer motor
and label polarity if necessary. Use two Electric Steer
Motor
wrenches to avoid twisting the terminal
stud.
5. Remove the two lower mounting bolts.
Steer
Pump
78d14063s
Figure 7-12: Removing the Steer Pump
7-12 PDMM-0089 Issued: 6/24/02

Steering and Controls Installation
! CAUTION
The steer motor is heavy. Use a
suitable lifting device if necessary.
6. While supporting the steer motor, remove

the two top mounting bolts and remove the
motor.
7. Remove the impeller shroud by removing
the three screws holding the impeller to the
standoff studs.
NOTE: Be careful not to break the blades when
removing the impeller.
8. Remove the impeller by removing the center
bolt holding the impeller to the motor shaft.
9. Remove the three standoff studs from the
motor.
10. Remove the coupling half from the motor.
Installation
=
1. Using thread-locking compound Torque: 45 to 55 in. lb

(P/N 990-536), attach the three standoff (5.0 to 6.2 N•m) Terminal Stud
studs to the motor.
2. Place the impeller over the motor shaft and
secure with the mounting bolt.
3. Attach the impeller shroud to the standoffs
with three screws. Spin the impeller to
verify that it turns freely. Motor Housing
Flat Washer
4. Attach the power cables to the 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 45 to 55 in. lb
(5.0 to 6.2 N•m). See Figure 7-13. Fiber Washer
5. Install the motor, aligning the impeller 7cablenut1.wmf
shroud to the lift motor. Apply Figure 7-13: Correct Torque for Steer Motor Terminals
thread-locking compound (P/N 990-536),
tighten, and torque the four motor
mounting bolts. Reference “Torque Chart -
Standard (Ferrous)” on page A-5.
6. Attach the coupling half to the motor shaft.
7. Apply thread-locking compound
(P/N 990-536) to the steer pump mounting
bolts.
PDMM-0089 Issued: 6/24/02 7-13

Installation Steering and Controls
8. Attach the pump to the motor, mating the

two halves of the coupling with the rubber
coupling cushion in between. Tighten and
torque the steer pump mounting bolts. See
page A-4 in the Appendix.
the key switch ON. Test the steering
function. Check for leaks.
10. Attach the front covers.
7-14 PDMM-0089 Issued: 6/24/02

Steering and Controls Wheel/Tire Assemblies
Wheel/Tire Assemblies
Inspection
Inspect the tire for:
• Bond failure
• Cracks
• Excessive wear
• Flat spots
• Gouges
Inspect the wheel for:
• Cracks
• Excessive corrosion
• Excessive wear in the bolt holes (from loose
mounting bolts)
• Tightness of mounting bolts
Drive Wheel/Tire
Removal
1. Slightly loosen all eight bolts that attach
the wheel to the drive unit.
! WARNING
lift truck is jacked up. Never block
or jack stands beneath it to support 7110.tif
it. DO NOT rely on the jack alone to Figure 7-14: Removing the Drive Wheel/Tire Bolts
2. Jack the lift truck up so that the tire is

raised off the ground.
PDMM-0089 Issued: 6/24/02 7-15

Steerable Wheel/Tire Steering and Controls
3. Now remove all of the eight bolts that you

loosened in Step 1. Remove the drive
wheel/tire assembly off the lift truck.
Installation
1. Position the drive wheel/tire assembly next
to the side of the drive unit. Align the holes.
2. Loosely install the eight bolts that hold the
drive wheel/tire assembly to the drive unit.
3. Tighten and torque the eight bolts to
108 ft lb (151 N•m).
Steerable Wheel/Tire
Removal
1. Turn the steerable wheel so that the axle
nut is visible.
! WARNING
it. DO NOT rely on the jack alone to 7dock43.tif
support the lift truck. See “Jacking Figure 7-15: Remove Axle Nut
3. Jack and block the lift truck up so that the

steer wheel is off the floor.
4. Remove the axle nut. See Figure 7-15.
7-16 PDMM-0089 Issued: 6/24/02

Steering and Controls Steerable Wheel/Tire
5. Using a drift pin, dislodge then drive the

axle approximately 1/2 in. (13 mm) toward
the battery. See Figure 7-16.
6. Turn the steerable wheel so the opposite
end of the axle is visible.
7dock47.tif
Figure 7-16: Dislodge Axle

7. Remove the axle using a pry bar. Use a
shim under the wheels to support the
weight of the tires. This may help in
removing the axle. See Figure 7-17.
8. With the axle removed, remove the wheels.
7dock50.tif
Figure 7-17: Remove Axle
9. Remove, clean, and repack the wheel
bearings. Add additional grease to the pivot
spindle and hub so that when the unit is
assembled, it is 50-75% full of grease.
NOTE: Anytime the wheels are removed, clean
the axle bearings, then inspect and
repack with grease. Removing the
bearings requires a new outer axle seal.
See Figure 7-18.
Axle Seal Axle Seal
Tire Replacement
1. Press the old tire off the hub.
2. Press the new tire onto the hub. Make sure Bearing Bearing
Axle Seal
the hub is flush with the tire within 7axleout.wmf
1/16 in. (1.6 mm). Figure 7-18: Axle Seals and Bearings
PDMM-0089 Issued: 6/24/02 7-17

Steerable Wheel/Tire Steering and Controls
NOTE: A minimum pressure of 5 tons (4536 kg)

is required to press on the new tire. If
the minimum pressure is not met, a new
hub is required.
Installation
1. Place the wheel assemblies under the lift
truck and position them in the steer pivot.
2. Insert the axle through the steer pivot,
through each wheel, and out the other side
of the steer pivot. See Figure 7-19.
NOTE: When you insert the axle, be careful not
to damage the bearing seals.
3. Install the axle nut. Tighten the axle nut
until the wheels start to bind when you
turn them by hand. Then turn the axle nut
1/4 turn counterclockwise.
4. Lower the lift truck to the floor. Steer Pivot
Wheel
5. Replace any covers that were removed. Assembly
7axleout.wmf
Figure 7-19: Install Wheel Assemblies
7-18 PDMM-0089 Issued: 6/24/02

Steering and Controls Steerable Wheel Assembly
Steerable Wheel Assembly

Removal
2. Remove the Steer Compartment Cover.
3. Take the steer chain off the steer plate by
removing the nut on the threaded end of
the chain anchor. See Figure 7-20.
4. Disengage the steer chain from the steer
motor assembly. You can leave the chain
attached to the other side of the steer plate.
7030.tif
Figure 7-20: Steer Chain Nut

5. Remove the steer position proximity sensor
bracket. See Figure 7-21.
7137.tif
Figure 7-21: Steer Proximity Switch Bracket
6. Remove the steer sensing ring from the top
of the steer plate. See Figure 7-22.
7138.tif
Figure 7-22: Steer Sensor Plate
PDMM-0089 Issued: 6/24/02 7-19

Steerable Wheel Assembly Steering and Controls
7. Scribe a mark from the top of the steer hub

onto the steer plate (so you can reinstall the
steer plate in the proper position). See
Figure 7-23.
7141.tif
Figure 7-23: Scribe Mark from Hub to Steer Plate

8. Remove the bolts that hold the steer plate
in place. Remove the steer plate. See
Figure 7-24.
7139.tif
Figure 7-24: Steer Plate Bolts
9. Remove the six mounting bolts holding the
steerable wheel assembly to the truck
frame. See Figure 7-25.
10. Place chocks in front of the drive wheels.
Mounting Bolts (6)
7dock67.tif
Figure 7-25: Mounting Bolts
7-20 PDMM-0089 Issued: 6/24/02

11. Reinstall one of the steer plate bolts. Wrap a

piece of heavy wire around this screw. Use
this as a temporary support. You will use
this temporary support to lower the steer
assembly to the floor when the truck is
jacked up. See Figure 7-26.
12. Jack the rear of the truck. As the truck is
jacked, the steerable wheel assembly
separates from the tractor frame.
NOTE: Removing the steerable wheel first
reduces the jacking height and makes it
easier to remove the assembly. See
“Steerable Wheel/Tire” on page 7-16.
7dock64.tif
Figure 7-26: Temporary Support to Steerable Wheel

13. Continue to jack the truck until the upper
hub on the steerable wheel is flush with the
tractor frame. Block the truck in this
position. See Figure 7-27.
Hub flush with

tractor frame
7dock65.tif
Figure 7-27: Steerable Wheel Installation
! CAUTION
The steerable wheel assembly is
heavy. Use a suitable lifting device if
necessary.
14. While holding the wire, slowly move the

steerable wheel assembly out from under
the truck. As the wheels come out, lower
the casting to the floor. Move the steerable
wheel assembly down and out from beneath
the truck. See Figure 7-28.
7dock60.tif
Figure 7-28: Steerable Wheel Removal
PDMM-0089 Issued: 6/24/02 7-21

Steerable Wheel Assembly Steering and Controls
Disassembly
Nut
Upper Steer
1. Remove the nut that holds the upper steer Key Hub
hub to the steer pivot. See Figure 7-29.
2. Use a three-arm puller to remove the upper Bearing
Pivot Hub
steer hub.
3. Pull the steer pivot out of the pivot hub. Steer Pivot
4. Clean the inside of the pivot hub.

5. Clean and inspect the bearings. Replace
any defective components.
6. Remove, clean, and inspect the key. Clean
and inspect the keyway.
7strwhl.tif
Figure 7-29: Steerable Wheel Assembly
Assembly
1. Pack the bearings with grease, see
Appendix for lubrication specifications. Add
additional grease to the pivot spindle and
hub so that when the unit is assembled, it
is 50-75% full of grease.
2. Slide the steer pivot into the pivot hub. See
Figure 7-30.
3. Coat the key and keyway with
thread-locking compound (P/N 990-536).
4. Install the upper steer hub.
5. Install the nut. Tighten the nut while
7119.tif
rotating the pivot hub that mounts to the
Figure 7-30: Steerable Wheel Disassembled
tractor frame. Continue to tighten the nut
until the pivot hub just starts to resist
rotation.
7-22 PDMM-0089 Issued: 6/24/02

Installation
1. Position the steerable wheel assembly into
the tractor frame. While holding the steer
wheel assembly upright, lower the tractor
down until it is near the mounting flange.
Remove the wire and bolt from the steer
plate. Position the stop correctly. See
Figure 7-31.
(P/N 990-536) to the six mounting bolts.
7dock64.tif
Figure 7-31: Steerable Wheel Installation

3. Install the mounting bolts and torque to
55 ft lb (77 N•m). See Figure 7-32.
Mounting Bolts
7dock67.tif
Figure 7-32: Mounting Bolts
4. Install the steer plate. Align the scribe
marks, made during disassembly, between
the hub and the steer plate. Install the four
mounting bolts and tighten.
See Figure 7-33.
Steer Plate
7139.tif
Figure 7-33: Steer Plate Bolts
PDMM-0089 Issued: 6/24/02 7-23

Steer Chain Adjustment Steering and Controls
5. Install the steer sensing ring on top of the

steer plate. See Figure 7-34.
Steer Sensing Ring
6. Install the steer position proximity sensor
bracket. See Figure 7-35. The gap between
the bottom face of the sensor and the upper
surface of the steer plate should measure
0.080 ±0.02 in. (2 ±0.005 mm).
7. Install and adjust the steer chain. See
“Steer Chain Adjustment” on page 7-24.
the key switch ON. Run Test I18 - Steer
Position Sensor (Page 6-109). This will
verify that the steer position proximity
sensor is adjusted properly.Turn the key
switch OFF and disconnect the battery 7138.tif
connector. Figure 7-34: Steer Sensor Plate
9. Remove any blocks supporting the truck.

Lower the truck to the floor.
10. Install the utility cover.
the key switch ON. Test the steering
function.
7137.tif
Figure 7-35: Steer Proximity Switch Bracket
Steer Chain Adjustment

1. Turn the steerable wheel assembly from
stop-to-stop to find the tight point in the
chain tension.
2. With the chain at its maximum tension
position, adjust the steer chain tensioner so
that the chain deflects approximately
1/8 in. (1.6 mm) at midpoint. See
Figure 7-36.
7030.tif
Figure 7-36: Steer Chain Adjustment
7-24 PDMM-0089 Issued: 6/24/02

Steering and Controls Operator Display Card
Operator Display Card

The Operator Display Card (ODC) contains the
primary memory (including serial number, hour
meters, options and so on) for the truck. This
information is uploaded to the new ODC from
the VM. If the VM is bad, the replacement ODC
must be programmed by the Raymond Parts
Distribution Center.
Removal
78d14121s
Figure 7-37: Operator Display

the battery connector. Operator Connection JPD1
2. Remove the console cover. Display
! CAUTION
observed against electrostatic EPO Switch
on page 2-12. Operator
Key Switch Connection JPD2 Display Card
3. Remove two of the four screws that secure 78d14101s
the display assembly to the OD mounting Figure 7-38: Operator Display Bezel Removal
bracket.
4. Loosen the other two mounting screws and
slide the OD bezel off the bracket. See
Figure 7-38.
5. Disconnect the OD flat cable at connector
JPD2.
6. Unplug connector JPD1 from the bottom of
the circuit card in the OD.
7. Remove the four screws holding the ODC to
the standoffs. See Figure 7-39.
Installation
1. Install the ODC to the standoffs with four
screws. Do NOT overtighten the screws.
Connect JPD1 from the VM.
78d14089s
2. Connect JPD2 from the display bezel.
Figure 7-39: Operator Display Card
PDMM-0089 Issued: 6/24/02 7-25

Installation Steering and Controls
! CAUTION
Make sure the cable is not twisted or
misaligned. The connector is not
keyed and it is possible to mate the
connector backwards.
3. Slide the display assembly onto the OD

mounting bracket (making sure that
display is correctly aligned with the display
lights). Secure using the four screws.
4. Install the console cover.
7-26 PDMM-0089 Issued: 6/24/02

Steering and Controls Control Handle
Control Handle
The control handle assembly is located in the
middle of the operator console, to the right of
the steering wheel. See Figure 7-40.
Removal
2. Remove the console cover.
! CAUTION
on page 2-12.
Handle Securing Screw
78D14092S.TIF
3. Unplug the control handle wiring harness
Figure 7-40: Control Handle Assembly (Condensation
from the VM at JPC6. Remove any cable Cover Pulled Back For Clarity)
ties that secure the wiring harness.
4. Loosen the Allen head screw that secures
the control handle assembly to its support
Return Spring
5. Slide the control handle assembly to the
left, out of its support bracket.
Lift Knob
Disassembly
Set Screw
NOTE: Do not disassemble a solid state control
Potentiometer
handle. Replace the handle.
Shaft
2. Remove the control handle.
3. Using a hex key, loosen the two set screws.
Remove the lift knob. See Figure 7-41. 7chandle.wmf
Figure 7-41: Control Handle Lift Knob Removal

4. Remove the return spring that attaches to
the potentiometer shaft.
5. Using a hex key, loosen and remove the
seven screws located on the handle. Note
the locations of the three different size
screws carefully for later reassembly.
6. Gently separate the two halves of the
control handle, being careful not to lose any
springs or small parts.
PDMM-0089 Issued: 6/24/02 7-27

Assembly Steering and Controls
7. Note the orientation of the parts to ensure

proper assembly.
Assembly
1. Making sure all internal assemblies are
positioned correctly, piece the two halves of
the control handle back together.
2. Replace the seven screws on the control
handle, making sure that they are located
correctly. Use a hex key to tighten securely.
3. Position the thumb control return spring
onto the control handle. Make sure that the
ears of the spring are positioned correctly.
See Figure 7-42.
NOTE: To avoid premature handle failure, do
not bend the ears on the spring. Spring ears
straddle pin
4. Align the lift knob with the potentiometer
shaft. Slide the lift knob onto the shaft until 7sprng1_1.tif
fully seated. Figure 7-42: Thumb Control Return Spring
5. Move the lift knob to verify that it works

freely and returns to neutral.
6. Using a hex key, replace and tighten the
two set screws attaching the knob to the
control handle.
Installation
1. Insert the shaft of the control handle
assembly into the support bracket.
(P/N 990-536) to threads of Allen head
securing screw.
3. Hold the control handle in place, aligning
the hole in the shaft with the securing
screw hole. Torque the securing screw to
30 ft lb (42 N•m).
4. Route the control handle wiring harness
and plug into the VM at JPC6.
5. Secure the control handle wiring harness in
place with cable ties. Make sure the cable
extends out of the handle as straight as
possible to avoid kinking.
the key switch ON. Run Learn controls.
7. Reinstall the console cover.
7-28 PDMM-0089 Issued: 6/24/02

Steering and Controls Control Handle Replacement
Control Handle Replacement

A newer control handle assembly with
non-contact potentiometers can be installed to
replace the existing handle on an EASi Pacer™
Lift Truck. See Table 7-1. The newer control
handle benefits from the use of solid state lift
and travel potentiometers.
Table 7-1: Control Handle Production with Non-contact (solid state) Potentiometers
Model Trucks Produced After: Serial Number Above:
R30 11/15/2000 R30-00-02479
R35 11/16/2000 R35-00-02484
R40 11/14/2000 R40-00-02089
R50 11/20/2000 R50-00-02494
1. Determine the appropriate replacement

handle for the truck you are working on.
See Table 7-2.
Table 7-2: New Control Handle
Type New Handle
Non-Cold Storage P/N 828-006-161/005
Cold Storage P/N 828-006-161/008
2. Check to see if the truck is already

equipped with a solid state module:
a. The solid state handle assembly is
installed directly on any truck with a
solid state module
(P/N 154-012-569/001). These solid
state modules are on all trucks
produced with solid state handles. See
Table 7-1.
b. If the truck does not have a solid state
module, a solid state module
(P/N 154-012-569/001) and cable
assembly (P/N 223-003-012) is
required. See “Control Module
Installation” on page 7-31.
3. Confirm that the truck has software
version 4.0 (P/N 074-302-001/040) or 4.1
(P/N 074-302-001/041) or greater.
PDMM-0089 Issued: 6/24/02 7-29

Control Handle Replacement Steering and Controls
4. Make sure that the new handle is installed

with a service loop as detailed in the
following instructions.
NOTE: The lift knob on solid state handles
should not require any adjustment. The
lift potentiometer neutral for handles
(P/N 828-006-161/ALL) can range
between 2.0 and 3.0V. The lift
potentiometer voltage at fully
Clockwise (CW) should not exceed 4.6V.
The lift potentiometer voltage at fully
Counterclockwise (CCW) should not
measure below 0.45V. If the lift
potentiometer voltages are out of range,
replace the entire handle.
Lift Knob Repair/Replacement

1. Rotate the lift potentiometer shaft fully
CCW.
2. Install the lift knob on the potentiometer
shaft. Do not tighten the set screws yet.
3. Rotate the lift knob fully CCW and tighten
the set screws.
4. Verify the lift potentiometer voltages (see
Note above).
5. Install the nylon set screws on the lift
knobs that are fully threaded (ESD
protection).
NOTE: The solid state potentiometers used in
this handle are ESD sensitive. DO NOT
open the handles for any reason. These
handles are not field repairable.
When installing the wire harness, a service
loop is required.
1. Install the handle and route the harness
last, after all the other wires are routed
through this area.
2. Make sure that all other wires are tied back
and away from the handle harness service
loop. Do not route through or under any
components.
3. Test the motion of the service loop by
cycling the handle. The entire length of the
loop should absorb the twist. Ensure that
the loop does not hang up on adjacent
wires, cable ties, or structure.
7-30 PDMM-0089 Issued: 6/24/02

Steering and Controls Control Module Installation
Control Module Installation

A control module is available that allows the
use of solid state control handles
(P/N 828-006-161/005, /006 or /008) with VM
P/Ns 223-001-068/001 or /002.
NOTE: DO NOT use this module with VM P/Ns
223-003-023/001, /002 or /003).
1. Fully lower the forks. Turn the key switch
OFF and disconnect the battery connector.
2. Remove the top cover.
3. Scribe a mark on the OD mounting bracket
on the pivot point. Scribe another mark
where the base of the bracket rests on the
frame. This allows the bracket to be
repositioned after the module is installed.
4. Disconnect the EPO wires.
5. Remove the key switch.
6. Unplug JPD1 and remove the OD mounting
bracket.
7. Position the control module with the decal
side flush with the top edge of the bracket.
The closest hole should be centered 1.25 in.
(31.75 mm) from the key switch cutout.
8. Mark the mounting holes.
NOTE: To prevent potential damage to the OD,
place a small wooden board and a shop
cloth between the OD and the location
where the mounting holes are to be
drilled.
9. Drill and tap the mounting holes for a M4
screw.
10. Install the control module using two M4 x 6
screws (P/N 5-010-009). Make sure that
the decal is positioned up when the bracket
is reinstalled.
11. Reinstall the operator’s display mounting
bracket, using the scribe marks made in
step 3 as a guide.
12. Reconnect the EPO wires and JPD1.
Reinstall the key switch.
13. Install the new control handle. See “Control
Handle Replacement” on page 7-29.
14. Plug the new solid state control handle into
the female connector of the control module.

Control Module Installation Steering and Controls
15. Install cable assembly (P/N 223-003-012)

in the male connector on the control
module. Connect the other end into JPC6
on the VM.
the key switch ON.
17. Run Learn for controls.
18. Test the operation of the truck and return
to service.
7-32 PDMM-0089 Issued: 6/24/02

Drive and Brake

Drive and Brake
PDMM-0089 Issued: 6/24/02 7-33

Drive Units Drive and Brake
Drive Units
Adding Oil
1. Remove the oil level check screw. See Vent Oil Level
Figure 7-43. Check Screw
2. Remove the fill screw.

3. Determine the correct type of gear lubricant
(or oil for cold storage lift trucks) by using
the chart on page A-2.
NOTE: The drive unit must be installed before
filling the drive unit with oil.
4. Slowly pour the lubricant in the fill hole.
Watch the oil level check screw hole. When
Fill Hole
the lubricant is level with the bottom of the Screw
screw hole, stop pouring. Allow all excess 7108.TIF
oil to drain out. Figure 7-43: Adding Oil to Drive Unit

5. Reinstall the oil level check screw and fill
screw.
7-34 PDMM-0089 Issued: 6/24/02

Drive and Brake Replacement
Replacement
! CAUTION
Drive unit weighs approximately
175 lb (79 kg). Use a suitable lifting
device if necessary. Have additional
help available when removing or
installing the drive unit.
Removal
2. Remove the mast from the lift truck. See
“Partial Removal” on page 7-84.
3. Drain all the lubricant out of the drive unit.
Use a drain pan that is approximately 1.5 78D14066S.TIF
gallons (5.7 liters). See Figure 7-44. Figure 7-44: Drive Unit, Draining
4. Remove the brake assembly. See “Brake
Assembly” on page 7-47.
5. Remove the drive motor. See “Drive Motor”
on page 7-63. Lifting Eye hook
6. Install a lifting eye hook into one of the Locating Pins
drive motor mounting holes. See
Figure 7-45.
7du-pins.wmf
Figure 7-45: Lifting the Drive Unit
PDMM-0089 Issued: 6/24/02 7-35

Replacement Drive and Brake
7. Loosen, but do not remove, the eight bolts

that secure the wheel and tire assembly to
the drive unit.
! WARNING
78D14044S.TIF
Figure 7-46: Drive Wheel Removal

8. Jack the side of the lift truck to remove the

drive unit. Place blocks beneath the lift
truck to support it. See Figure 7-46.
9. Remove the eight bolts that secure the
wheel and tire assembly to the drive unit.
10. Remove the six bolts securing the drive unit
to the lift truck frame. See Figure 7-47.
78D14072.TIF
Figure 7-47: Drive Unit Mounting Bolts (6)
7-36 PDMM-0089 Issued: 6/24/02

Drive and Brake Installation
Installation
1. Make sure the drain plug is installed in the
drive unit.
(P/N 990-536) to the two locating pins.
Install the locating pins into the drive unit
casting. See Figure 7-45.
3. Position the drive unit in place. Align the
bolt holes in the mounting flange with the
bolt holes in the tractor frame.
4. Install the six bolts that hold the drive unit
to the tractor frame. Torque bolts to
120 ft lb (168 N•m).
5. Install the drive wheel and tire assembly.
Install the wheel mounting bolts.
6. Lower the truck to the floor. Torque wheel
mounting bolts to 110 ft lb (151 N•m).
7. Reinstall the drive motor. See “Drive Motor”
on page 7-63.
8. Reinstall the brake assembly. See “Brake
Assembly” on page 7-47. Be sure to remove
the brake release bolts from the brakes.
9. Refill the drive unit with gear oil until the
fluid is even with the bottom of the fluid
check hole located on the side of the drive
unit. See Figure 7-43 on page 7-34.
10. Install the mast. See “Partial Removal” on
page 7-84.
PDMM-0089 Issued: 6/24/02 7-37

Axle Seal Drive and Brake
Axle Seal
Maintenance or replacement of components
used in the drive unit is limited to the
replacement of the axle oil seal.
Any major rework/service that the drive unit
may need requires the drive unit to be sent
back to the factory.
If the axle is removed for any reason, replace
the axle oil seal.
Removal
1. Remove the mast from the lift truck. See
“Partial Removal” on page 7-84.
3. Loosen, but do not remove, the eight bolts
holding the drive tire to the axle shaft.
! WARNING
4. Jack the drive tire off the floor. See

page 2-14.
7-38 PDMM-0089 Issued: 6/24/02

Drive and Brake Removal
5. Place a suitable container under the drive

unit. Remove the drain plug. Allow the fluid
to drain from the drive unit.
See Figure 7-48.
6. Remove the drive tire.
7dso1.tif
Figure 7-48: Draining Fluid from Drive Unit

7. Remove the drive unit cover by removing
the screws that secure it. Break the
adhesive bond and remove the cover plate.
See Figure 7-49.
7dso4.tif
Figure 7-49: Cover Plate Removal
PDMM-0089 Issued: 6/24/02 7-39

Removal Drive and Brake
8. Loosen the clamp nut locking screw. See

Figure 7-50.
7ds08.tif
Figure 7-50: Loosen Clamp Nut Locking Screw

9. Use a spanner tool to remove the clamp nut
from the axle. See Figure 7-51. Spanner Tool
7ds12.tif
Figure 7-51: Remove Clamp Nut

10. Support the spiral bevel gear and drive the
axle out of the drive unit housing enough to
allow you to remove the spiral bevel gear.
See Figure 7-52.
11. Remove the axle from the drive unit
housing using a rubber mallet if necessary.
Do not damage the gear surfaces.
NOTE: Remove the brake and drive motor as
one assembly if the weight of the
combined assembly does not pose a
hazard.
12. Remove the brake. Refer to page 7-44.
13. Remove the drive motor. Refer to page 7-63.
7ds19.tif
Figure 7-52: Spiral Bevel Gear Removal
7-40 PDMM-0089 Issued: 6/24/02

14. Use a bearing puller to carefully remove the

bearing cone from the axle.
See Figure 7-53.
NOTE: Observe the orientation of the axle seal
on the axle shaft before removing it. Bearing Puller
7ds21.tif
Figure 7-53: Bearing Cone Removal

15. Remove the axle seal from the axle shaft.
16. Clean and inspect all components. See Axle Shaft
Figure 7-54.
Installation Bearing Cone

1. Lubricate (by hand) the lip of the new seal
and place new axle seal onto the axle shaft. Axle Seal
Make sure that the seal is oriented
properly.
2. Carefully place bearing cone onto axle.
Press the bearing onto the axle shaft. Press
the bearing cone until it is properly seated.
7ds23.tif
Figure 7-54: Axle Shaft, Bearing Cone, and Axle Seal

3. Place axle assembly into housing. Mate axle
with the spiral bevel gear. See Figure 7-55.
4. Install the clamp nut on the axle shaft and
hand tighten. See Figure 7-56.
5. Place a seal pressing tool between the axle
seal and tire mounting flange on the axle
shaft.
7ds19.tif
Figure 7-55: Spiral Bevel Gear
PDMM-0089 Issued: 6/24/02 7-41

Installation Drive and Brake
6. Tighten the clamp nut; this will draw the

axle shaft inward. The axle seal will press
into the housing. Make sure the seal is Clamp Nut
flush with the drive unit housing.
7. Loosen the clamp nut.
8. Drive the axle shaft out of the drive unit
housing just enough to allow removal of the
pressing tool. Remove the pressing tool. See
Figure 7-57.
9. Tighten the clamp nut to draw the unit
until the bearing cone and bearing cup
make contact. 7ds15.tif
10. Remove the clamp nut. Figure 7-56: Install Clamp Nut

(P/N 990-536) to the clamp nut threads
and the threads of the screw in the clamp
nut.
12. Install the clamp nut on the axle shaft and
hand tighten.
13. Turn the axle several revolutions by hand
(in both directions). This seats the bearings
in the bearing cones.
14. Torque the clamp nut to 125 ft lb
(170 N•m). This process establishes the
proper preload on the bearings.
7ds29.tif
Figure 7-57: Install Seal Pressing Tool Halves

(P/N 990-536) to the clamp nut screw.
Torque to 140 in. lb (8 N•m). See
Figure 7-58.
16. There should be no axle end play. The axle
shaft should rotate smoothly.
17. Clean the cover plate and mating surface
on the drive unit. Apply gasket eliminator
(P/N 990-411) to sealing surface.
18. Install the cover. Torque all screws equally
to 6 ft lb (8.6 N•m).
19. Install the drain plug.
20. Install the drive motor. See “Drive Motor” on
page 7-63. 7ds10.tif
21. Fill the drive unit with the proper lubricant. Figure 7-58: Torque Clamp Nut Screw
See page A-2 for the Lubrication
Equivalency Chart.

NOTE: The drive unit must be installed before

filling the drive unit with oil.
22. Install the brake. See “Brake Assembly” on
page 7-47.
23. Install the drive tire. Torque the wheel
mounting screws to 110 ft lb (151.2 N•m).
24. Lower the lift truck to the floor.
page 7-84.
PDMM-0089 Issued: 6/24/02 7-43

Brake Drive and Brake
Brake
A brake assembly is located on top of each of
the drive motors. See Figure 7-59.
Inspection Brakes
1. Perform Test O17 - Toggle Traction Motor
Brake #1 (left) (Page 6-135) or Test O18 -
Toggle Traction Motor Brake #2 (right)
(Page 6-136).
2. With the brake applied, the total air gap
should be 0.008 to 0.018 in.
(0.20 to 0.45 mm).
Installation (Stromag Brake)

1. Install brake release bolts (7-710-006/030)
into each stromag brake, two bolts per
brake.
Drive Motors
2. Install woodruff key (5-026-005) into the
keyway of the motor shaft. After key is in 78D14080S.TIF
place, install brake hub (a spline gear) onto Figure 7-59: Brake Location (Mast Removed for Clarity)
the motor shaft and over woodruff key.
3. Install hardened washer (771-164/003)
and nut (5-015-008) onto motor shaft.
Apply loctite 243 to threads on motor shaft
before installing nut. Torque nut to 120 ft.
lbs. using spanner wrench tool to hold the
hub.
4. Place brake over shaft and down onto
splined brake rotor. Rotate brake on the
motor shaft in order to align three brake
mounting holes with the holes on the
motor.
5. Orient brake so that connector cable and
Mfg. label are facing out. Apply loctite 243
(990-536) to bolts (5-002-008) and install
them through brake and into motor. Each
bolt should be torqued to 15 ft. lb.
6. Remove (7-710-006/030) brake release
bolts from brake and store in tractor frame
holes located in front of overhead guard
mounting pad.
7. Plug brake connector into connector
coming off motor.
8. Verify proper braking operation.

Drive and Brake Brake Air Gap Adjustment
Brake Air Gap Adjustment

The proper air gap is between 0.008 - 0.018 in.
(0.20 - 0.45 mm). During normal use, the
friction plate will wear (get thinner). This causes
the air gap to increase. Refer to Figure 7-60.
With the brake turned off, use a feeler gauge to
determine the gap between the main coil body
and the first armature plate around the entire
diameter of the brake. The air gap should be
uniform when measured at various points
around the brake. If the air gap is greater than
0.055 in. (1.4 mm) and all of the shims have
been removed, replace the friction disc. If the
gap is less than 0.008 in. (0.20 mm) or greater
than 0.018 in. (0.45 mm), adjustment is
necessary.
Adjust both brakes at the same time.
Brake Release Bolt

Compression (normally stowed on tractor frame) Brake Coil
Assembly Screw Spring Assembly
Shims
(The shims can
be located on top
of or below the
spacer.)
Air Gap
0.008 to 0.018 in.
Armature Disk (0.20 to 0.45 mm)
Spacer (Wearable Material) Friction Plate Splines Mounting Plate

Friction Plate Brake Assembly
Mounting Bolt
7eurobrak.wmf
Figure 7-60: Brake Assembly Components

Brake Air Gap Adjustment Drive and Brake
Shim Adjustable Style Brakes

NOTE: Various size shims and spacers are
available for adjusting the air gap.
Adjustments can be made without
removing the brake assembly from the
lift truck.
1. Remove the three assembly screws.
2. Add or remove shims as necessary equally
to each location to obtain the desired air
gap.
3. When the correct air gap is obtained, torque
the assembly screws to 9 ft. lb. (12 Nm).
4. Operate the truck and test the brake for
proper stopping distance.
Adjustable Spacer Style Brakes
1. Slightly loosen the three assembly screws. Assembly
See Figure 7-61. Screw
2. Turn the three black adjustable spacers

clockwise to decrease the air gap and
counterclockwise to increase the air gap as
necessary.
Adjustable Spacer
NOTE: Turning the adjustable spacers approx.
1/6 turn will produce a change of
approx. 0.008 in. (0.203 mm).
Make sure the air gap is uniform around
the circumference of the brake.
3. Tighten the three assembly screws to
eurobrak.wmf
16 ft. lb. (21.7 Nm) Figure 7-61: Adjustable Spacer Location

4. Operate the truck and test the brake for
proper stopping distance.
7-46 PDMM-0089 Issued: 6/24/02

Drive and Brake Brake Assembly
Brake Assembly
Brake Coil
Removal
Speed Sensor JPS4
1. Lower the forks all the way.
3. Remove the front covers.
4. Cut the tie wraps joining the brake coil
harness and the speed feedback sensor
harness and temperature sensors. Brake Coil
Disconnect the brake coil assembly Connection
JPB2 Drive Motor
electrical connector JPB4 or JPB3 from the 78D14052S.TIF
lift truck’s harness. See Figure 7-62. Figure 7-62: Brake Coil Connector JPB3 and JPB4
5. Install the brake release bolts. Tighten to
release the brake.
6. Remove the three screws that hold the

brake assembly to the motor. Lift the brake
assembly off the drive motor.
Disassembly
1. Remove the three bolts that hold the lower
Top Plate and Brake Coil
friction plate to the brake coil. See Springs
Figure 7-63.
NOTE: Be careful not to lose the shims or
spacers.
2. Remove and inspect the brake friction disc.
3. Clamp brake assembly in vise with “C”
clamps.
4. Remove the brake release bolts and top
friction plate from the brake coil. See
Figure 7-63.
Lower Friction Disc Brake Release
NOTE: When removing the top friction plate Friction Plate Bolts
and Hub
from the brake coil, hold the coil
inverted so the brake springs will remain 78D14057S.TIF
in the coil assembly. Figure 7-63: Brake Components
PDMM-0089 Issued: 6/24/02 7-47

Brake Assembly Drive and Brake
Assembly and Installation

1. Place the springs evenly in the holes in the
brake coil. (There may be fewer springs
used than there are holes.)
78D14058S.TIF
Figure 7-64: Brake Coil Assembly, Top Plate

2. Place the top friction plate over springs. See
Figure 7-65.
3. Carefully clamp assembly together.
4. Install the two brake release bolts and
tighten.
5. Center the friction disc on the upper
friction plate.
6. Place the spacers into the three p[ositions
on the coil. Place the lower friction plate
over the friction disk.
(P/N 990-536) to the three bolts previously
removed and place them through the brake 78D14059S.TIF
Figure 7-65: Brake Coil Assembly, Top Friction Plate

coil assembly.
8. Secure the brake coil assembly to the lower
friction plate assembly. Torque to 9 ft lb
(12 N•m).
9. Install the brake assembly onto the drive
motor. Make sure the friction disc fits over
the splined hub. Brake
Mounting Bolt
Spacer
78D14054S.TIF
Figure 7-66: Brake Mounting Bolt, Spacer
7-48 PDMM-0089 Issued: 6/24/02

Drive and Brake Brake Assembly
10. Tighten the three mounting bolts to 13 ft lb

(18 N•m). See Figure 7-66.
11. Remove the brake release bolts and store
for future use.
! WARNING
Make sure that all the brake release
bolts are removed before using the
lift truck. The brake will not work if
the brake release bolts are not
removed.
12. Plug the wiring harness connector from the

brake coil into the connector from the VM
(JPB2 for the right brake coil; JPB3 for the
left brake coil).
13. Re-install the front covers.
the key switch ON.
15. Check the operation of the brake. Travel
with a rated load traveling forks-first at full
speed, depress the EPO button. The lift
truck should stop within 7 to 10 ft. This
distance will vary depending on floor
conditions.
PDMM-0089 Issued: 6/24/02 7-49

Brake Assembly Drive and Brake
7-50 PDMM-0089 Issued: 6/24/02

Electrical Components
Electrical Components
PDMM-0089 Issued: 6/24/02 7-51

Fuses Electrical Components
Fuses
All fuses except FU12 are located on the
Contactor Fuse Panel located on the right front
frame of the top console. See Figure 7-68.
Fuse FU12 is an inline fuse located in the
wiring harness.
Fuse Panel
78D14023S.TIF
Figure 7-68: Fuse Panel Location
Fuse No. Size Location What it Protects

FU1 40A Positive battery voltage to the steer motor
Positive battery voltage to the traction
FU2 600A Contactor Panel
amplifiers
FU3 500A Positive battery voltage to the lift amplifier
Positive battery voltage to the key switch
FU5 15A
circuits
Battery negative for lights
FU6 15A
or cold storage heaters
Fuse Panel
Circuit Card Battery positive for lights
FU7 15A
or cold storage heaters
FU8 5A Battery negative for fans
FU9 5A Battery positive for fans
FU10 15A Battery negative fused for VM
FU12 1.5A Inline Wiring Battery positive for strobe lights
7-52 PDMM-0089 Issued: 6/24/02

Electrical Components Contactor Fuse Panel
Contactor Fuse Panel

The Contactor Fuse Panel is located on the
upper-right portion of the operator
compartment to the right of the control handle.
See Figure 7-69.
Removal
! CAUTION
on page 2-12. Contactor Fuse Panel
78D14023S.TIF
3. Remove fuses FU1, FU2, and FU3. See
Figure 7-69: Contactor Fuse Panel Location
“Fuses” on page 7-52.
4. Remove B+ power cable, three B+ control
wires, TPC-2, and LPC-2 power cables.
Label if necessary.
5. Remove the bus bar screws. Slide the bus
bar off and set aside.
6. Remove harnesses at connectors JPF1,
JPF2, JPF3, JPF4, JPF5, and FU-T1. Label
harnesses if necessary.
7. Remove the six mounting screws on the
front of the contactor fuse panel.
8. Remove the contactor fuse panel and
inspect for damage.
9. Check fuses FU8, FU6, FU10, FU7, FU5,
and FU9 for damage.
PDMM-0089 Issued: 6/24/02 7-53

Installation Electrical Components
Installation
1. Place the circuit card on the contactor fuse
panel support. Install the six mounting
screws. See Figure 7-70.
2. Reconnect connectors JPF1, JPF2, JPF3,
JPF4, JPF5, and FU-T1.
3. Install the bus bar.
4. Reconnect B+ cable and TPC-2 and LPC-2
Mounting Screw (6)
power cables. Ensure that TPC-2 and
LPC-2 are routed behind the bus bar.
5. Connect the three B+ control wires on the
B+ cable terminal. Contactor Fuse Panel
6. Install fuses FU1, FU2, and FU3. Verify
correct placement. 78D14113S.TIF
7. Reinstall the console cover. Figure 7-70: Contactor Fuse Panel

the key switch ON. Test the lift truck for
proper operation.
7-54 PDMM-0089 Issued: 6/24/02

Electrical Components Contactors
Contactors
Testing Contactor
Visually inspect the contactor for any signs of
burning or physical damage. See “Contactor Tip
Inspection” on page 7-55.
1. Run Test O00 - Toggle the TPC Contactor Traction
Contactor Lift Contactor (LPC)
(Page 6-116). (TPC)
2. Run Test O01 - Toggle the LPC Contactor
(Page 6-117). Steer Contactor (STR)
3. Run Test O03 - Toggle the Load Hold
Contactor Tip Inspection

When you inspect contactor tips, follow these
guidelines: 78D14113S.TIF
Figure 7-71: Contactors

• Darkened points do not indicate burning.
• Burning indicates a loss of contact point
material.
• Replace the contact points if there is not
enough contact point material to last until
the next regular inspection or severe pitting
is evident. See Figure 7-72.
• The silver alloy part of the point is usable
contact material; the copper backing is not.
• Do not file contact points to remove
discoloration or minor irregularities. This
practice produces a surface more
susceptible to sticking.
• If a cone and crater appear, replace the tips.
78a21032s.tif
Figure 7-72: Severely Pitted Contactor
PDMM-0089 Issued: 6/24/02 7-55

Vehicle Manager Electrical Components
Vehicle Manager
The Vehicle Manager (VM) is located under the
operator display under the console cover
Vehicle Manager
Removal (Under Bracket)
1. Record the configuration settings of the old

VM for restoration in the new VM.
Mounting
Bolts
! CAUTION
on page 2-12.
78D14121S.TIF
Figure 7-73: Vehicle Manager Location

4. Remove the two bolts that secure the
operator display hinge.
5. Disconnect all connectors to the VM. Label
if necessary.
6. Using a wrench, loosen and remove the two
front fasteners and one back fastener from
the VM.
7. Remove the VM, making sure to check for
any remaining attached wires.
Installation
1. Position the VM on the truck and align the
mounting holes.
2. Replace and tighten the two front fasteners
and one rear fastener onto the VM.
NOTE: Do not pinch any wires or cables while
reinstalling the VM.
3. Reconnect all wiring harness connectors
that were previously removed.
4. Reconnect the operator display connector.
5. Attach with the two operator display hinge
mounting bolts.
6. Reinstall the console cover.
7-56 PDMM-0089 Issued: 6/24/02

Electrical Components Installation

the key switch ON.
8. Test the lift truck for proper operation.
NOTE: After VM replacement, run Learn on the
truck. Also, check configurable settings
and reset as necessary.
PDMM-0089 Issued: 6/24/02 7-57

Cold Storage Conditioning Electrical Components
Cold Storage
Conditioning
Perform field upgrade for Cold Storage
conditioning with the items listed below;
Description Part Number
Class A - S207 Ref. PDMM-0043
Cold Storage Handle Ref. PDMM-0043
Silicone Grease 990-564
Sealing Compound 990-542
LPS3 Spray 990-644
Field Upgrade
1. Spray LPS3 on the steering plate.
2. Apply sealing compound to the unused F1
and F2 terminals on the lift power amplifier.
3. Fill the two small holes in the body and
shank of the key switch with sealing
compound.
4. Apply silicone grease to the following
electrical connections;
• terminals of the switch mounted on the
underside of the deadman pedal
• all terminals and connectors on all three
power amplifiers
• both connectors on the operator display.
• the back side of the VM connectors
(including unused connectors)
• the back side of the communications
jack (JPC1)
• the free hanging connectors in the
harnesses
• all three connectors of the Attachment
Card assembly
• the connector coil terminals
• fuse bodies, cable terminals, and
terminal studs on the contactor panel
• connectors, fuses terminal strips and
the relays where they plug into the
sockets
7-58 PDMM-0089 Issued: 6/24/02

Electrical Components Remounting Attachment Module
• all terminals on the hydraulic solenoids

• all terminals on the horn
• terminals of the key switch and EPO
switch
• sensor wire assembly connector and
terminals on lift motor
• terminals of the steer motor
• terminals and connectors on both
traction motors
5. Install the recommended hydraulic fluid
and gear case oil.
Remounting Attachment Module

Remounting the attachment module assembly
in a vertical position is necessary in some cold
storage applications where moisture is
collecting on the module.
Installation
1. Remove mounting screws and washers (if
necessary) from the attachment card
module.
2. Drill two new holes 2.0 in. (50.8 mm) to the
left of, and parallel to, the existing holes.
3. Attach mounting bracket
(P/N 223-001-851) to the two new holes
using two pan head machine screws. Figure 7-74: Vertical Attachment Module Mounting
4. Mount attachment module assembly to the
inside surface of the mounting bracket
using pan head machine screws
(P/N 5-010-010).
5. Test the truck operation.
PDMM-0089 Issued: 6/24/02 7-59

Motors, General Electrical Components
Motors, General
Motor Cleaning
s, General
Periodic cleaning is essential to prevent

overheating and electrical leakage (short).
Wear safety glasses or goggles to protect your
eyes from dust and debris.
Using an OSHA approved air nozzle, use clean,
dry, low pressure (30 psi/207 kPa) compressed
air to blow carbon dust and other foreign matter
from:
• Motor Housing
• Brush Holders
• Commutator
• Field and Armature Windings (if accessible)
7MOTOR.WMF
Figure 7-75: Motor Cleaning with Compressed Air

! 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 requires complete

disassembly and drying. Motor
cleaning should only be performed
by an authorized motor repair shop.
7-60 PDMM-0089 Issued: 6/24/02

Electrical Components Electric Motor Tests
Electric Motor Tests

BRUSH LENGTH
Motor Types
Refer to Figure 7-76. Shunt-Wound or Separately-Excited Drive Motor
• A shunt-wound or separately excited motor,

such as a drive motor, has four external E2
connections: two armature (A) and
two field (E).
• A series-wound motor, such as a lift motor,
has two external connections. The E1
armature and field windings are connected
internally.
Series-Wound Lift Motor
• A permanent magnet motor, such as a steer
motor, has two external connections. The D
field is produced by an internal magnet.
NOTE: Shunt wound motor field connections
are labeled S or D. Series wound motor
field connections are labeled S.
Open Circuit Motor Test

An open circuit is where the electrical circuit
within the motor was broken. Possible causes
are:
• Bad brushes or brush springs
Steer Motor
• A broken wire in the field or armature
winding +
• A loose or bad connection

Refer to Figure 7-76 for the following procedure:
1. Isolate the motor from the truck circuit by –
removing the power cables. Use two
7DSCHEM.EPS
stud. Figure 7-76: Motor Circuits
2. With the motor at room temperature,

connect the leads of a digital ohmmeter
between the individual circuits in the
motor.
3. You should observe the following
measurements:
Motor Probe Points Resistance

Traction Armature A1 to A2 >0.5 ohms
(Drive) Field E1 to E2 >1.8 ohm
Lift A to D <0.5 ohm
Steer + to – <0.5 ohm
PDMM-0089 Issued: 6/24/02 7-61

Electric Motor Tests Electrical Components
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, a motor rebuilding
facility must disassemble the motor 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. Causes are either by direct
contact or through conductive foreign material.
The ground can be caused by:
• Insulation breakdown
• Brush leads touching the motor housing
• Build-up of carbon dust or other
materials
To test for a grounded motor, follow the “Shorts
to Frame” test procedure on page 5-6.
7-62 PDMM-0089 Issued: 6/24/02

Electrical Components Drive Motor
Drive Motor
! CAUTION Drive Motor Drive Motor

Discharge the power amplifiers
energy storage capacitors before
removing any large fuse or motor
cable for service. To discharge, turn
the key switch OFF, disconnect the
battery, and manually push in the
plungers on all three contactors.
Drive Units
78D14080S.TIF
Figure 7-77: Location of Drive Motors (mast removed)
Removal
2. Remove the three front covers.
3. Remove the brake assembly. See “Brake
4. Remove the friction plate retaining nut.
5. Disconnect the four power cables from the
terminals on the drive motor and label if
necessary for later installation. Use two
studs. See Figure 7-78. 78D14067S.TIF
Figure 7-78: Drive Motor Power Cable Removal
PDMM-0089 Issued: 6/24/02 7-63

Removal Electrical Components
6. Disconnect the drive speed feedback sensor

harness connector JPS3 (left) or JPS4
(right). See Figure 7-79.
78D14055S.TIF
Figure 7-79: Drive Speed Feedback Sensor Connector

7. Disconnect the brush wear sensor and
temperature sensor connector JPS11 (left)
or JPS12 (right). See Figure 7-80.
7SENSOR.TIF
Figure 7-80: Brush Wear Sensor/Temperature Sensor
Connector
8. Place a drain pan beneath the drive unit.
Remove the drain plug and drain
approximately two pints (one liter) of drive
unit oil. This prevents oil from spilling when
the drive motor is removed.
See Figure 7-81.
9. Remove the four bolts that attach the drive
motor to the top of the drive unit.
78D14066S.TIF
Figure 7-81: Drive Unit Drain Plug
7-64 PDMM-0089 Issued: 6/24/02

Electrical Components Installation
10. To break the drive-motor-to-drive-unit seal:

a. Install two of the bolts you removed in
step 9 into the two “blind” holes on the Drive Motor
drive motor mounting flange. See
Figure 7-82.
b. Evenly turn each bolt clockwise.
c. As you turn the bolts, the drive motor
pushes upward, breaking its seal to the
drive unit.
! CAUTION Drive Unit

Bolt In “Blind” Hole
The drive motor is heavy. Use a

suitable lifting device to move it if 78D14068S.TIF
Figure 7-82: Drive Motor Removal, Breaking Seal

necessary.
11. Lift the drive motor off the drive unit.
12. If you won’t be reinstalling a drive motor,

use plastic film and masking tape to seal
the opening for the traction motor so that
no debris can fall into the drive unit.
13. Remove the pinion gear from the drive
motor shaft. See Figure 7-83.
Installation
1. Install the pinion gear on the drive motor
shaft and torque to 45 ft lb (63 N•m).
2. Thoroughly clean the mating areas on the
top of the drive unit and the bottom of the
drive motor mounting flange. 78D14069S.TIF
3. Apply a coat of gasket cement Figure 7-83: Drive Motor Pinion Gear
(P/N 990-556) to the mating surface on the
top of the drive unit.
4. Position the drive motor on top of the drive
unit and align the mounting holes.
(P/N 990-536) to the four motor mounting
bolts and install the bolts. Torque to
13 ft lb (18.2 N•m.).
NOTE: If installing a new motor, remove the
snap ring from the top of the armature
shaft and discard. Install an additional
spacer to the shaft. Do not use a spacer
from an old motor, and do not reinstall a
snap ring prior to installing the brake.
PDMM-0089 Issued: 6/24/02 7-65

6. Install the brake assembly. See “Brake

7. Reconnect the cables to the terminals on
the drive motor. Use two wrenches to avoid
twisting the terminal studs. Torque cable
securing nuts to 100 to 120 in. lb
(11.2 to 11.36 N•m).
8. Reconnect the harnesses to the drive speed
feedback sensors, brush wear indicators,
and temperature sensors previously
removed.
9. Add the drive unit gear oil previously
removed to the drive unit through the filler
plug hole. See page 7-34.
page 7-84.
7-66 PDMM-0089 Issued: 6/24/02

Electrical Components Lift Motor
Lift Motor
Electric
Steer Motor
! CAUTION
Discharge the power amplifiers
Lift Motor
energy storage capacitors before
removing any large fuse or motor
cable for service. To discharge, turn
the key switch OFF, disconnect the
battery, and manually push in the
plungers on all three contactors.
Removal
1. Remove the mast. See “Partial Removal” on
page 7-84.
Lift/Aux Pump
the battery connector. 78D14080S.TIF
Figure 7-84: Lift Motor Location

3. Remove the three front covers.
4. Remove the electric steer motor. See “Steer
Motor” on page 7-12.
5. Remove the two power cables, labeling if
necessary for later installation. Use two JPS8
studs.
6. Disconnect connector JPS8 to the motor
brush wear sensor.
7. Remove the two bolts securing the front
cover mounting bracket to the reservoir.
8. Remove the lift pumps from the lift motor
without disconnecting the lift pump hoses.
See “Lift/Aux Pump” on page 7-75. Lift Motor
Lift/Aux
9. Place blocks of wood beneath the lift motor Pump
to help support it during removal. Leave no
more than a 1/2 in. (13 mm) gap between
the top of the blocks of wood and the
bottom bell of the lift motor.
78D14064S.TIF
Figure 7-85: Lift Motor and Pump

! CAUTION (Electric Steer Motor removed for clarity)
The lift motor is heavy. Use a suitable
lifting device if necessary.
10. Remove the mounting nuts that hold the lift

motor to the frame.
PDMM-0089 Issued: 6/24/02 7-67

11. Carefully slide the lift motor off the

mounting studs.
Installation
(P/N 990-536) to the lift motor mounting
studs.
2. Carefully place the lift motor on the
mounting bolts on the frame. Support the
motor on the blocks of wood used during
removal.
3. Install washers and mounting nuts and
tighten.
4. Apply a thin coat of anti-seize compound
(P/N 990-638) to the spline on the end of
the lift/aux pump. See Figure 7-86.
5. Mate the lift/aux pump to the lift motor.
Apply thread-locking compound
(P/N 990-536) to the mounting bolts and
install.
6. Reconnect the power cables to the motor.
Use two wrenches to avoid twisting the
terminal studs. Torque to
100 to 120 in. lb (11.2 to 13.6 N•m).
7. Reconnect motor brush wear sensor
connector JPS8.
8. Remove the blocks of wood from beneath
the lift/aux pump.
9. Reinstall the front cover mounting bracket.
78D14074S.TIF
10. Install the electric steer motor. See “Steer Figure 7-86: Lift/Aux Pump
Motor” on page 7-12.
page 7-84.
the key switch ON.
13. Test lift/lower functions. Check for
hydraulic leaks where mast hoses were
removed.
14. Install the three front covers.
7-68 PDMM-0089 Issued: 6/24/02

Hydraulic Components
Hydraulic Components
PDMM-0089 Issued: 6/24/02 7-69

Hydraulic Fluid Hydraulic Components
Hydraulic Fluid
Fluid Level
To check the level of the hydraulic fluid in the
system:
NOTE: The temperature of the hydraulic fluid
should measure approximately room
temperature.
1. Tilt the mast all the way back.
2. Unscrew the fill cap from the hydraulic
reservoir.
3. The hydraulic fluid should be 1/2 to 1 in.
(12.6 to 25.4 mm) above filler screen.
Reservoir capacity is approximately 5.8 gal
(22 liters). See Figure 7-87.
78D14083S.TIF
Selecting Hydraulic Fluid Type Figure 7-87: Hydraulic Fluid Filler Screen
See “Lubrication Equivalency Chart” on

page A-2.
Bleeding the Hydraulic System

You must bleed the hydraulic system (to remove
any trapped air) whenever you:
• Change the hydraulic fluid and filter
• Change a hydraulic hose
• Disconnect a hydraulic fitting
• Notice that the load is bouncing
• Remove a hydraulic cylinder
• Remove a hydraulic pump
• Remove the hydraulic reservoir
NOTE: When bleeding the hydraulic system, Bleed Screw
bleed all three cylinders.
1. Turn the key switch to ON. Step on the
deadman pedal and lift the forks 6 to 12 in.
(150 to 300 mm) off the ground.
2. Bleed the lift system.
a. Loosen (do not remove) the bleed screw 78D14012S.TIF
on the lift cylinder to let any air escape. Figure 7-88: Main Lift Cylinder Bleed Screw
See Figure 7-88. Hold a shop rag close
7-70 PDMM-0089 Issued: 6/24/02

Hydraulic Components Bleeding the Hydraulic System
to and beneath the bleed screw to keep

any hydraulic fluid from spraying out.
b. When all of the air has escaped and
hydraulic fluid starts coming out of the
bleed screw hole, securely tighten the
bleed screw.
3. Lower the forks all the way down to the
floor.
4. Bleed the auxiliary system.
a. Tilt the mast all the way forward and
backward several times.
b. If this truck has sideshift, shift the
carriage all the way to the left and right
several times.
5. Check the hydraulic fluid level. See “Fluid
Level” on page 7-70. Add hydraulic fluid as
necessary.
PDMM-0089 Issued: 6/24/02 7-71

Pressure Adjustment Hydraulic Components
Pressure Adjustment
Auxiliary System Pressure Aux System
Adjustment Pressure
Adjustment
A pressure sensing coupler and a calibrated
pressure gauge capable of measuring 3000 psi View From
Operator
(20684 kPa) at mid-range is required to set the Compartment
system pressure. (Turned 180o)
3. Connect the pressure gauge to the auxiliary
pressure test port (AP) on the main Top
hydraulic manifold. See Figure 7-89 and View
Figure 7-90.
NOTE: Trucks equipped with optional hydraulic
attachments will have SOL9. Trucks
with no optional hydraulic attachments SOL9 or
REL2
will have REL2.
4. Loosen the lock nut on the auxiliary
pressure relief valve. View From
Mast
the key switch ON.
7P1812.EPS
6. Tilt the mast back against the stops. Figure 7-89: Aux Pressure Test Port
7. Continue to tilt the mast backward, turning
the aux pressure adjusting screw to obtain
the correct pressure given below:
SOL9 - 1800 ±100 psi (12411 ±689 kpa)
REL2 - 2000 ±100 psi (13789 ±689 kpa)
Turn the adjusting screw CW to increase
pressure, CCW to decrease pressure.
8. Tighten the lock nut on the auxiliary
pressure relief valve.
9. Check the pressure again. If the value has Aux System
changed, repeat this procedure until the Pressure
correct pressure reading is obtained. Port
78D14118S.TIF
10. Turn the key switch OFF and disconnect Figure 7-90: Aux System Pressure Adjustment
11. Remove the pressure gauge.
12. Reinstall the front covers.
7-72 PDMM-0089 Issued: 6/24/02

Hydraulic Components Setting Lift System Pressure Relief Valve
Setting Lift System Pressure

Relief Valve
NOTE: To set the system pressure, you will
need a pressure sensing coupler and a View From
REL1
calibrated pressure gauge capable of Operator
measuring 3000 psi (20684 kPa) at Compartment
(Turned 180o)
mid-range.
2. Remove the front covers. Main Lift
System
3. Connect the pressure gauge to the lift Pressure Top
pressure test port (PP) on the main Relief View
Valve
hydraulic manifold. See Figure 7-91 and
Figure 7-92.
the key switch ON.
5. Place a maximum rated load on the forks.
6. Elevate the forks. Record the pressure that
is required to lift the load. Make sure that View From
the load is elevated near the maximum Mast
rated height for that load when taking the
pressure reading. 7P1812.EPS
7. Lower the forks and remove the load. Figure 7-91: Lift Pressure Test Port
8. Loosen the lock nut on the lift pressure

relief valve (REL1).
9. Elevate the forks until the upper limit is
REL1
reached.
10. Continue to try and elevate and turn the lift
pressure adjusting screw to obtain a
pressure reading 100 psi (689 kPa) greater
than that required to lift the maximum
rated load (the value recorded in step 6).
Turn the adjusting screw clockwise to
increase pressure, counterclockwise to
decrease pressure.
11. Tighten the lock nut on the lift pressure
relief valve. 78D14118S.TIF
Figure 7-92: Lift System Pressure Adjustment

12. Check the pressure again. If the value has
changed, repeat this procedure until the
correct pressure reading is obtained.
14. Remove the pressure gauge.
PDMM-0089 Issued: 6/24/02 7-73

Steer Pump Hydraulic Components
Steer Pump
Removal
1. Tilt the mast all the way forward. Steer Pump
4. Place shop rags beneath the steer pump
and around the electric steer motor Steer Motor
impeller to prevent parts from falling into
the lift motor. Coupling
Cushion
5. Place a drain pan beneath the steer pump.
Disconnect and cap the two steer pump
hydraulic hoses.
78D14063S.TIF
6. Remove the two bolts securing the steer Figure 7-93: Steer Pump Mating to Steer Motor
pump to the steer motor.
7. Remove the coupling from the pump shaft.
See Figure 7-93.
Installation
1. Attach the coupling to the steer pump
shaft.
2. Apply a thin coat of thread-locking
compound (P/N 990-536) to the couplings
and coupling cushion.
3. Attach the pump to the motor, mating the
two halves of the coupling with the rubber
cushion in between. See Figure 7-93. Apply
thread-locking compound (P/N 990-536) to
the two pump mounting bolts and tighten.
4. Connect the two hydraulic hoses to the
steer pump. 78D14083S.TIF
5. Check the fluid level in the hydraulic Figure 7-94: Hydraulic Fluid Level
reservoir. See “Fluid Level” on page 7-70.
See Figure 7-94.
6. Adjust the steer pressure bypass to
1200 to 1600 psi (8274 to 11032 kPa).
7-74 PDMM-0089 Issued: 6/24/02

Hydraulic Components Lift/Aux Pump
Lift/Aux Pump Lift Motor

The EASi Pacer™ Lift Truck uses a dual pump
assembly driven by one motor.
Spline Gear
Removal
1. Remove the mast. See “Partial Removal” on
page 7-84.
4. Place a drain pan beneath the lift/aux
pump.
NOTE: When the hydraulic hoses are
disconnected from the lift/aux pump,
the hydraulic reservoir will drain. Make Lift/Aux Pump
sure that the drain pan has the capacity
78D14074S.TIF
to hold at least 8 gal (30 liters).
Figure 7-95: Removal of Lift/Aux Pump
5. Disconnect the hydraulic hoses connected
to the lift/aux pump.
6. Remove the bolts that secure the lift/aux
pump to the bottom of the lift motor.
See Figure 7-95.
Installation
1. Apply a thin coat of anti-seize compound
(P/N 990-638) to the lift/aux pump spline.
2. Mate the spline to the motor and attach the
lift/aux pump to the motor with the two
mounting bolts. Tighten and torque.
3. Reconnect the two hydraulic hoses to the
lift/aux pump.
4. Install the mast. See “Installation after
Partial Removal” on page 7-85.
5. Fill the reservoir with hydraulic fluid. See
“Lubrication Equivalency Chart” on
page A-2. Reservoir holds approximately
5.8 gal (22 liters).
the key switch ON.
7. Bleed the hydraulic system. See “Bleeding
the Hydraulic System” on page 7-70.
PDMM-0089 Issued: 6/24/02 7-75

Installation Hydraulic Components
8. Check the fluid level in the hydraulic

reservoir. See “Fluid Level” on page 7-70.
7-76 PDMM-0089 Issued: 6/24/02

Hydraulic Components Lift Cylinders
Lift Cylinders
Replacement of Seals and
Wipers
1. Block up the fork carriage a few inches
from the floor so that the chains are loose.
2. Remove chain and hose pulleys.
NOTE: Cleanliness is very important when
working with hydraulic components.
For free lift cylinder, use Raymond End
Cap tool P/N 223-001-811.
For main lift cylinder, use Raymond End
Cap tool P/N 223-001-813.
3. Use the correct cylinder end cap tool and
remove the end cap.
4. Replace the seal, wiper, and square seal.
NOTE: When handling seals, be careful not to
cut seal lip.
5. Clean threads on the end cap and cylinder
and apply Raymond P/N 990-571 adhesive
to the threads.
6. Reinstall the end cap and torque to
200 ft lb (271 N•m).
PDMM-0089 Issued: 6/24/02 7-77

Flow Control Valve Hydraulic Components
Flow Control Valve

Replacement
1. Place a jack stand under the center of the
carriage and lower the carriage onto the
jack stand. See Figure 7-96.
! CAUTION
Make sure the carriage is supported
by the jack stand and not the
sideshift carriage.
2. Continue lowering until the free lift cylinder

is completely collapsed.
4. Remove the old flow control valve. Figure 7-96: Jack Stand Position
5. Install the new flow control valve in the
center cylinder with the arrow pointing
down. This signifies the direction of
restricted flow.
the key switch ON.
7. Slowly elevate the carriage, making sure the
hoses rest in the pulleys on the free lift
cylinder without being pinched or chaffed.
Make sure the carriage chains extend fully
without flipping over onto themselves.
8. Remove the jack stand and test operate the
lift truck.
7-78 PDMM-0089 Issued: 6/24/02

Hydraulic Components Quad Mast Hose Replacement
Quad Mast Hose

Replacement
This procedure provides the necessary steps to
install replacement hydraulic hoses on the
35D Quad mast.
Installation
See Figure 7-97. The numbered arrows in the
figure correspond to the steps that follow.
1. Connect the short hoses to the carriage
bracket fittings. Hand tighten the fittings.
Double Function: The No. 4 hoses connect
to the two left fittings (viewed from the
operator’s seat).
2. Route the hoses over the crosshead pulleys.
Tighten the cover capscrew and torque to
63 ft lb (85 N•m).
3. Route the hoses down between the freelift
cylinder and crossmember. Position the
hoses in their natural curve over the
crosshead pulleys. Tighten the hose ends at
the carriage bracket.
4. Connect the long hoses to the short hoses
behind the freelift cylinder.
Double Function: The right side hoses
(viewed from the operator’s seat) are
approximately 14 in. (355 mm) longer than
the left side hoses.
5. Pull down on the hoses with approximately
30 lb (13.5 kg) force. Clamp the hoses to
the lower bracket attached to the inner
upright crossmember. Tighten the clamp
capscrew and torque to 11 ft lb (15 N•m).
6. Route hoses up to the left through the
guide. Position the hoses in the guide as
indicated. Reinstall the retainer bar with
the end in the bracket slot.
7. Route hoses up and over the upper bracket
pulleys, then down to the middle hose
guide.
8. Pull down on the hoses with 40 lb (18 kg)
force. Clamp the hoses to the top of the
middle hose guide. Tighten the clamp
capscrews and torque to 11 ft lb (15 N•m).
PDMM-0089 Issued: 6/24/02 7-79

Installation Hydraulic Components
13
7 14
21 21 14
12
4 3
12 34
12
10
Single Double 8
Function Function
2
15
12 3 412 3 41 2
3 9
11
3 5
2 24
21 4321
1 13
3
1 4
5
1
2 2 3 6
Single 1 Double Single Double
Function Function Function Function
Figure 7-97: Quad Mast Hose Routing
7-80 PDMM-0089 Issued: 6/24/02

Hydraulic Components Hose and Bracket Adjustment
9. Clamp the hoses to the lower location on

the middle hose guide. Arrange the hoses in
the clamp as shown. Tighten the capscrews
and torque to 11 ft lb (15 N•m). 3
10. Reinstall the upper hose guide to the
tapped bar on the outer upright. Leave the
capscrews loose.
11. Loop the hoses 5 in. (125 mm) below the 5
bottom of the middle hose guide and route
upward into the upper hose guide.
12. Feed the hose ends up between the chain
anchors. Install the hose retainer bar at the
top of the upper hose guide. Tighten the
capscrews and torque to 11 ft lb (15 N•m).
13. Reinstall the guide bar between the upper
hose guide and tapped bar on the outer
upright. Route the hoses to the right of the
guide bar. Tighten the guide capscrews and 5
torque to 36 ft lb (50 N•m). 3
14. Clamp the hoses to the guide bar. Tighten
the capscrews and torque to 11 ft lb
(15 N•m).
15. Clamp the hoses to the back side of the
upper hose guide. Tighten the capscrews
and torque to 11 ft lb (15 N•m).
2, 4
Hose and Bracket Adjustment
See Figure 7-98. The numbered arrows in the
figure correspond to the steps that follow.
1. Raise the mast slowly, checking all guides
and brackets for proper clearances and
alignment.
2. Check for a sufficient length of hose
between the middle and upper hose guides
at full extension.
3. Check the hoses for proper tracking over
the sheaves. 5
4. Check the hoses for even tracking in the
hose guides.
5. Raise and lower the mast slowly through
several cycles for a final check. Check all
clamp capscrews for proper torque and
retighten if necessary.
Figure 7-98: Quad Mast Hose and Bracket Adjustment
PDMM-0089 Issued: 6/24/02 7-81

Hose and Bracket Adjustment Hydraulic Components
7-82 PDMM-0089 Issued: 6/24/02

Mast Components
Mast Components
PDMM-0089 Issued: 6/24/02 7-83

Mast Removal/Installation Mast Components
Mast
Removal/Installation
Partial Removal
NOTE: For this procedure, you will need a hoist
or lift truck with a capacity of at least
five tons.
2. Remove the console and front covers.
3. Remove the forks.
4. Verify that the mast is in a vertical position. Hoist Strap
5. Position the truck beneath the hoist or lift

truck.
7. Wrap a chain or lifting strap around the top
of the mast. Attach the chains or straps to a
hoist or lift truck. See Figure 7-99.
Figure 7-99: Attaching Hoist to Mast

8. Lift the hoist just enough to take the slack
out the chain or strap.
9. Count the number of threads visible in Tilt Cylinder Clevis
back of the jam nut for reference in Pivot Block Pin
re-assembly. Loosen the tilt cylinder jam
nuts. Remove the piston from the tilt
cylinder pivot block. See Figure 7-100. Tilt
10. Reconnect the battery connector and turn Cylinder
the key switch ON. Actuate the tilt control
and retract the tilt rams.
Jam Nut
12. Carefully lay the tilt cylinder down on the
brake assembly.
7
Figure 7-100: Tilt Cylinder Removed from Mast
7-84 PDMM-0089 Issued: 6/24/02

Mast Components Installation after Partial Removal
13. Using the hoist or lift truck, carefully tilt

the mast forward until it is tilted no more
than 45° from the vertical position. See
Figure 7-101.
! CAUTION
Tilting the mast too far forward will
cause the bottom of the mast upright
to gouge the drive unit cover.
See Figure 7-102.
Figure 7-101: Mast Tilted Forward with Hoist Support
Installation after Partial

Drive Unit
Removal
or lift truck of suitable capacity.
Mast Drive
1. With the mast securely held by a strap and Wheel
chain, carefully raise the mast until it is
vertical.
2. Attach the tilt cylinders to the pivot blocks
on the mast.
the key switch ON.
4. Slowly, extend the tilt rams until you are
able to thread the piston into the pivot
block. Screw the jam nut snug against the
pivot block. Adjust so the number of Avoid Contact
Between Mast
threads showing behind the jam nut is the
and Drive Unit
same as before removal. Plate
5. Remove the lifting device and any 78D14108S.TIF
chains/straps used to lift the mast. Figure 7-102: Mast Partial Removal (Detail)
6. Install the forks.
7. Install the covers.
PDMM-0089 Issued: 6/24/02 7-85

Complete Mast Removal Mast Components
Complete Mast Removal

NOTE: See also “Partial Removal” procedure
which precedes for an alternative means
of gaining access to motors and pumps.
For this procedure, you will need a hoist
the key switch ON. Elevate the fork carriage Lower Mounting Bolts
about 18 in. (450 mm). Place blocks under
the fork carriage. Lower the fork carriage 78D14030S.TIF
onto the blocks. See Figure 7-103. Figure 7-103: Mast Pivot Bearing Caps

6. Remove the lower mounting bolt only from
each mast bearing cap. Do not remove the
upper bolt. See Figure 7-103.
the key switch ON. Elevate the fork Hoist Strap
carriage, remove the blocking, and lower
the fork carriage all the way to the floor.
8. Verify that the mast is in a vertical position.
9. Position the truck beneath the hoist.
of the mast. Attach the chains or straps to a
hoist. See Figure 7-104.
12. Lift the hoist just enough to take the slack
out the chain or strap. 78D14032S.TIF
Figure 7-104: Attaching Hoist to Mast
7-86 PDMM-0089 Issued: 6/24/02

Mast Components Complete Mast Removal
13. Count the number of threads visible in

back of the jam nut for reference in
re-assembly. Loosen tilt cylinder jam nuts. Tilt Cylinder
Pivot Block Clevis
Remove the piston from the tilt cylinder
Pin
pivot block. See Figure 7-105.
the key switch ON. Actuate the tilt control Tilt
and retract the tilt rams. Cylinder
brake assembly. Jam Nut
78D14034S.TIF
Figure 7-105: Tilt Cylinder Removed from Mast

17. Disconnect the hose from the lift/lower
manifold being careful not to spill hydraulic
fluid. Plug/cap each fitting to prevent
contamination from entering the hydraulic
system. See Figure 7-106.
18. Remove the upper mounting bolt securing
the mast pivot bearing cap on each drive
unit. Remove the mast pivot bearing cap.
See Figure 7-107.
19. Use the hoist or other lift truck to lift the
mast just enough to allow it to be moved
away from the tractor.
7
Figure 7-106: Mast Hydraulic Hose Disconnection
20. Using tie wraps, attach the hose to the lift
chain to keep it in place. Drive Unit
Shims
21. Have wood blocks positioned to support the
mast off the floor.
Drive Wheel
22. Carefully lower the mast onto the support Mast
blocks with the fork carriage facing down.
23. Note the number of shims between the
Oilite bearings and mast. See Figure 7-107.
Pivot
Oilite Bearing Cap
Bearing
78D14035S.TIF
Figure 7-107: Mast Pivot Bearing Parts
PDMM-0089 Issued: 6/24/02 7-87

Installation after Complete Removal Mast Components
Installation after Complete

Removal
1. Ensure the pivot bearings are shimmed as
they were when the mast was removed.
of the mast. Attach the chains or straps to
the lifting device.
3. Slowly lift the mast up and off the wooden
blocks.
4. Slowly move the mast towards the truck.
5. Position the lower pivot bearings on the
mast at the same height as the pivot yokes
on the drive units.
6. Carefully engage the mast pivot bearings
with the yokes on the drive unit.
7. Place the mast pivot bearing caps over both
mast pivot bearings. Install the upper
mounting bolt in both mast pivot bearing
caps.
8. Reconnect the hydraulic hose at the main
manifold.
the key switch ON.
10. Slowly, extend the tilt rams until you are
able to thread the piston into the tilt
cylinder pivot block. Screw the jam nut
snug against the pivot block. Adjust so the
number of threads showing behind the jam
nut is the same as before removal.
11. Remove the lifting device and any
chains/straps used to lift the mast.
12. Slowly elevate and tilt the mast. Check for
any hydraulic leaks.
13. Elevate the fork carriage about 18 in.
(450 mm). Place blocks under the fork
carriage. Lower the fork carriage onto the
blocks.
(P/N 990-536) to the lower mast mounting
bolts and torque to 43 ft lb (60 N•m).
7-88 PDMM-0089 Issued: 6/24/02

Mast Components Installation after Complete Removal
16. Remove the upper mast mounting bolts.

Apply thread-locking compound
(P/N 990-536) to the bolts and torque to
43 ft lb (60 N•m).
the key switch ON.
18. Elevate the fork carriage and remove any
blocking.
19. Install the forks.
20. Bleed the hydraulic system. See “Bleeding
the Hydraulic System” on page 7-70.
21. Install the covers.
PDMM-0089 Issued: 6/24/02 7-89

Mast Disassembly Mast Components
Mast Disassembly
NOTE: For this procedure you will need a hoist
or lift truck capable of lifting at least five
tons.
the key switch ON. Elevate the fork carriage
about 18 in. (450 mm). Place blocks under
the fork carriage. Lower the fork carriage
onto the blocks. See Figure 7-108.
of the load backrest. Attach the chains or
strap to a hoist or lift truck. Lower Mounting Bolt
6. Remove the bolts that secure the backrest 7
to the carriage. Remove the load backrest. Figure 7-108: Mast Pivot Bearing Caps
7. Raise the carriage back and higher than the
chain anchor attachment points.
8. Attach the hoist chain through the
carriage’s inside hydraulic parts for side
approach, at points over the ram housing.
Hoist Chains
See Figure 7-109.
10. Disconnect the hydraulic line at the
connections to both standard aux. hoses,
being careful not to spill hydraulic fluid.
Plug/cap each fitting to prevent
contamination from entering the hydraulic
system.
NOTE: If hi-speed aux function is mounted on
the carriage, disconnect and cap the
additional hoses.
NOTE: Make sure hoses are not be twisted at
reassembly.
Figure 7-109: Hoist Chains Through Carriage Assembly
7-90 PDMM-0089 Issued: 6/24/02

Mast Components Mast Disassembly
11. Raise the hoist until the cotter pin master

link in the free lift chain anchor assembly is
exposed.
12. Remove the cotter pins. The anchor chain
should slacken just enough for removal.
Remove the connector links from both
chains. See Figure 7-110.
the key switch ON.
14. Remove the carriage stops. Tilt mast back.
7
15. Turn the key switch OFF and disconnect Figure 7-110: Remove Connector Link
16. Pull out the chains and disconnected
hoses. Hang them over the front carriage to
keep them out of the way. See
Figure 7-111.
Figure 7-111: Chains and Hoses Over Carriage

17. Disassemble the pulley assembly. See
Figure 7-112. Remove the pulley from the
bracket at the top of the lift ram.
Figure 7-112: Remove Pulley from Bracket
PDMM-0089 Issued: 6/24/02 7-91

18. Raise the hoist to lift the carriage assembly

up and out of the mast. See Figure 7-113.
NOTE: Avoid damage to hoses and chains when
carriage is moved.
Figure 7-113: Carriage Assembly Removal

19. Move the carriage assembly away from the
mast and set on a pallet, with the roller
bearings down. See Figure 7-114.
! CAUTION
The carriage assembly is very heavy.
Keep fingers out of harms way.
Figure 7-114: Roller Bearings on Pallet
20. Disconnect aux. hose fittings at mid-mast

location, being careful not to spill hydraulic
fluid. Plug/cap fittings and hoses.
21. Remove the hydraulic hose bracket from
the left side at mid-mast, with the hoses
still attached. See Figure 7-115. Remove
the hose assembly to the pallet area to
prevent damage. Note the hose orientation
as disassembled from the manifold to
ensure proper reassembly.
22. Cut the cable ties that secure the light
cords to the hoses. Remove any other
accessories such as lights from the mast
assembly to avoid damage.
Figure 7-115: Hose Bracket Removal
7-92 PDMM-0089 Issued: 6/24/02

23. Remove the main lift hose.

24. Reposition the hoist back on top of the
mast, with the chain through all three
cross-ties.
25. Count the number of threads visible in
back of the jam nut for reference in
reassembly. Loosen the tilt cylinder jam
nuts. Remove the piston from the tilt
cylinder pivot block. See Figure 7-116.
Figure 7-116: Piston Removed from Piston Block

26. Remove the lower mounting bolt only from
each mast pivot bearing cap. Do not
remove the upper mounting bolt yet. See
Figure 7-117.
the key switch ON. Actuate the tilt control
and retract the tilt rams.
brake assembly.
30. Remove the upper mounting bolt securing
the mast bearing cap on each drive unit.
Remove the mast bearing cap(s). 7
Figure 7-117: Mast Pivot Bearing Caps
31. Use the hoist or lift truck to lift the mast
7
just enough to allow movement away from
the tractor.
32. Carefully lower the mast, fork carriage side
facing down, onto the support blocks at the
bottom and jack stands at the top. See
Figure 7-118.
Figure 7-118: Supported Mast Assembly
PDMM-0089 Issued: 6/24/02 7-93

33. Remove the cotter pin and connector link

7
from the main lift chain.
34. Remove the two allen head bolts from the
lower chain anchor blocks. Remove the
chain and chain anchor blocks from the
mast assembly. See Figure 7-119.
35. Disconnect and cap the right side free lift
hydraulic hose. Disconnect and cap the
main lift interconnect hoses. (Remove the
right hand tee connection ONLY if
necessary to inspect or replace the flow
controls within.) See Figure 7-120.
36. Using a wrench, loosen the tee fitting
connection just enough for air to escape
Figure 7-119: Chain and Blocks Removed
allowing free movement of the cylinder.
37. Replace the hoist straps at the top bracing
7
of the outer telescopic. Pull the outer
telescopic up enough to expose the pulley
assemblies.
38. Pull the hydraulic hoses, still banded
together, out through the mast housing.
Disconnect the two aux hoses at the lower
bracket fittings and remove. Remove the
four bolts that mount the hose bracket
assembly to the inner telescopic. Remove
the assembly and set it aside.
Figure 7-120: Disconnect Hose Connection

39. Remove the hose pulley from the center bolt
7
at the top of the mast. See Figure 7-121.
Figure 7-121: Hose Pulley Removal
7-94 PDMM-0089 Issued: 6/24/02

40. Disassemble the chain pulley by removing

7
the set screw. See Figure 7-122. Lift out the
pulley shaft.
Figure 7-122: Chain Pulley Removal

41. Remove the bolt from the top of the piston.
7
(Direct heat applied to the head of the bolt
may aid in loosening.) Use a strap wrench
to keep the piston from spinning during
bolt removal and to protect the piston
surface from damage. See Figure 7-123.
Figure 7-123: Strap Wrench on Piston
PDMM-0089 Issued: 6/24/02 7-95

42. Press the cylinder down into the housing

enough to provide minimal exposure for
possible damage to the piston surface.
Wrap the hoist strap around the piston
cylinder and remove the cylinder from the
mast assembly. See Figure 7-124. Repeat
for right side.
7
Figure 7-124: Piston Cylinder Removal
43. Place the hoist strap around the free lift
(center) cylinder for support. Remove the
adjusting nut and Nyloc nut from the chain
anchor bolts. Hoist out the cylinder. See
Figure 7-125.
44. Using the hoist, with straps attached on
one side, flip the entire mast assembly to
remove any backside loading resistance
from the telescopics for further
disassembly. Again place mast assembly on
jack stands at the top and blocks toward
the bottom.
Figure 7-125: Center Cylinder Removal

45. Slide out the inner telescopic from the mast
frame until the cross-tie is even with the
cross-tie on the top of the main mast.
Secure these cross-ties together with a
chain to prevent unexpected sliding. See
Figure 7-126.
Figure 7-126: Secured Cross-ties
7-96 PDMM-0089 Issued: 6/24/02

46. Place a block at the bottom between the

mast frame and the outer telescopic to
secure against unexpected movement. See
Figure 7-127.
Figure 7-127: Secure with Block

47. With the outer telescopic’s upper roller
bearings now exposed, remove the flathead
hex screws that retain them. See
Figure 7-128.
48. Remove the screws and the seated collar
from the roller bearing assembly. A
screwdriver placed behind the bearing
during removal will prevent it from rolling
back down the channel once loose.
See Figure 7-129.
Figure 7-128: Exposed Roller Bearings

NOTE: The telescopic will drop about 1/8 in.
(3.175 mm) from position when the
bearing is removed.
NOTE: The bearing adapter is eccentric to the
bearing boss. Use a prick punch to mark
the bearing boss before removal to note
orientation of “up” (towards the top of
the mast) for proper reinstallation.
Figure 7-129: Bearing Disassembled
PDMM-0089 Issued: 6/24/02 7-97

49. Use a hoist to remove the inner telescopic

and place it aside. See Figure 7-130.
Figure 7-130: Inner Telescopic Removal

50. Use a hoist to remove the outer telescopic.
Locate the strap at the center for a better
balance advantage. See Figure 7-131.
Figure 7-131: Outer Telescopic Removal

51. Remove the bolt and washer along with the
set screw to replace the roller bearing in the
outer telescopic. Note that this bearing boss
is also eccentric. See Figure 7-132.
Figure 7-132: Roller Bearing Replacement
7-98 PDMM-0089 Issued: 6/24/02

Mast Components Mast Shimming
Mast Shimming
1. Install the bearings onto the lower outer
telescopic bosses and check the fit by
sliding the outer telescopic into the mast
frame. See Figure 7-133.
2. Shim the bearings to the tightest point in
the outer telescopic, Use an equal number
of shims on both sides if possible.
3. Slide the outer telescopic all the way into
the mast frame. Attach the upper outer
telescopic bearings onto the mast frame
with the seated collar and bearing adaptors
removed previously. Figure 7-133: Lower Outer Telescopic Bearing
NOTE: The outer telescopic will need to be
raised 1/8 in. (3.175 mm) to allow
installation of the upper telescopic
bearing.
Check the shimming of the upper bearings
by dry fitting (placing the bearing on the
boss and checking the fit by sliding the
bearings between the outer telescopic and
the mast frame).
Figure 7-134: Inner Telescopic Installation

4. Orient the bearing boss with the alignment
marks made during disassembly for proper
reorientation. Make sure that the bearing
remains flush with the mast frame.
Screwing the set screw in too far will push
the bearing away from the web of the mast
frame. Adjust the fit with different
combinations of shims. Use an equal
number of shims on both sides if possible.
Make sure the fit is tight enough so that the
outer telescopic does not glide freely in the
mast frame.
When shimmed correctly, no more than
half of the face of the bearing drags on the Figure 7-135: Inner Telescopic Bearing Installation
web of the outer telescopic.
5. Install the lower inner telescopic bearing
into the outer telescopic. Shim the bearings
to the tightest point in the inner telescopic,
Use an equal number of shims on both
sides if possible.
PDMM-0089 Issued: 6/24/02 7-99

Mast Shimming Mast Components
6. Slide the inner telescopic all the way into

the outer telescopic and dry fit the upper
inner telescopic bearings (place the bearing
on the boss and check the fit by sliding the
bearings between the outer telescopic and
the mast frame).
7. Assemble the upper inner telescopic
bearings and bearing bosses. When
tightening the bearing bolt, the locating
hole in the boss should face up (out of the
telescopic). Make sure that when the
locating hole is facing up, the thin step of
the recess is facing the load and away from
the rams.
When installed correctly, no more than half
of the face of the bearing drags on the web
of the outer telescopic.
! CAUTION
Secure the inner telescopic, outer
telescopic and mast frame against
unexpected sliding before
attempting mast reassembly.
7-100 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual Theory of Operation
Theory of Operation 8:
PDMM-0089 Issued: 6/24/02 8-1

Theory of Operation EASi Pacer™ Lift Truck Maintenance Manual
Navigation Instructions for the Pin-Out Matrix
Navigation Instructions
for the Pin-Out Matrix
The Pin-Out Matrix is designed to be used in
conjunction with the electrical schematics (see
page A-13) to assist in testing and
troubleshooting the truck. The following text
describes the columns in which the information
appears and the information given.
No. - line sequence number in the matrix. Has
no relevance to the schematic.
Wire/Comp - the actual wire/connection
references or component abbreviations on the
electrical schematics.
Function Description - brief description of the
signal carried on the wire.
Theory of Operation - detailed description of
the signal carried on the wire. If the signal can
be variable, it indicates the state of a related
component that will cause the signal to vary.
Identifies possible causes for lack of proper
signal.
Identifies the device or connection carrying the
signal one level upstream from the Signal
Source.
Device - identifies the major system component
related to the signal.
CFP - Contactor Fuse Panel
EPO - Emergency Power OFF
LA - Left Traction Power Amplifier
LPC - Lift Power Control
ODI - Operator Display Interface
PA - Lift Power Amplifier
RA - Right Traction Power Amplifier
STR - Steer Contactor
TPC - Traction Power Control
VM - Vehicle Manager
Normal Voltage - signal value that is usually
seen on that wire for the state indicated.
Signal Source - device or connection that
supplies the signal directly to the wire.
Signal User - device or connection that the wire
directly delivers the signal to.
Function - wire one level downstream from the
Signal User.
8-2 PDMM-0089 Issued: 6/24/02

No. Wire / Function Theory of Operation Device Normal Signal Signal Function
Comp Description Voltage Source User
79 154 Service 24v from service brake hydraulic pressure switch (SW19) when A Open - J28-2 J6-15 200
Brake pedal is depressed. The circuit remains open when service brake +24v (SW19) (SCH)
(pressure pedal is released. (braking)
switch) If voltage is not present, check brake hydraulic pressure switch,
wires, and connectors.
This voltage is dependent on the presence of voltage at (J23) on
the DC/DC converter.
ONE LEVEL UPSTREAM

The Wire/Comp reference becomes the Function
for one level upstream theory and
troubleshooting.
99 202 +24v to 24v to service brake hydraulic pressure switch. If voltage is not A 24v J23 J28-1 154
brake switch present, check wiring and connectors. This voltage is dependent (DC/DC) (SW19)
(pressure) on the presence of 24v at (J23) on the DC/DC converter.
ONE LEVEL DOWNSTREAM

The Function reference becomes the Wire/Comp reference for one
level downstream theory and troubleshooting.
94 200 Brake light 24v from fuse (F4) on Auxiliary Board when service brake pedal is A Open - J7-4 (SCH) J18-4
supply to depressed. This circuit will remain open when the service brake +24v (LP1)
LP1 pedal is released. If voltage is not present, check fuse, wiring, and (braking)
connectors. This voltage is dependent upon the presence of 24v at
(J7-1, J7-2, J7-3) on the Auxiliary Board.
95 200 Brake light 24v from fuse (F4) on Auxiliary Board when service brake pedal is A Open - J7-4 (SCH) J17-4
supply to depressed. This circuit will remain open when the service brake +24v (LP2)
LP2 pedal is released. If voltage is not present, check fuse, wiring, and (braking)
connectors. This voltage is dependent upon the presence of 24v at
(J7-1, J7-2, J7-3) on the Auxiliary Board.
PDMM-0089 Issued: 6/24/02 8-3

8-4 PDMM-0089 Issued: 6/24/02


Pin-Out Matrix
Wire/ Function Normal Signal Signal
No. Theory of Operation Device Function
Comp. Description Voltage Source User
1 JPF1-1 B+ for option B+ to FU9 on the Contactor Fuse Panel (CFP) when the battery is CFP B+ TP1 FU9 Work lights,
hookup connected. This voltage is used for optional devices such as left/ reverse light
right work lights & reverse lights.
2 JPF1-10 B+ for FU7 B+ to FU7 on the CFP when the battery is connected. This voltage CFP B+ TP1 FU7 Strobe/ rotating
is used for optional devices such as a strobe or rotating light and light, fans
fans.
3 JPF1-3 B+ for FU7 B+ to FU7 on the CFP when the battery is connected. This voltage CFP B+ TP1 FU7 Strobe/rotating
is used for optional devices such as a strobe or rotating light and light, fans
fans.
4 JPF1-8 B+ for FU5 B+ to FU5 on the CFP when the battery is connected. This voltage CFP B+ TP1 FU5, K2, Key switch
provides power to the key switch (S1) and contact tips of K2 and K3
K3 relay.
5 JPF1-9 B+ for FU5 B+ to FU5 on the CFP when the battery is connected. This voltage CFP B+ TP1 FU5, K2, Key switch
provides power to the key switch (S1) and contact tips of K2 and K3
K3 relay.
6 TS1-1 B+ for lights B+ from FU9 on the CFP. This voltage is used for optional devices CFP B+ FU9 S10, S15 Work lights,
such as left and right working lights and reversing lights. reverse light
7 TS1-2 B+ for strobe B+ at the CFP when the contact tips of K1 close. This voltage is CFP B+ K1 FU12, Strobe/rotating
light/fan used for optional devices such as a strobe or rotating light and (when FU13 light, fans
fans. closed)
8 TS1-3 B+ for working B+ at the CFP when the contact tips of K1 close. This voltage is CFP B+ K1 Work lights
and reverse lights used for optional devices such as strobe lights, rotating lights and (when
fans. closed)
9 JPF3-4 B+ for key switch B+ to the key switch (S1). CFP B+ FU5 S1 Key switch
Theory of Operation
10 JPF3-2 B+Key B+Key at the CFP when the key switch is closed. B+ is available CFP B+ S1- K1, K2, K3 All key switch
at K1, K2 and K3 relay coils. related
functions
Pin-Out Matrix
11 JPF2-5 B+Key B+Key from the CFP when the key switch is closed. This provides CFP B+ S1 VM VM
B+Key to the VM.
12 JPF2-7 B+KC B+KC from the CFP when the contact tips of relay K3 close. This CFP B+ K3 VM Steer, traction,
voltage is used at the VM for steering, traction and lift contactors. lift
8-5
8-6
Pin-Out Matrix
Theory of Operation
13 T1 B+KB B+KB from the CFP when the contact tips of relay K3 close. This CFP B+ K3 VM Brakes
voltage is used at the VM for the brakes.
14 JPF2-2 B+KA B+KA from the CFP when the contact tips of relay K2 close. This CFP B+ K2 VM Hydraulic
voltage is used at the VM for the hydraulic solenoids and horn. functions, horn
15 JPF2-8 B+KA B+KA from the CFP when the contact tips of relay K2 close. This CFP B+ K2 VM Hydraulic
voltage is used at the VM for the hydraulic solenoids and horn. functions, horn
16 JPF2-1 Battery Sense B+ from the CFP when the battery is connected. The VM uses this CFP B+ minus 2V JPF1-9 VM BSOC
voltage for BSOC calculation and to check battery voltage. This calculation
voltage will not be 36V when read with a meter because of a
5.1kohm resistor in the circuit on the CFP. There should be a 2V
(approx) drop across the resistor depending upon the voltage of
the battery. If the voltage is not between 28 and 44V, a code
should be displayed.
17 JPF2-6 EPO Sense The VM uses this sense line to determine if the EPO switch is CFP 36V or 0V S21 VM VM
closed or open. The voltage will either be high (open) or low depending
(closed). on state of
switch
18 JPF4-1 B+ for Attach. B+KA from the CFP when contact tips of K2 close, to the optional CFP B+ K2 Attach. Attach. Card
Card Attach. Card Card

19 JPF5-1 B+ for PA B+K2 from the CFP when contact tips of K2 close, providing B+ CFP B+ K2 PA Lift
to the Lift Power Amplifier.
20 JPF5-2 B+ for RA B+K2 from the CFP when contact tips of K2 close, providing B+ CFP B+ K2 RA Travel
to the Right Traction Power Amplifier.
21 JPF5-4 B+ for LA B+K2 from the CFP when contact tips of relay K2 close, providing CFP B+ K2 LA Travel
B+ to the Left Traction Power Amplifier.
22 JPF5-5 B+ for RA Node B+K2 from the CFP when contact tips of relay K2 close. This CFP B+ K2 RA Travel
Select provides Node Select to the Right Traction Power Amplifier. This
is used to differentiate between the left and right amplifier. The
drive motors turn in opposite directions during travel and thus the
amplifiers must drive the motors differently.
23 JPF3-1 B– out of EPO B– at the EPO switch (S21). Provides B– for K3 and allows EPO EPO B+ w/switch S21 K3 Brakes,
sense to change state. open Hydraulic coils
24 JPF3-3 B– for EPO B– at the EPO switch (S21). EPO B– w/switch FU10 S21 Brakes,
open hydraulic coils
25 JPF5-3 NC B– at the CFP. Currently not used. CFP B– FU10 NC


26 JPF5-6 NC B– at the CFP. Currently not used. CFP B– FU10 NC
27 JPF2-4 B– for Dgnd B– at the CFP. Used for Dgnd by the VM. CFP B– FU10 VM VM
28 JPF2-9 B–F B–F from the CFP to the VM. CFP B– FU10 VM VM
31 JPF2-12 B–F B–F from at the CFP to the VM. CFP B– FU10 VM VM
32 JPF4-2 B–F for Attach. B–F from the CFP to the Attach. Card. CFP B– FU10 Attach. Attach. Card
Card Card
33 TS2-1 B– for lights/fan B– at the CFP. Provides B– for optional devices. CFP B– FU6 Lights, fan
34 TS2-2 B– for lights B– at the CFP. Provides B– for optional devices such as strobe or CFP B– FU6 Strobe/ rotating
rotating lights, work lights and reversing lights. light, work and
reverse lights
35 TS2-3 B– for Options B– at the CFP. Provides B– for optional devices. CFP B– FU8 S36 Fan
36 JPF1-5 B– for FU10 B– at the CFP from TP4. One of three pins that provides B– to CFP B– TP4 FU10 VM
FU10.
FU10.
FU10.
39 JPF1-13 B– for FU6 B– at the CFP from TP4 to FU6. This is one of two pins that CFP B– TP4 FU6 Strobe/ rotating
provide B– to optional devices such as strobe lights, rotating light, work and
lights, left and right work lights and reversing lights. reverse lights
40 JPF1-14 B– for FU6 B– at the CFP from TP4 to FU6. This is one of two pins that CFP B– TP4 FU6 Strobe/ rotating
provide B– to optional devices such as strobe lights, rotating light, work and
Theory of Operation
lights, left and right work lights and reversing lights. reverse lights
41 JPF1-7 B– for FU8 B– to the CFP from TP4 to FU8. This provides B– for optional CFP B– TP4 FU8 Optional
Pin-Out Matrix
devices. devices
42 JPTL1-1 B+K2 on LA B+K2 at the Left Traction Power Amplifier. Provides B+ for the LA B+ K2 LA Left motor
control circuitry inside the Left Traction Power Amplifier. traction
8-7
43 JPTL2-3 BUS+ on LA BUS+ at the Left Traction Power Amplifier. One of two LA 5.3V VM LA BUS+ & BUS–
communication lines between the VM and the amplifiers. communications
8-8
Pin-Out Matrix
Theory of Operation
44 JPTL2-6 BUS– on LA BUS– at the Left Traction Power Amplifier. One of two LA –5.3V VM LA BUS+ & BUS–
45 JPTL2-4 NC BUS– at the Left Traction Power Amplifier. Not connected on this LA –5.3V VM LA Not used
amplifier.
46 JPTL2-5 NC Terminating pin on the Left Traction Power Amplifier. This is the LA 0V LA LA Not used
terminal connected to an internal terminating resistor. If resistor is
not used, this pin will not be connected. The terminating resistor is
not connected on this amplifier.
47 JPTR1-1 B+K2 on RA B+K2 at the Right Traction Power Amplifier. Provides B+ to the RA B+ K2 RA BUS+ & BUS–
control circuitry inside the Right Traction Power Amplifier. communications
48 JPTR1-2 Node Select on Provides Node Select to the Right Traction Power Amplifier. Used RA B+ K2 RA BUS+ & BUS–
RA to differentiate between the left and right amplifier. The drive communications
motors turn in opposite directions during travel, therefore the
amplifiers must drive the motors differently.
49 JPTR2-3 BUS+ on RA BUS+ at the Right Traction Power Amplifier. One of two RA 5.3V VM RA BUS+ & BUS–
50 JPTR2-6 BUS– on RA BUS– at the Right Traction Power Amplifier. One of two RA 5.3V VM RA BUS+ & BUS–

51 JPTR2-4 NC BUS– at the Right Traction Power Amplifier. Not connected on this RA 5.3V VM RA Not used
amplifier.
52 JPTR2-5 Term on RA Terminating pin at the Right Traction Power Amplifier connected RA 0V RA RA Not used
to an internal terminating resistor. If resistor is not used, this pin
will not be connected. The terminating resistor is not connected
on this amplifier.
53 JPL1-1 B+K2 on PA B+K2 at the Lift Power Amplifier. Provides B+ to the control PA B+ K2 PA Lift/Aux
circuitry inside the Lift Power Amplifier.
54 JPL2-3 BUS+ on PA BUS+ at the Lift Power Amplifier. One of two communication lines PA 5.3V VM PA BUS+ & BUS–
between the VM and the amplifier. communications
55 JPL2-6 BUS– on PA BUS– at the Lift Power Amplifier. One of two communication lines PA 5.3V VM PA BUS+ & BUS–
between the VM and the amplifier. communications
56 JPL2-4 BUS– on PA BUS– at the Lift Power Amplifier jumpered to an internal PA 5.3V VM PA BUS+ & BUS–
terminating resistor in the amplifier to reduce communications communications
noise interference.

57 JPL2-5 Term on PA Terminating pin at the Lift Power Amplifier connected to an PA 5.3V VM PA BUS+ & BUS–
internal terminating resistor. The terminating resistor is connected communications
on this amplifier.
58 JPC8-9 FU1_Sense FU1_Sense at the VM. This is B+ when the battery is connected VM B+ w/STR STR, VM FU1 Sense
and steering contactor tips are closed. This is how the VM contactor FU1
determines if the steering motor power circuit is energized. closed
59 JPC10-19 B+KB B+KB passes through the VM as the (+) supply for the brakes. VM B+ K3 Brakes Brakes
60 JPC8-17 B+Key B+Key to the VM for internal circuitry and power supply to VM B+ S1 VM VM
devices fed from the VM.
61 JPC8-13 B+KC B+KC passes through the VM as the (+) supply for the STR, TPC, VM B+ K3 Steer, Steer, Travel, Lift
and LPC contactors. Travel, Lift Contactors
Contactors
62 JPC8-4 B+KA B+KA to the VM. One of two lines from the CFP that provide VM B+ K2 Hydraulic Hydraulic
B+KA to the VM. Passes through the VM as the (+) supply for the Solenoids, Solenoids, Horn
horn and hydraulic solenoids. Horn
63 JPC8-5 B+KA B+KA at the VM. One of two lines from the CFP that provide VM B+ K2 Hydraulic Hydraulic
B+KA to the VM. Passes through the VM as the (+) supply for the Solenoids, Solenoids, Horn
horn and hydraulic solenoids. Horn
64 JPC8-7 Battery_Sense_In B+ from the CFP when the battery is connected. The VM uses this VM B+ minus 2V CFP VM ODI
voltage for BSOC calculation and to check battery voltage. This
voltage will not be 36V when read with a meter because of a
5.1kohm resistor in the circuit on the CFP. There should be a 2V
(approx) drop across the resistor depending upon the voltage of
the battery. If the voltage is not between 28 and 44V, a code
should be displayed.
65 JPC8-11 EPO_Sense The VM uses this sense line to determine if the EPO switch is VM 36 or 0V S21 VM
closed or open. The voltage will either be high (open) or low depending
(closed). on state of
Theory of Operation
switch
66 JPC4-9 BUS+ BUS+ at the VM. One of two communication lines between the VM 5.3V LA, RA, VM BUS+ & BUS–
Pin-Out Matrix
VM and the power amplifiers. PA communications
67 JPC4-10 BUS– BUS– at the VM. One of two communication lines between the VM –5.3V LA, RA, VM BUS+ & BUS–
VM and the power amplifiers. PA communications
8-9
8-10
Pin-Out Matrix
Theory of Operation
68 JPC5-1 +12VP +12VP from the VM to the Display. This voltage is fed through a VM, ODI 11.3V VM ODI Display & Input
diode to prevent spikes or stray voltages from feeding back into keys
the 12V power supply. Approx 11.3V will be read due to the
voltage drop across the diode.
69 JPC5-2 Addr_Latch Line between the Display and the VM. VM, ODI VM ODI Display & VM
70 JPC5-3 Data_Latch Line between the Display and the VM. VM, ODI VM ODI Display & VM
71 JPC5-4 Disp_Miso Line between the Display and the VM. VM, ODI VM ODI Display & VM
72 JPC5-5 Alarm_Pwm Line between the Display and the VM. Voltage varies when tones VM, ODI Between 0V VM ODI Display
are enabled. and 12V wrt
+12V
73 JPC5-6 Shift_Clock Line between the Display and the VM. VM, ODI VM ODI Display & Input
keys
74 JPC5-7 Data_Out Line between the Display and the VM. VM, ODI VM ODI Display & Input
keys
75 JPC5-8 Dgnd B– supply to the Display. VM, ODI B– VM ODI Display & Input
keys
76 JPD2-5 Return to Down The VM monitors this voltage to determine when the button is ODI up = 0 ODI Key Pad Up Button
button on key pad depressed. dwn = 4.5

wrt TP4
77 JPD2-3 Supply to Enter The VM monitors this voltage to determine when the button is ODI up =11.0 ODI Key Pad Down Button
wrt TP4
78 JPD2-1 Supply to Up The VM monitors this voltage to determine when the button is ODI up = 11.0 ODI Key Pad Enter Button
wrt TP4
79 JPD2-2 Supply to Down The VM monitors this voltage to determine when the button is ODI up = 11.0 ODI VM Enter Button
wrt TP4
80 JPD2-4 Return from Enter The VM monitors this voltage to determine when the button is ODI up = 0 ODI VM Down Button
wrt TP4
81 JPD2-6 Return from Up The VM monitors this voltage to determine when the button is ODI up = 0 ODI VM Up Button
wrt TP4

82 JPC8-6 Dgnd Used for Dgnd at the VM. This is the B– supply to the VM. VM B– CFP VM VM
83 JPC8-1 B–F B–F to the VM. This is B– supplied to the VM for internal use. VM B– CFP VM VM
87 JPC9-3 B+KA B+KA from the VM. This is B+ supply to solenoids 4, 6, 12, 7, 1, VM B+ VM Sols 4, 6, Lift, Side Shift,
5, 8, 9, and 2. 12, 7, 1, Lower
5, 8, 9, 2
88 JPC9-1 Tilt_Sol Negative supply provided by a coil driver inside the VM to Sol4 B– when on VM Sol4 Tilt
energize the Tilt solenoid. (wrt B+)
89 JPC9-8 Sol6_Out Negative supply provided by a coil driver inside the VM to Sol6 B– when on VM Sol6 Aux Dir
energize Sol6. (wrt B+)
90 JPC9-9 Sol7_Out Negative supply provided by a coil driver inside the VM to Sol7 B– when on VM Sol7 Lift/Aux1
91 JPC9-6 Load_Hld_Sol Negative supply provided by a coil driver inside the VM to Sol1 B– when on VM Sol1 Lower
energize the load holding solenoid. (wrt B+)
92 JPC9-7 Sol5_Out Negative supply provided by a coil driver inside the VM to Sol5 B– when on VM Sol5 2nd stage lift
93 JPC9-10 Sol8_Out Negative supply provided by a coil driver inside the VM to Sol8 B– when on VM Sol8 HS Lift, Aux
energize Sol8. (wrt B+) Functions
94 JPC9-2 Sol9_Out Negative supply provided by a coil driver inside the VM to Sol9 B– when on VM Sol9 HS Aux
energize Sol9. (wrt B+) Functions
95 JPC9-5 Prop_Lwr_Sol Negative supply provided by a coil driver inside the VM to Sol3 15V when VM Sol3 Proportional
energize the proportional lower solenoid. on (wrt B+) Lowering
Theory of Operation
96 JPC9-11 B+KA-P B+KA-P from the VM to the Proportional Lower Solenoid coil. This Sol3 B+ VM Sol3 Proportional
is the (+) supply to the coil. This will not measure B+ because of a Lowering
Pin-Out Matrix
diode in the circuit to prevent spikes or backfeed from affecting
the power supply inside the VM.
97 JPC9-12 Side_Shift_Out Negative supply provided by a coil driver inside the VM to Sol2 B– when on VM Sol2 Side Shift
energize the side shift solenoid. (wrt B+)
8-11
8-12
Pin-Out Matrix
Theory of Operation
98 JPC7-5 Dgnd Dgnd from the VM to the Deadman switch (S2). Causes S2 B– VM S2 All functions
On_Deadman input to go low when switch is closed. requiring
Deadman
99 JPC7-16 On_Deadman On_Deadman to the VM from the Deadman switch (S2). When VM, S2 0V when S2 VM All functions
the switch is closed, the input, On_Deadman will go low. When depressed. requiring
the switch is open, On_Deadman will remain hi. 5V when Deadman
open
100 JPC7-1 +12VP +12VP from the VM to the Steer Position Sensor. This (+) supply Steer Sensor 11.3V VM Steer Steer position
will not measure 12V because of a diode in the circuit to prevent Sensor feedback
spikes or backfeed from affecting the power supply inside the
VM. Approx 11.3 volts will be read. This voltage is produced in
the VM and is also provided to other devices. If the voltage is
low, disconnect other devices to determine if another device
could be pulling the voltage down.
101 JPC7-17 Steer_ChA Input to the VM to determine steering position. This is one of three Steer Sensor, <2V when it Steer VM Steer position
input lines from the Steer Position Sensor to the VM. The state of VM sees metal, Sensor
the switch will be high or low depending upon whether the >7V when it
proximity switch sees metal or not. does not
102 JPC7-18 Steer_ChB Input to the VM to determine steering position. This is one of three Steer Sensor, <2V when it Steer VM Steer position

103 JPC7-8 Steer_ChC Input to the VM to determine steering position. This is one of three Steer Sensor, <2V when it Steer VM Steer position
104 JPC10-8 Left_Trac_BWI1 Left_Trac_BWI1 input to the VM to indicate if brushes are worn M1, VM With TPC M1 VM Travel
down to a predetermined point. If brushes are worn, the switch closed,
will close and armature voltage will be sensed by the VM. 0V = brushes
OK
36V =
brushes bad
105 JPC10-3 Mux_Temp1_LTM Mux_Temp1_LTM to the VM. The VM uses this to determine VM, M1 Changing M1 VM Travel
temperature of the left traction motor. A small voltage is sent from voltage -
the VM, through the temperature thermistor of the motor to Dgnd. depends on
As temperature increases, the resistance in the thermistor temp
decreases. The VM senses a change in voltage and thus derives
a temperature.

106 JPC10-24 Dgnd_P Dgnd at the VM. This is a return path to B– for the voltage that the VM, M1 B– M1 VM Travel
VM sends out to the temperature thermistor to determine motor
temperature.
107 JPC10-9 Left_Trac_BWI2 Left_Trac_BWI2 input to the VM to indicate if brushes are worn VM, M1 With TPC M1 VM Travel
down to a predetermined point. If brushes are worn, the switch closed
OK
36V =
brushes bad
108 JPC10-13 Right_Trac_BWI1 Right_Trac_BWI1 input to the VM to indicate if brushes are worn VM, M2 With TPC M2 VM Travel
OK
36V =
brushes bad
109 JPC10-2 Mux_Temp1_RTM Mux_Temp1_RTM to the VM. The VM uses this to determine VM, M2 Changing M2 VM Travel
temperature of the right traction motor. A small voltage is sent voltage -
from the VM, through the temperature thermistor of the motor to depends on
Dgnd. As temperature increases, the resistance in the thermistor temp
a temperature.
110 JPC10-23 Dgnd_P Dgnd_P at the VM. This is used for a return path to B– for the VM, M2 B– VM M2 Travel
voltage that the manager sends out to the temperature thermistor
to determine motor temperature.
111 JPC10-10 Right_Trac_BWI2 Right_Trac_BWI2 input to the VM to indicate if brushes are worn VM, M2 With TPC M2 VM Travel
OK
36V =
brushes bad
Theory of Operation
112 JPC10-14 Lift_BWI1 Lift_BWI1 input to the VM to indicate if brushes are worn down to VM, MP With TPC MP VM Lift
a predetermined point. If brushes are worn, the switch will close closed
Pin-Out Matrix
and armature voltage will be sensed by the VM. 0V = brushes
OK
36V =
brushes bad
8-13
8-14
Pin-Out Matrix
Theory of Operation
113 JPC10-1 Mux_Temp3_LM Mux_Temp3_LM to the VM. The VM uses this to determine VM, MP Varies - MP VM Lift
temperature of the right traction motor. A small voltage is sent depending
from the VM, through the temperature thermistor of the motor to on temp
Dgnd. As temperature increases, the resistance in the thermistor
a temperature.
114 JPC10-22 Dgnd_P Dgnd_P at the VM. Used for a return path to negative for the VM, MP B– VM MP Lift
voltage that the manager sends out to the temperature thermistor
to determine motor temperature.
115 JPC10-15 Lift_BWI2 Lift_BWI2 input to the VM to indicate if brushes are worn down to VM, MP With TPC MP VM Lift
a predetermined point. If brushes are worn, the switch will close closed
and armature voltage will be sensed by the VM. 0V = brushes
OK
36V =
brushes bad
116 JPC6-15 Pot_Sup (Travel) Voltage from the VM that is fed through the travel pot anytime the Control 5V VM VR1 Travel
VM is powered. Handle, VM (Control
Handle)
117 JPC6-10 Travel_Pot_Input Input from Travel Pot to the VM. This is the wiper for the pot. As Control Neut = 1.3 VR1 VM Travel
the wiper is moved, the resistance changes, thus changing the Handle, VM FF = 1.8 (Control
voltage back to the VM. TF = 0.7 Handle)

118 JPC6-13 Travel Return Travel Return from the VM to the Travel Pot. This is the reference Control B– VR1 VR1 & VR2 Travel & Lift
for the Travel Pot and Lift Pot supply voltage. Handle, VM (Control
Handle)
119 JPC6-9 N/C No connection.

120 JPC6-11 Lift_Pot_Input Input from Lift Pot to the VM. This is the wiper for the pot. As the Control Neut = 1.3 VR2 VM Lift
wiper is moved, the resistance changes, thus changing the Handle, VM Dwn = 1.8
voltage back to the VM. Up = 0.7
121 JPC6-8 Pot_Sup (Lift) Voltage from the VM that is fed through the lift pot. Control 5V VM VR2 Lift
Handle, VM
122 JPC6-7 Horn_Input When horn button is closed, the voltage goes low. If switch is not Control Open = 5V S3 VM Horn
depressed (open), the input will be high. This is how the VM Handle, VM Closed = 0V
knows if the horn button has been depressed or not.
123 JPC6-3 Tilt_Up_Input When tilt up button is closed, the voltage goes low. If switch is not Control Open = 5V S8 VM Tilt Down
depressed (open), the input will be high. This is how the VM Handle, VM Closed = 0V
knows if the tilt up button has been depressed or not.

124 JPC6-4 Tilt_Down_Input When tilt down button is closed, the voltage goes low. If switch is Control Open = 5V S9 VM Tilt Down
not depressed (open), the input will be high. This is how the VM Handle, VM Closed = 0V
knows if the tilt down button has been depressed or not.
125 JPC6-6 SS_Right_Input When S/S Right button is closed, the voltage goes low. If switch Control Open = 5V S6 VM S/S Right
is not depressed (open), the input will be high. This is how the Handle, VM Closed = 0V
VM knows if the S/S Right button has been depressed or not.
126 JPC6-5 S/S_Left_Input When S/S Left button is closed, the voltage goes low. If switch is Control Open = 5V S7 VM S/S Left
knows if the S/S Left button has been depressed or not.
127 JPC6-1 Option_A_Input When Option A switch is closed, the voltage goes low. If switch Control Open = 5V S4 VM Option A
is not depressed (open), the input will be high. This is how the Handle, VM Closed = 0V
VM knows if the Option A switch has been depressed or not.
128 JPC6-2 Option_B_Input When Option B switch is closed, the voltage goes low. If switch is Control Open = 5V S5 VM Option B
knows if the Option B button has been depressed or not.
129 JPC6-14 Dgnd_P This is the reference for the voltage that is sent to the control Control B– VM S3 thru S9 Horn, Tilt, S/S,
handle switches. Handle, VM Options A & B
130 JPC6-12 N/C No connection.
131 JPC8-18 STR_Contactor B– for the steering contactor coil provided by a coil driver inside STR B+ when VM STR Steering
the VM. Contactor, open, contactor
VM 0V when
closed (wrt
B–)
132 JPC8-19 Spare Spare connection
133 JPC8-20 TPC_Contactor B– for the TPC contactor coil provided by a coil driver inside the TPC B+ when VM TPC Travel
VM. Contactor, open, contactor
VM 0V when
Theory of Operation
closed (wrt
B–)
Pin-Out Matrix
134 JPC8-14 B+KC B+KC from the VM. This is B+ for the coils for steering, traction STR, TPC & B+ VM STR, TPC & Steering, Travel,
and lift. LPC LPC Lift
Contactors, Contactors
VM
8-15
8-16
Pin-Out Matrix
Theory of Operation
135 JPC8-21 LPC_Contactor This is B– for the LPC contactor coil provided by a coil driver LPC B+ when VM LPC Lift
inside the VM. Contactor, open, Contactor
VM 0V when
closed (wrt
B–)
136 JPC10-4 HE_Supply1 This is 12V that is supplied by the VM. This voltage is used for the VM, Left approx VM Left Speed Travel
internal circuity of the Left Speed Sensor. Speed 11.5V wrt Sensor
Sensor JPC10-6
137 JPC10-12 Gear_Sense1 This is what the VM looks at to determine speed. 5V at rest, 3.1V VM, Left Approx 5V Left VM Travel
to 2.9V when traveling. Voltage will decrease as speed Speed wrt Speed
increases. Sensor JPC10-6 Sensor
138 JPC10-6 HE_Dgnd This is B– for HE_Supply. VM, Left B– VM Left Speed Travel
Speed Sensor
Sensor
139 JPC10-5 HE_Supply2 12V that is supplied by the VM. This voltage is used for the VM, Right approx VM Travel
internal circuity of the Right Speed Sensor. Speed 11.5V wrt
Sensor JPC10-7
140 JPC10-11 Gear_Sense2 This is what the VM looks at to determine speed. 5V at rest, 3.1V VM, Right approx 5V Right VM Travel
to 2.9V when traveling. Voltage decreases as speed increases. Speed wrt Speed
Sensor JPC10-7 Sensor

141 JPC10-7 HE_Dgnd HE_Dgnd at the VM. This is B– for HE_Supply. VM, Right B– VM Right Travel
Speed Speed
Sensor Sensor
142 JPC10-17 Left_Brake1 B– for the left brake coil provided by a coil driver inside the VM. VM, B1 B+ when VM B1 Brake
open,
0V when
closed (wrt
B–)
143 JPC10-20 B+KB B+KB from the VM to Left Brake coil. This is the (+) supply for the VM, B1 B+ B+KB B1 Brake
coil.
144 JPC10-16 Right_Brake2 B– for the right brake coil provided by a coil driver inside the VM, B2 B+ when VM Brake
VM. open,
0V when
closed (wrt
B–)

145 JPC10-21 B+KB B+KB from the VM to Right Brake coil. This is the (+) supply for VM, B2 B+ B+KB Brake
the coil.
146 JPC8-15 B+KA B+KA from the VM to the horn. VM, Horn B+ B+KA Horn Horn
147 JPC8-16 Horn Enable B– for the horn provided by a coil driver inside the VM. VM, Horn B+ when VM Horn Horn
open,
0V when
closed (wrt
B–)
148 LA B+ B+ to LA Supplies B+ to the amplifier for the field windings of the motor LA B+ TPC tips LA Left Motor
and also to one side of the motor armature. Traction
149 LA F1 Field connection B+ or B– to the field windings of the left traction motor field, LA Varies LA, LA M1 Left Motor
from LA depending on direction of travel. FF = 3 to 5V, TF = 0V wrt B– B+ Traction
150 LA F2 Field connection B+ or B– to the field windings of the left traction motor field, LA Varies LA, LA M1 Left Motor
from LA depending on direction of travel. FF = 0V, TF = 3 to 5V wrt B– B– Traction
151 LA M– M– to M1 Negative return path for the current through the motor armature. LA B– LA, LA M1 Left Motor
The amplifier completes the current path to B– from M– inside the B– Traction
amplifier.
152 LA B– B– to LA This is B– for the armature and the field windings of the Left LA B– LA, LA M1 Left Motor
Traction Power Amplifier. B– Traction
153 RA B+ B+ to RA This supplies B+ to the amplifier for the field windings of the RA B+ TPC tips M2 Right Motor
motor and also to one side of the motor armature. Traction
154 RA F1 Field connection B+ or B– to the field windings of the right traction motor field, RA Varies RA, RA M2 Right Motor
from RA depending on direction of travel. FF = 0V, TF = 3 to 5V wrt B– B+ Traction
during travel. Plug TF to FF = 27V
155 RA F2 Field connection B+ or B– to the field windings of the right traction motor field, RA Varies RA, RA M2 Right Motor
from RA depending on direction of travel. FF = 3 to 5V, TF = 0V wrt B– B– Traction
during travel. Plug TF to FF = 27V
Theory of Operation
156 RA M– M –to M2 Negative return path for the current through the motor armature. RA B– RA, RA M2 Right Motor
The amplifier completes the current path to B– from M– inside the B– Traction
Pin-Out Matrix
amplifier.
157 RA B– B– to RA This is B– for the armature and the field windings of the Right RA B– RA, RA M2 Right Motor
Traction Power Amplifier. B– Traction
8-17
158 PA B+ B+ to PA Supplies B+ to the amplifier and to the lift motor. PA B+ LPC tips PA Lift/Aux
8-18
Pin-Out Matrix
Theory of Operation
159 PA M– M– to MP Current path to B– from M– inside the amplifier. 0V to 32V, PA B– PA, PA PA Lift/Aux
increasing with speed wrt B+. B–
160 PA B– B– to PA This is B– for the lift motor and internal circuits of the amplifier. PA B– PA, PA PA Lift/Aux
B–
161 JPC8-22 Travel Alarm/ B– supply to the Travel Alarm/Light provided by a coil driver VM, Travel B+ when off VM H2 Travel Alarm/
Light enable inside the VM. Alarm/Light and 0V Light
signal when on (wrt
B–)
162 JPC12-1 +12VP +12VP from the VM to power the Hall Effect circuitry of S11 & VM, S11, 12V VM S11, S18 Tilt & Lift
S18 for the Bottler's Tilt Option. S18
163 JPC12-6 Output to S11 Output to the Tilt and Mast Limit Switches (if Bottler's Tilt Option is VM, S11, 12V VM S11, S18 Tilt & Lift
and S18 installed). The VM looks at this to determine the position of the tilt S18
and limit mast travel. When the switch is open, the voltage is high
and when closed, the voltage goes low.
164 JPC12-3 Dgnd B– for S11 & S18. VM, S11, B– VM S11, S18 Tilt & Lift
S18
165 JPC12-1 +12VP +12VP from the VM to power the Hall Effect circuitry of the VM, S11 11.3V VM S11 High Speed
optional High Speed Limit Switch (S11). Travel

166 JPC12-6 High_Speed_Limit The VM looks at this to determine the state of the switch (S11). If VM, S11 12V VM S11 High Speed
open, the signal will be hi. If closed or shorted to Gnd, the signal Travel
will go low.
167 JPC12-3 Dgnd for S11 B– for S11. VM, S11 B– VM S11 High Speed
Travel
168 JPC12-4 +12VP +12VP to power the Hall Effect circuitry of the optional Lift Limit VM, S12 11.3V VM S12 Lift
Switch (S12).
169 JPC12-5 Lift_Limit Lift_Limit from the VM to the Lift Limit Switch (S12). The VM looks VM, S12 12V VM S12 Lift
at this to determine the state of the switch. If open, the signal will
be hi. If closed, the signal will go low.
170 JPC12-2 Dgnd for S12 B– for S12. When S12 is open the input seen is high and when VM, S12 0V VM S12 Lift
shorted to Gnd, the signal goes low.
171 JPC11-4 +12VP for +12VP from the VM to the Pressure Transducer. VM, Pressure 11.3V VM Pressure Weight Sensing
Pressure Sensor #1 Sensor #1
Sensor #1

172 JPC11-3 Pressure_In to Input the VM uses to determine how much weight is on the forks. VM, Pressure 1-11V, Pressure VM Weight Sensing
Pressure As the resistance in the sensor changes due to weight change, Sensor #1 increases as Sensor
Sensor #1 the voltage sent back to the VM will also change. The change in weight #1
voltage will correlate to different weights on the forks (approx 1V increases.
fully lowered).
173 JPC11-2 Dgnd for Pressure B– for pressure sensor. VM, Pressure 0V VM Pressure Weight Sensing
Sensor #1 Sensor #1 Sensor #1
174 JPC11-1 Dgnd for Pressure B– for the shield around the wires for the optional pressure VM, Pressure 0V VM Pressure Weight Sensing
Sensor #1 transducer. This is the only end of the shield that should be Sensor #1 Sensor #1
shield connected to Dgnd. If both ends are connected to Dgnd, the
shield will not work properly. The shield is designed to prohibit
unwanted electrical noise from being introduced into the sensor
circuit.
175 JPC1-1 BUS– to Smarti BUS– for the optional Smarti Module. This is one of two VM, Smarti 5.3V VM Smarti, Smarti
Module communication lines between the VM and the Smarti module. VM
176 JPC1-2 TXD_Out (NC) Currently not used. VM, Smarti NC VM NC Smarti
177 JPC1-3 RXD_In (NC) Currently not used. VM, Smarti NC VM NC Smarti
178 JPC1-4 BUS+ to Smarti BUS+ for the optional Smarti Module. This is one of two VM, Smarti 5.3V VM Smarti, Smarti
Module communication lines between the VM and the Smarti module. VM
179 JPC1-5 Dgnd for Smarti B– for the Smarti module. VM, Smarti 0V VM JPS1-5 Smarti
180 JPC1-6 NC No connection VM, Smarti NC VM NC Smarti
181 JPC1-7 Boot Currently not used. VM, Smarti NC VM NC Smarti
182 JPC1-8 NC No connection VM, Smarti NC VM NC Smarti
183 JPC1-9 12VF for Smarti +12V supply for the Smarti module. VM, Smarti 12V VM Smarti Smarti
184 JPC7-15 Battery Gate at Input to the VM from JPA3-3 when S22A & B are closed. VM, Attach. 10-12V w/ VM Attach. Side gate
Theory of Operation
the VM Card gate in, <1V Card sensing
when out
Pin-Out Matrix
185 JPC7-4 12VP to Attach. Approx 11.3V will be read because of a diode in the circuit. This VM, Attach. 11.3V VM Attach. Attach. Card
Card diode protects the power supply from unwanted spikes and Card Card
electrical noise from the Attach. Card.
186 JPC7-13 Attach_Sw1 to Attach_Sw1 at the VM to the Attach. Card. Switch 1 of an VM, Attach. 12V VM Attach. Attach. Sw1
8-19
Attach. Card optional attachment is input to the VM here. Card Card

8-20
Pin-Out Matrix
Theory of Operation
187 JPC7-14 Attach_Sw2 to Attach_Sw2 at the VM to the Attach. Card. Switch 2 of an VM, Attach. 12V VM Attach. Attach. Sw2
Attach. Card optional attachment is input to the VM here. Card Card
188 JPC7-12 Press_Opt_In to Press_Opt_In at the VM to the Attach. Card. Optional pressure VM, Attach. Depends on VM Attach. Optional
Attach. Card sensing devices connected to the Attach. Card are inputted to the Card weight Card pressure
VM here. sensing
189 JPC7-9 Sol12_En to Sol12 is used in trucks with optional high speed auxiliary VM, Attach. Approx 4.5V VM Attach. Sol12
Attach. Card functions. This enable command is sent from the VM to a coil Card when Card
driver on the Attach. Card. commanded
on
on
on
192 JPC7-7 Dgnd for Attach. B– to the Attach. Card. VM, Attach. 0V VM Attach. Attach. Card
Card Card Card

193 JPA3-8 +12V for Battery +12V to the Hall Effect switches for the Battery Gates. This 12V Attach. Card 12V Attach. S22A & Battery Gate
Gate Hall Effect supply (from JPC7-4 on the VM) is for the internal circuitry of the & Batt. Gate Card S22B Switches
switches Hall Effect switches (S22A and S22B). switches
194 JPA3-5 Signal out Out at the Attach. Card to the Hall Effect switches of the optional Attach. Card 10-12V w/ Attach. Battery Gate
connection for battery gates. When a switch is open, this output will be high & Batt. Gate gate out, Card, VM Switches
battery gates and when closed the output will be low. This output is then sent to switches <1V when in
the VM via the Attach. Card as “Battery Gate”.
195 JPA3-3 Gnd for battery B– from the Attach. Card to the Hall Effect switches of the Battery Attach. Card 0V VM S22A & Battery Gate
gate switches Gates. & Batt. Gate S22B Switches
switches
196 JPA2-8 Aux_Dump_Sol Negative return path for Sol12 and is provided by a coil driver Attach. Card 36V when Attach. Sol12 Sol12
signal on the Attach. Card. If this negative is not present when it should & Sol12 off Card
be, the Attach. Card may be bad. 0V when on
197 JPA2-3 B+KA from B+ to Sol10 & Sol11. Attach. Card 36V Attach. Sol10, Sol11, Sol12
Attach. Card & Sol10 & Card Sol11
Sol11

198 JPA2-9 HS Aux1_Sol B– for Sol10 provided by a coil driver on the Attach. Card. Attach. Card 0V wrt Dgnd Attach. Sol10 Sol10
& Sol10 when on, Card
36V when
off
199 JPA2-10 HS Aux2_Sol B– for Sol11 provided by a coil driver on the Attach. Card. Attach. Card 0V wrt Dgnd Attach. Sol11 Sol11, Sol12
& Sol11 when on, Card
36V when
off
200 JPA2-4 B+KA to Attach. B+KA to the Attach. Card from the CFP. Attach. Card 36V VM Attach. Attach. Card,
Card & CFP Card Sol10, Sol11
201 JPA2-5 B–F connection to B–F to the Attach. Card from the CFP. Attach Card B– CFP Attach. Attach. Card
Attach. Card & CFP Card
202 FU1 40A fuse Fuses the B+ output from TP1 on the CFP to terminal 1 of the STR
Contactor.
203 FU2 600A fuse Fuses the B+ output from TP1 on the CFP to terminal 1 of the TPC
Contactor.
204 FU3 500A fuse Fuses the B+ output from TP1 on the CFP to terminal 1 of the LPC
Contactor.
205 Sol1 Load Holding 36V solenoid. This solenoid, when de-energized, keeps the
Solenoid hydraulic oil in the lift cylinders from returning to tank when lift is
not requested. When lift is requested, oil can flow through the
solenoid to lift. When lower is requested, 36V is applied to the
coil and the valve will open allowing the oil from the lift cylinders
to return to tank and thus lower.
206 Sol2 S/S Solenoid 36V solenoid. This solenoid is used to control optional side shift.
When 36V is applied to the valve, oil will pass through it to the
sideshift ram and from the ram back to tank.
Theory of Operation
207 Sol3 Proportional 24V solenoid. This solenoid is used to control lowering speeds of 0 to 32V
Lower Solenoid the lift rams. When maximum lowering speed is requested, 32V
will be seen across the solenoid coil. The speed of lowering will
Pin-Out Matrix
be determined by the amount of voltage applied to the coil, up to
a maximum of approximately 32 volts. When no lowering is
requested, 0V will be seen across the solenoid coil.
8-21
8-22
Pin-Out Matrix
Theory of Operation
208 Sol4 Tilt Solenoid 36V solenoid. This solenoid is used to control tilt. When tilt is
requested, 36V is applied to the solenoid coil and the valve is
activated in a position to allow oil to flow into and out of the tilt
rams.
209 Sol5 Lift/Aux Solenoid 36V solenoid. This solenoid is used to supply oil to the lift rams
when there is more than a 90% request for lift. Below 90%
request, the valve is de-energized allowing the oil from the
second stage pump to return to tank.
210 Sol6 Aux Direction 36V solenoid. This solenoid is used to establish direction for the
Solenoid auxiliary functions. When de-energized, oil will flow in one
direction and when energized the flow will be in the opposite
direction.
211 Sol7 Lift/Aux Solenoid 36V solenoid. This solenoid is used to allow either lift or high
speed auxiliary functions. When 36V is applied to the coil, oil
will be directed to the lift cylinders and flow will be blocked to
high speed auxiliary functions. When de-energized, oil will flow
to the high speed lift cylinders and oil flow to the cylinders will be
blocked.
212 Sol8 Lift/Aux2 36V solenoid. This solenoid is used to allow either 2nd stage lift
Solenoid or aux functions. When 36V is applied to the solenoid coil, oil is
directed through the valve and supplied to the solenoid valves for

auxiliary functions. When de-energized, oil is directed to Sol5.
213 Sol9 Proportional 24V solenoid. Proportional Relief Solenoid. This valve is used to 0 to 32 V
Relief Solenoid allow variation in pressure in high speed aux functions. The
higher the voltage applied to the valve, the greater the bypass
pressure. This valve is only used in high speed aux applications
and the pressure settings are set in configuration.
214 Sol10 High Speed Aux 36V solenoid. High Speed Aux Solenoid. This valve is used to 36V when
Solenoid control the flow of oil to a high speed auxiliary device such as a energized
clamp. When 36V is applied to the valve, oil will flow into and
out of the ram for that particular function.
215 Sol11 High Speed Aux 36V solenoid. High Speed Aux Solenoid. This valve is used to 36V when
Solenoid control the flow of oil to a high speed auxiliary device such as a energized
clamp. When 36V is applied to the valve, oil will flow into and
out of the ram for that particular function.
216 Sol12 Aux Dump 36V solenoid. Aux Dump Solenoid. This valve is used to direct 36V when
Solenoid the flow of oil back to the tank when auxiliary functions are not energized
requested.
Lift/Lower System
Lift/Lower System
NOTE: Raymond EASi Pacer™ Lift Trucks can Unique System Features
be configured with optional hydraulic
attachments which utilize a “hi-flow” The coils used for the lift/lower system are
auxiliary hydraulic system. This section either 24V (proportional solenoids) or 36V (all
covers the operation of both standard other solenoids). The voltage can be verified by
auxiliary and hi-flow auxiliary hydraulic looking at each respective coil. This is
systems. accomplished by the VM pulsing the
appropriate coil driver. The coil drivers are
NOTE: The schematics in this chapter are located inside the VM. If a truck is 36V, the VM
intended for general understanding of will pulse width modulate a 24V coil driver at a
theory of operation and may not rate of 66% (66% x 36V = 24V). The VM pulse
reflect latest developments in width modulates 36V coils at a rate of 100%.
circuitry.
The VM monitors the lift pump motor by way of
DO NOT use these schematics to the lift power amplifier. If the control is moved
troubleshoot or repair the lift truck. from lift to lower, the VM will not allow the
ALWAYS USE the schematics in the carriage to lower until the lift pump motor has
Appendix for troubleshooting and stopped. This allows smooth, controlled
repair. lowering of the carriage without a “bump.” The
length of the delay depends on the oil viscosity,
pump/motor tightness, temperature, and the
System Overview load on the carriage.
All inputs and outputs related to the lift/lower The lift pump will start to rotate when the
system are controlled by the Vehicle Manager lift/lower potentiometer (VR2) is rotated to the
(VM). The VM determines what actions are lift position. The farther the potentiometer is
required based on inputs from the operator and rotated to lift, the faster the pump rotates. The
from system feedback. proportional lower solenoid (SOL3) is only used
The VM sends voltage through lift/lower during lower, not during lift.
potentiometer VR2. As VR2 is moved by the
operator, a voltage, proportional to the position
of the control, is sent back to the VM.
When the lift/lower control is moved to lift,
voltage from VR2 increases; when it is moved to
lower, the voltage from VR2 decreases. As the
lift/lower control is moved, VR2 voltage is
sensed by the VM, which determines whether to
lift or lower. This is accomplished by the VM
comparing the present voltage to the Learned
voltage values.
The VM then sends a request to the lift power
amplifier by way of the BUS± communication
lines to turn the lift motor on, if lift has been
requested.
PDMM-0089 Issued: 6/24/02 8-23

Lift/Lower (w/Standard Aux)
Lift/Lower (w/Standard Aux) engage when the voltage from VR2 was
at least 3.6V (4.0 x 90% = 3.6). When
this voltage is reached, SOL5 is
Lift energized, stopping oil from the second
(Serial Numbers 0100-1729) stage of the lift pump from dumping to
NOTE: On electrical schematics, only circuits the reservoir. Hydraulic flow from both
related directly with lift or lower are lift pumps is sent to the lift cylinder. See
addressed. Figure 8-2.
With the key switch ON and deadman pedal 1. As the lift potentiometer (VR2) is rotated
depressed, moving the lift/lower control on the and the lift pump starts to rotate, fluid from
multi-function control handle to lift causes: pump P1 is sent under pressure to SOL7,
the Lift/AUX1 select valve. At the same
time, fluid from pump P2 will flow into
Variable Lift
Port1, out of Port2 of the PFR valve to the
(below 90% request)
energized SOL5, where it joins with the oil
1. VR2 to output a voltage higher than when from P1.
in the neutral position. 2. During lift, SOL5 (P2 dump) and SOL7
2. The VM senses this increase in voltage at (Lift/AUX1 select) are energized by signals
JPC6-11. The VM energizes the LPC from the VM at JPC9-7 and JPC9-9,
contactor coil. This closes the LPC respectively. This supplies B– to the
contactor tips and starts the lift pump solenoids and energizes their coils.
motor. See Figure 8-1.
NOTE: All coil drivers are located within the VM
3. The further VR2 is moved from neutral and are not replaceable separately.
during lift, the faster the lift motor will
3. Fluid then flows through the de-energized
turn. This is accomplished by the VM
load holding solenoid, SOL1, and to the lift
sending a signal to the lift Power Amplifier
cylinders.
through the BUS±, which starts the lift
motor. 4. During the lift operation, SOL3
(proportional lower solenoid) remains
4. When the request for lift is less than 90% of
closed.
the learned value of the lift pot, oil from
pump P1 will flow through the energized
solenoids SOL7 and de-energized SOL1 to
the lift cylinders. Oil from P2 flows into
Port1, out of Port2 of the PFR, through
de-energized SOL5 to the hydraulic
reservoir.
5. Hi-speed lift operating parameters will vary
for different mast configurations.
Regardless of the mast configuration,
voltage from VR2 must reach 90% of the
learned maximum for lift before hi-speed
lift is activated.
Hi-Speed Lift (above 90% request)

NOTE: Hi-speed lift (SOL5) is activated when
voltage from VR2 is at least 90% of the
maximum Learned value.
Example: If the maximum Learned value
from VR2 is 4V, hi-speed lift would
8-24 PDMM-0089 Issued: 6/24/02

PP LP
PP LP
M SOL7
SOL1
M LIFT/
SOL7 LOAD
AUX1 SOL1
LIFT/ HOLD C
3 LOAD
1 2
P1 P1 AUX1
2 HOLD C
3 1 2
P1
LIFT/ P1 2 1
LIFT
H/S AUX
LIFT/ 3 2 1 2
LIFT
H/S AUX SOL5
3 P22 SOL3 2
SOL5 2
DUMP PROP
1 P2 SOL3
PLUG
2 LOWER
1
DUMP PROP 1 REL1
1 3 PLUG LOWER
1 REL1
2 1 3
P2 P2 PFR
2
P2 1 3 PFR T1
P2
LIFT/ SOL8 2 4 SOL4
2 1
AUXLIFT/ LIFT/ 1 3
SOL6 TILTSOL4 T1
SOL8 2 4
AUX AUX2
LIFT/ AUXSOL6 TILT 2 1
1 DIRAUX CB1
AUX2 3
1 1 2
DIR 2 1 CB1
T2
M 1 2 2 1 3
3
3 4 CB2 T2
M 4 3
3
3 4 4 3 CB2 TILT
2 1
TILT
P3
2 1
P3
A1 A2
A1 A2
2
2 P1 P2
P1 P2
SR SOL2
1
SR SIDESHIFT
SOL2
1
2 1
SIDESHIFT A1
2 1 A1
AP 2 4 3
REL2 A2
AP 2 4 3
REL2 A2 SIDE
T
Legend SHIFT
SIDE
SHIFT
T
1
Pressure
1
Return
Energized Solenoid
Figure 8-1: Variable Lift Function (below 90% request) - Serial No. 0100-1729
PP LP
M SOL7
SOL1
LIFT/
LOAD
AUX1
HOLD C
3 1 2
P1 P1 2
LIFT/ 1
LIFT
H/S AUX
3 2 2
SOL5
P2 2
SOL3
1
DUMP PROP
PLUG LOWER
1 REL1
1 3
P2 P2 PFR
1 3 T1
LIFT/ SOL8 2 4 SOL4
2 1
AUX LIFT/ SOL6 TILT
AUX2 AUX
1 DIR CB1
3
1 2 2 1
T2
M 3
3 4 4 3 CB2
TILT
2 1
P3
A1 A2
2
P1 P2
SR SOL2
1
SIDESHIFT
2 1 A1
AP 2 4 3
REL2 A2
SIDE
T
Legend SHIFT
1
Pressure
Return
Energized Solenoid
Figure 8-2: Hi-Speed Lift Function - Serial No. 0100-1729
PDMM-0089 Issued: 6/24/02 8-25

Lower
1. With the key switch ON and the deadman
depressed, rotating the lift/lower control
VR2 to the lower position will send a signal
to the VM (signal is a decreasing voltage).
2. The VM, due to its Learned values, senses
the request for lower and at what rate lower
is requested.
3. The VM sends a signal to the load holding
solenoid (SOL1) at JPC9-6 to energize its
coil.
4. After the load holding solenoid opens, the
proportional lower solenoid (SOL3) opens
by a signal from the VM at JPC9-5 to allow
fluid to flow back to the reservoir. See
Figure 8-3. The solenoid opens
proportionally to the amount that VR2 is
moved from neutral during lower.
5. Voltage across the proportional lower
solenoid varies, depending on the position
of the lift/lower control (VR2).
• Low voltage = slow lowering
• High voltage = fast lowering
8-26 PDMM-0089 Issued: 6/24/02

PP LP
M SOL7
SOL1
LIFT/
LOAD
AUX1
HOLD C
3 1 2
P1 P1 2
LIFT/ 1
LIFT
H/S AUX
3 2 2
SOL5
P2 2
SOL3
1
DUMP PROP
PLUG LOWER
1 REL1
1 3
P2 P2 PFR
1 3 T1
LIFT/ SOL8 2 4 SOL4
2 1
AUX LIFT/ SOL6 TILT
AUX2 AUX
1 DIR CB1
3
1 2 2 1
T2
M 3
3 4 4 3 CB2
TILT
2 1
P3
A1 A2
2
P1 P2
SR SOL2
1
SIDESHIFT
2 1 A1
AP 2 4 3
REL2 A2
SIDE
SHIFT
T 1 Legend
Pressure
Return
Energized Solenoid
8
Figure 8-3: Lower Function - Serial No. 0100-1729
PDMM-0089 Issued: 6/24/02 8-27


Lift stage of the lift pump from dumping to
(Serial Numbers 1730 and up) the reservoir. Hydraulic flow from both
lift pumps is sent to the lift cylinder. See
NOTE: On electrical schematics, only circuits Figure 8-5.
related directly with lift or lower are
1. As the lift potentiometer (VR2) is rotated,
addressed.
and the lift pump starts to rotate, fluid from
With the key switch ON and deadman pedal pump P1 is sent under pressure to SOL7,
depressed, moving the lift/lower control on the the Lift/AUX1 select valve. At the same
multi-function control handle to lift causes: time, fluid from pump P2 will flow through
the de-energized SOL8 (Lift/AUX2) and
Variable Lift through the energized SOL5 (P2 dump),
(below 90% request) where it joins with the oil from P1.
1. VR2 to output a voltage higher than when 2. During lift, SOL5 (P2 dump) and SOL7
in the neutral position. (Lift/AUX1 select) are energized by signals
from the VM at JPC9-7 and JPC9-9,
2. The VM senses this increase in voltage at respectively. This supplies B– to the
JPC6-11. The VM energizes the LPC solenoids and energizes their coils.
contactor coil. This closes the LPC
contactor tips and starts the lift pump NOTE: All coil drivers are located within the VM
motor. See Figure 8-4. and are not replaceable separately.
3. The further VR2 is moved from neutral 3. Fluid then flows through the de-energized
during lift, the faster the lift motor will load holding solenoid, SOL1, and to the lift
turn. This is accomplished by the VM cylinders.
sending a signal to the lift Power Amplifier 4. During the lift operation, SOL3
through the BUS±, which starts the lift (proportional lower solenoid) remains
motor. closed.
pump P1 will flow through the energized
the lift cylinders. Oil from P2 flows through
de-energized solenoids SOL8 and SOL5 to
the hydraulic reservoir.
lift is activated.

from VR2 is 4V, hi-speed lift would
engage when the voltage from VR2 was
at least 3.6V (4.0 x 90% = 3.6). When
this voltage is reached, SOL5 is
energized, stopping oil from the second
8-28 PDMM-0089 Issued: 6/24/02

PP LP
M SOL7
M SOL1
LIFT/
SOL-7 LOAD
AUX1 SOL-1
LIFT/ HOLD
3 LOAD 1 2 C
P1 P1 AUX1
2 HOLD C
3 1 2
P1 LIFT/ P1 2 1
LIFT
H/S AUX
LIFT/ 3 2 1 2
LIFT
SOL5
H/S AUX SOL3
3 2 P2 2 2
SOL-5
DUMP PROP
1
P2 2 PLUG SOL-3
LOWER
1
DUMP PROP 1 REL1
1 PLUG
3 LOWER
2 1 REL-1
1 3
P2 P2 PFR
P2 1
1 3 T1
P2 LIFT/ SOL8 2
2 4 SOL4
2 1
AUX LIFT/ SOL6 TILT T1
LIFT/ AUX2
3 SOL-4
SOL-8 AUX 2 1
AUX SOL-6 TILT CB1
1 DIR
LIFT/ 3
1 2AUX 2 1
AUX2 DIR CB-1 T2
M 1 2 2 1 3
3 3
3 4 4 CB2 T2
M 3
TILT
3 4 4 3 CB-2
2
P3 1 TILT
2 1
P3 A1 A2
2 A1 A2
P1 P2
2
SR P1 P2 SOL2
1
SIDESHIFT
SR SOL-2
1 2 1 A1
SIDESHIFT
AP 2 2 4 1 3 A1A2
REL2
AP 2 4 3
SIDE
REL-2 A2 SHIFT
T SIDE
1
SHIFT
T 1
Legend
Pressure
Return
Energized Solenoid
Figure 8-4: Variable Lift Function (below 90% request) - Serial No.1730-Up
PP LP
M SOL-7
SOL-1
LIFT/
LOAD
AUX1
HOLD C
3 1 2
P1 P1 2
LIFT/ 1
LIFT
H/S AUX
3 2 2
SOL-5
P2 2
SOL-3
1
DUMP PROP
PLUG LOWER
1 REL-1
1 3
P2 P2 2
1
T1
LIFT/ 3 SOL-4
2 1
AUX SOL-8 SOL-6 TILT
LIFT/ AUX
AUX2 DIR CB-1
3
1 2 2 1
T2
M 3
3 4 4 3 CB-2
TILT
2 1
P3
A1 A2
2
P1 P2
SR SOL-2
1
SIDESHIFT
2 1 A1
AP 2 4 3
REL-2 A2
SIDE
SHIFT
T 1
Legend
Pressure
Return
Energized Solenoid
Figure 8-5: Hi-Speed Lift Function (above 90% request) - Serial No. 1730-Up
PDMM-0089 Issued: 6/24/02 8-29

Lower
is requested.
coil.
proportional lower solenoid (SOL3) is
opened by a signal from the VM at JPC9-5
to allow fluid to flow back to the reservoir.
See Figure 8-6. The solenoid is opened
solenoid will vary depending on the position
8-30 PDMM-0089 Issued: 6/24/02

PP LP
M SOL-7
SOL-1
LIFT/
LOAD
AUX1
HOLD C
3 1 2
P1 P1 2
LIFT/ 1
LIFT
H/S AUX
3 2 2
SOL-5
P2 2
SOL-3
1
DUMP PROP
PLUG LOWER
1 REL-1
1 3
P2 P2 2
1
T1
LIFT/ 3 SOL-4
2 1
LIFT/ AUX
AUX2 DIR CB-1
3
1 2 2 1
T2
M 3
3 4 4 3 CB-2
TILT
2 1
P3
A1 A2
2
P1 P2
SR SOL-2
1
SIDESHIFT
2 1 A1
AP 2 4 3
REL-2 A2
SIDE
SHIFT
T 1
Legend
Pressure
Return
Energized Solenoid
Figure 8-6: Lower Function - Serial No. 1730-Up
PDMM-0089 Issued: 6/24/02 8-31

Lift/Lower (w/Hi-Flow Aux)
Lift/Lower (w/Hi-Flow Aux) when the voltage from VR2 is at least

3.6V (4.0 x 90% = 3.6). When this
voltage is reached, SOL5 is energized,
Lift stopping oil from the second stage of the
(Serial Numbers 0100-1729) lift pump from dumping to the reservoir.
NOTE: On electrical schematics, only circuits Hydraulic flow from both lift pumps is
related directly with lift or lower are sent to the lift cylinder. See Figure 8-8.
addressed. 1. As the lift potentiometer (VR2) is rotated,
With the key switch ON and deadman pedal and the lift pump starts to rotate, fluid from
depressed, moving the lift/lower control on the pump P1 is sent under pressure to SOL7,
multi-function control handle to lift causes: the Lift/AUX1 select valve. At the same
time, fluid from pump P2 flows into Port1,
out of Port2 of the PFR valve to the
Variable Lift
energized SOL5, where it joins with the oil
(below 90% request)
from P1.
1. VR2 to output a voltage higher than when 2. During lift, SOL5 (P2 dump) and SOL7
in the neutral position. (Lift/AUX1 select) are energized by signals
2. The VM senses this increase in voltage at from the VM at JPC9-7 and JPC9-9,
JPC6-11. The VM energizes the LPC respectively. This supplies B– to the
contactor coil. This closes the LPC solenoids and energizes their coils.
contactor tips and starts the lift pump
NOTE: All coil drivers are located within the VM
motor. See Figure 8-7. and are not replaceable separately.
3. The further VR2 is moved from neutral
3. Fluid then flows through the de-energized
during lift, the faster the lift motor will
load holding solenoid, SOL1, and to the lift
turn. This is accomplished by the VM
cylinders.
sending a signal to the Lift Power Amplifier
through the BUS±, which starts the lift 4. During the lift operation, SOL3
motor. (proportional lower solenoid) remains
closed.
pump P1 flows through the energized
the lift cylinders. Oil from P2 flows into
Port1, out of Port2 of the PFR, through
de-energized SOL5 to the hydraulic
reservoir.
lift is activated.

from VR2 is 4V, hi-speed lift will engage
8-32 PDMM-0089 Issued: 6/24/02

PP LP
M SOL7
LIFT/
AUX1
SOL1
LOAD Legend
P1 P1 1
3
HOLD
1 2 C Pressure
LIFT/ 2 1 LIFT
Return
H/S AUX
1 Energized Solenoid
3 2
SOL5 2 SOL3
P2 SOL12 2 PROP
AUX REL1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 PFR
1 3 T1
LIFT/ 2 4
2 1
AUX SOL8
SOL6
LIFT/
AUX SOL4 ATTACHMENT
AUX2 1 CB1
DIR TILT 3 SECONDARY
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB2
TILT
2 1
P3
A1 A2
SOL11
P1 P2 SOL10 (ON ATTACHMENT)
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL9 A2
T PROP HI FLOW
REL2 2 SOL2 AUX. 2
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
W / HIGH SPEED AUX
Figure 8-7: Variable Lift Function (below 90% request) - Serial No. 0100-1729 (Hi-Flow Aux)
PP LP
M SOL7
SOL1
LIFT/
LOAD
P1 3
AUX1
HOLD
1 2 C Legend
P1 1
Pressure
LIFT/ 2
Return
1 LIFT
H/S AUX
1
3 2
SOL5 2
SOL12
SOL3 Energized Solenoid
P2 2 PROP
AUX REL1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 PFR
1 3 T1
LIFT/ 2 4
2 1
AUX SOL8
SOL6
LIFT/
AUX SOL4 ATTACHMENT
AUX2 1 CB1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB2
TILT
2 1
P3
A1 A2
SOL11
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL9 A2
T PROP HI FLOW
REL2 2 SOL2 AUX. 2
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
W / HIGH SPEED AUX
Figure 8-8: Hi-Speed Lift Function (above 90% request) - Serial No. 0100-1729 (Hi-Flow Aux)
PDMM-0089 Issued: 6/24/02 8-33

Lower
is requested.
coil.
8-34 PDMM-0089 Issued: 6/24/02

PP LP
M SOL7
SOL1
LIFT/
LOAD
AUX1
P1 P1 1
3
HOLD
1 2 C Legend
LIFT/ 2 1 LIFT
Pressure
H/S AUX
1 Return
Energized Solenoid
3 2
SOL5 2 SOL3
P2 SOL12 2 PROP
AUX REL1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 PFR
1 3 T1
LIFT/ 2 4
2 1
AUX SOL8
SOL6
LIFT/
AUX SOL4 ATTACHMENT
AUX2 1 CB1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB2
TILT
2 1
P3
A1 A2
SOL11
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL9 A2
T PROP HI FLOW
REL2 2 SOL2 AUX. 2
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
W / HIGH SPEED AUX
Figure 8-9: Lower Function - Serial No. 0100-1729 (Hi-Flow Aux)
PDMM-0089 Issued: 6/24/02 8-35

Lift Hydraulic flow from both lift pumps is

(Serial Numbers 1730 and up) sent to the lift cylinder. See Figure 8-11.
1. As the lift potentiometer (VR2) is rotated,
NOTE: On electrical schematics, only circuits
and the lift pump starts to rotate, fluid from
related directly with lift or lower are
pump P1 is sent under pressure to SOL7,
addressed.
the Lift/AUX1 select valve. At the same
With the key switch ON and deadman pedal time, fluid from pump P2 will flow through
depressed, moving the lift/lower control on the the de-energized SOL8 (Lift/AUX2) and
multi-function control handle to lift causes: through the energized SOL5 (P2 dump),
where it joins with the oil from P1.
Variable Lift 2. During lift, SOL5 (P2 dump) and SOL7
(below 90% request) (Lift/AUX1 select) are energized by signals
1. VR2 to output a voltage higher than when from the VM at JPC9-7 and JPC9-9,
in the neutral position. respectively. This supplies B– to the
solenoids and energizes their coils.
2. The VM senses this increase in voltage at
JPC6-11. The VM energizes the LPC NOTE: All coil drivers are located within the VM
contactor coil. This closes the LPC and are not replaceable separately.
contactor tips and starts the lift pump 3. Fluid then flows through the de-energized
motor. See Figure 8-10. load holding solenoid, SOL1, and to the lift
3. The further VR2 is moved from neutral cylinders.
during lift, the faster the lift motor will 4. During the lift operation, SOL3
turn. This is accomplished by the VM (proportional lower solenoid) will remain
sending a signal to the Lift Power Amplifier closed.
through the BUS±, which starts the lift
motor.
pump P1 flows through the energized
the lift cylinders. Oil from P2 flows through
de-energized solenoids SOL8 and SOL5 to
the hydraulic reservoir.
5. Hi-speed lift operating parameters vary for
different mast configurations. Regardless of
the mast configuration, voltage from VR2
must reach 90% of the learned maximum
for lift before hi-speed lift is activated.

from VR2 is 4V, hi-speed lift will engage
when the voltage from VR2 is at least
3.6V (4.0 x 90% = 3.6). When this
voltage is reached, SOL5 is energized,
stopping oil from the second stage of the
lift pump from dumping to the reservoir.
8-36 PDMM-0089 Issued: 6/24/02

PP LP
M SOL-7
LIFT/
SOL-1 Legend
AUX1
LOAD
HOLD
Pressure
C
P1 P1 1
3 1 2
Return
LIFT/
H/S AUX
2 1 LIFT Energized Solenoid
1
3 2
SOL-5 2 SOL-3
P2 SOL-12 2 PROP
AUX REL-1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 2
1
T1
LIFT/ 3
2 1
AUX SOL-8
SOL-6
LIFT/
AUX SOL-4 ATTACHMENT
AUX2 CB-1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB-2
TILT
2 1
P3
A1 A2
SOL-11
P1 P2 SOL-10 (ON ATTACHMENT)
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL-11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL-9 A2
T PROP HI FLOW
REL-2 2 SOL-2 AUX. 2
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
W / HIGH SPEED AUX
Figure 8-10: Variable Lift Function (below 90% request) - Serial No.1730-Up (Hi-Flow Aux)
PP LP
M SOL-7
LIFT/
AUX1
SOL-1
LOAD Legend
HOLD
P1 P1 1
3 1 2 C Pressure
LIFT/ 2 1 LIFT
Return
H/S AUX
3 2
SOL-5 2 SOL-3
P2 SOL-12 2 PROP
AUX REL-1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 2
1
T1
LIFT/ 3
2 1
AUX SOL-8
SOL-6
LIFT/
AUX2 CB-1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB-2
TILT
2 1
P3
A1 A2
SOL-11
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL-11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL-9 A2
T PROP HI FLOW
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
W / HIGH SPEED AUX
Figure 8-11: Hi-Speed Lift Function (above 90% request) - Serial No. 1730-Up (Hi-Flow Aux)
PDMM-0089 Issued: 6/24/02 8-37

Lower
VR2 to the lower position sends a signal to
the VM (signal is a decreasing voltage).
2. The VM, due to its Learned values, will
sense the request for lower and at what rate
lower is requested.
3. The VM will send a signal to the load
holding solenoid (SOL1) at JPC9-6 to
energize its coil.
8-38 PDMM-0089 Issued: 6/24/02

PP LP
M SOL-7
LIFT/
SOL-1
LOAD
Legend
AUX1
3
HOLD
1 2 C Pressure
P1 P1
Return
1
LIFT/ 2
Energized Solenoid
1 LIFT
H/S AUX
1
3 2
SOL-5 2 SOL-3
P2 SOL-12 2 PROP
AUX REL-1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 2
1
T1
LIFT/ 3
2 1
AUX SOL-8
SOL-6
LIFT/
AUX2 CB-1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB-2
TILT
2 1
P3
A1 A2
SOL-11
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL-11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL-9 A2
T PROP HI FLOW
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
W / HIGH SPEED AUX
Figure 8-12: Lower Function - Serial No. 1730-Up (Hi-Flow Aux)
PDMM-0089 Issued: 6/24/02 8-39

Auxiliary Functions
Auxiliary Functions
NOTE: Raymond EASi Pacer™ Lift Trucks can The VM interprets this input and the following
be configured with an optional hi-flow occurs:
auxiliary system. This section covers the
• Solenoids and motor contactors are
operation of a standard auxiliary system
energized by coil drivers in the VM.
as well as hi-flow auxiliary system
equipped lift trucks. • Pumps P1 and P2 rotate at a speed
predetermined by the VM program.
Tilt (w/Standard Aux) • Oil from P1 flows through the de-energized
SOL7 (Lift/Aux1), through the plug, and
back to the reservoir.
(Serial Numbers 0100-1729)
• Oil from P2 flows through the energized
With the key switch ON and the deadman pedal SOL8 (Lift/Aux2), into Port 4 of the PFR
depressed, the following will occur to activate valve, and out of Port 3. From there, the oil
the tilt function. See Figure 8-13. flows through SOL6 (Aux Dir), the energized
SOL4 (Tilt), into the appropriate
Depressing the tilt up switch (S8) on the control
counterbalance check valve (CB1 or CB2),
handle sends an input to the VM at JPC6-3.
and into the tilt cylinder.
To tilt in the opposite direction, S9 is used and
SOL6 (Aux Dir) is positioned to allow flow in the
opposite direction.
PP LP
M SOL7
SOL1
LIFT/
LOAD
AUX1
HOLD C
3 1 2
P1 P1 2
LIFT/ 1
LIFT
H/S AUX
3 2 2
SOL5
P2 2
SOL3
1
DUMP PROP
PLUG LOWER
1 REL1
1 3
P2 P2 PFR
1 3 T1
LIFT/ SOL8 2 4 SOL4
2 1
AUX LIFT/ SOL6 TILT
AUX2 AUX
1 DIR CB1
3
1 2 2 1
T2
M 3
3 4 4 3 CB2
TILT
2 1
P3
A1 A2
2
P1 P2
SR SOL2
1
SIDESHIFT
2 1 A1
AP 2 4 3
REL2 A2
SIDE
SHIFT
T 1 Legend
Pressure
Return
Energized Solenoid
Figure 8-13: Tilt Function - Serial No. 0100-1729
8-40 PDMM-0089 Issued: 6/24/02

Tilt (w/Standard Aux)
(Serial Numbers 1730 and up) To tilt in the opposite direction, S9 is used and
With the key switch ON and the deadman pedal opposite direction.
depressed, the following will occur to activate
the tilt function. See Figure 8-14.
The VM interprets this input and the following
occurs:
• Pumps P1 and P2 rotate at a speed
• Oil from P1 flows through SOL7 (Lift/Aux1),
through the plug, and back to the reservoir.
SOL8 (Lift/Aux2) and SOL6 (Aux Dir),
through the energized SOL4 (Tilt), into the
appropriate counterbalance check valve
(CB1 or CB2), and into the tilt cylinder.
PP LP
M SOL-7
SOL-1
LIFT/
LOAD
AUX1
HOLD C
3 1 2
P1 P1 2
LIFT/ 1
LIFT
H/S AUX
3 2 2
SOL-5
P2 2
SOL-3
1
DUMP PROP
PLUG LOWER
1 REL-1
1 3
P2 P2 2
1
T1
LIFT/ 3 SOL-4
2 1
LIFT/ AUX
AUX2 DIR CB-1
3
1 2 2 1
T2
M 3
3 4 4 3 CB-2
TILT
2 1
P3
A1 A2
2
P1 P2
SR SOL-2
1
SIDESHIFT
2 1 A1
AP 2 4 3
REL-2 A2
SIDE
SHIFT
T 1
Legend
Pressure
Return
Energized Solenoid
Figure 8-14: Tilt Function - Serial No. 1730-Up shown
PDMM-0089 Issued: 6/24/02 8-41

Tilt (w/Hi-Flow Aux)
Tilt (w/Hi-Flow Aux) • Oil from P2 flows through the energized

SOL8 (Lift/Aux2), into Port 4 of the PFR
valve, and out of Port 3. From there, the oil
(Serial Numbers 0100-1729) flows through SOL6 (Aux Dir), through the
With the key switch ON and the deadman pedal energized SOL4 (Tilt), into the appropriate
depressed, the following will occur to activate counterbalance check valve (CB1 or CB2),
the tilt function. See Figure 8-15. and into the tilt cylinder.
Depressing the tilt up switch (S8) on the control To tilt in the opposite direction, S9 is used and
handle sends an input to the VM at JPC6-3. SOL6 (Aux Dir) is positioned to allow flow in the
The VM interprets this input and the following opposite direction.
occurs:
• Oil from P1 flows through de-energized
SOL7 (Lift/Aux1), down through
de-energized SOL12 (Aux Dump), and
returns to the reservoir.
PP LP
M SOL7
Legend
SOL1
LIFT/
LOAD
AUX1
HOLD
P1 P1 1
3 1 2 C
Pressure
LIFT/ 2 1 LIFT Return
H/S AUX
3 2
1
Energized Solenoid
SOL5 2 SOL3
P2 SOL12 2 PROP
AUX REL1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 PFR
1 3 T1
LIFT/ 2 4
2 1
AUX SOL8
SOL6
LIFT/
AUX SOL4 ATTACHMENT
AUX2 1 CB1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB2
TILT
2 1
P3
A1 A2
SOL11
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL9 A2
T PROP HI FLOW
REL2 2 SOL2 AUX. 2
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
W / HIGH SPEED AUX
Figure 8-15: Tilt Function - Serial No. 0100-1729 (Hi-Flow Aux)
8-42 PDMM-0089 Issued: 6/24/02

Tilt (w/Hi-Flow Aux)
(Serial Numbers 1730 and up) To tilt in the opposite direction, S9 is used and
With the key switch ON and the deadman pedal opposite direction.
the tilt function. See Figure 8-16.
The VM interprets this input and the following
occurs:
SOL7 (Lift/Aux1), through de-energized
SOL12 (Aux Dump), back to the reservoir.
through the energized SOL4 (Tilt), into the
appropriate counterbalance check valve
(CB1 or CB2), and into the tilt cylinder.
PP LP
M SOL-7
SOL-1
LIFT/
AUX1
LOAD
HOLD C
Legend
Pressure
3 1 2
P1 P1 1
LIFT/
H/S AUX
2 1 LIFT Return
Energized Solenoid
1
3 2
SOL-5 2 SOL-3
P2 SOL-12 2 PROP
AUX REL-1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 2
1
T1
LIFT/ 3
2 1
AUX SOL-8
SOL-6
LIFT/
AUX2 CB-1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB-2
TILT
2 1
P3
A1 A2
SOL-11
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL-11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL-9 A2
T PROP HI FLOW
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
W / HIGH SPEED AUX
Figure 8-16: Tilt Function - Serial No. 1730-Up shown (Hi-Flow Aux)
PDMM-0089 Issued: 6/24/02 8-43

Sideshift (w/Standard Aux)
Sideshift (w/Standard Aux) • Oil from P2 flows through the energized

With the key switch ON and the deadman pedal energized SOL2 (Sideshift), and into the
depressed, the following will occur to activate sideshift cylinder.
the sideshift function. See Figure 8-17. To sideshift in the opposite direction, S5 is used
Depressing the sideshift switch (S6) on the and SOL6 (Aux Dir) is positioned to allow flow
control handle sends an input to the VM at in the opposite direction.
JPC6-6. The VM interprets this input and the
following occurs:
SOL7 (Lift/Aux1), down through the plug,
and back to the reservoir.
PP LP
M SOL7
SOL1
LIFT/
LOAD
AUX1
HOLD C
3 1 2
P1 P1 2
LIFT/ 1
LIFT
H/S AUX
3 2 2
SOL5
P2 2
SOL3
1
DUMP PROP
PLUG LOWER
1 REL1
1 3
P2 P2 PFR
1 3 T1
LIFT/ SOL8 2 4 SOL4
2 1
AUX LIFT/ SOL6 TILT
AUX2 AUX
1 DIR CB1
3
1 2 2 1
T2
M 3
3 4 4 3 CB2
TILT
2 1
P3
A1 A2
2
P1 P2
SR SOL2
1
SIDESHIFT
2 1 A1
AP 2 4 3
REL2 A2
SIDE
SHIFT
T 1
Legend
Pressure
Return
Energized Solenoid
Figure 8-17: Sideshift Function - Serial No. 0100-1729
8-44 PDMM-0089 Issued: 6/24/02

(Serial Numbers 1730 and up)
(Serial Numbers 1730 and up) To sideshift in the opposite direction, S5 is used
and SOL6 (Aux Dir) is positioned to allow flow
With the key switch ON and the deadman pedal in the opposite direction.
the sideshift function. See Figure 8-18.
Depressing the sideshift switch (S6) on the
control handle sends an input to the VM at
following occurs:
SOL7 (Lift/Aux1), down through the plug,
and back to the reservoir.
through the energized SOL2 (Sideshift), and
into the sideshift cylinder.
PP LP
M SOL-7
SOL-1
LIFT/
LOAD
AUX1
HOLD C
3 1 2
P1 P1 2
LIFT/ 1
LIFT
H/S AUX
3 2 2
SOL-5
P2 2
SOL-3
1
DUMP PROP
PLUG LOWER
1 REL-1
1 3
P2 P2 2
1
T1
LIFT/ 3 SOL-4
2 1
LIFT/ AUX
AUX2 DIR CB-1
3
1 2 2 1
T2
M 3
3 4 4 3 CB-2
TILT
2 1
P3
A1 A2
2
P1 P2
SR SOL-2
1
SIDESHIFT
2 1 A1
AP 2 4 3
REL-2 A2
SIDE
SHIFT
T 1
Legend
Pressure
Return
Energized Solenoid
Figure 8-18: Sideshift Function - Serial No. 17320-Up
PDMM-0089 Issued: 6/24/02 8-45

Sideshift (w/Hi-Flow Aux)
Sideshift (w/Hi-Flow Aux) • Oil from P2 flows through the energized

With the key switch ON and the deadman pedal energized SOL2 (Sideshift), and into the
depressed, the following will occur to activate sideshift cylinder.
the sideshift function. See Figure 8-19. To sideshift in the opposite direction, S5 is used
following occurs:
de-energized SOL12 (Aux Dump), and
returns to the reservoir.
PP LP
M SOL7
SOL1
LIFT/
LOAD
P1 3
AUX1
HOLD
1 2 C Legend
P1 1
Pressure
LIFT/ 2
H/S AUX
1
1
LIFT
Return
3 2
SOL5 2 SOL3 Energized Solenoid
P2 SOL12 2 PROP
AUX REL1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 PFR
1 3 T1
LIFT/ 2 4
2 1
AUX SOL8
SOL6
LIFT/
AUX SOL4 ATTACHMENT
AUX2 1 CB1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB2
TILT
2 1
P3
A1 A2
SOL11
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL9 A2
T PROP HI FLOW
REL2 2 SOL2 AUX. 2
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
W / HIGH SPEED AUX
Figure 8-19: Sideshift Function - Serial No. 0100-1729 (Hi-Flow Aux)
8-46 PDMM-0089 Issued: 6/24/02

(Serial Numbers 1730 and up) • Oil from P2 flows through the energized
With the key switch ON and the deadman pedal through the energized SOL2 (Sideshift), and
depressed, the following will occur to activate into the sideshift cylinder.
the sideshift function. See Figure 8-20.
To sideshift in the opposite direction, S5 is used
following occurs:
de-energized SOL12 (Aux Dump), and back
to the reservoir.
PP LP
M SOL-7
LIFT/
SOL-1
LOAD
Legend
3
AUX1
HOLD
1 2 C Pressure
P1 P1
Return
1
LIFT/ 2 1
H/S AUX
1
LIFT
Energized Solenoid
3 2
SOL-5 2 SOL-3
P2 SOL-12 2 PROP
AUX REL-1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 2
1
T1
LIFT/ 3
2 1
AUX SOL-8
SOL-6
LIFT/
AUX2 CB-1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB-2
TILT
2 1
P3
A1 A2
SOL-11
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL-11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL-9 A2
T PROP HI FLOW
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
W / HIGH SPEED AUX
Figure 8-20: Sideshift Function - Serial No. 17320-Up (Hi-Flow Aux)
PDMM-0089 Issued: 6/24/02 8-47

Hi-Flow Auxiliary System
Hi-Flow Auxiliary System • Oil from P1 flows through de-energized

SOL7, energized SOL12 (Aux Dump), SOL6
(Aux Dir), and through to the appropriate
(Serial Numbers 0100-1729) hi-flow aux solenoid and specific function.
With the key switch ON and the deadman pedal
hi-flow aux functions. See Figure 8-21.
• When option A switch is closed, an input is
sent to the VM at JPC6-1. When option B
switch is closed, an input is sent to the VM
at JPC6-2. These inputs are sent to the
vehicle function controller located in the
VM.
• Only oil supplied by P1 is used for hi-flow
aux functions. Oil from P2 is directed back
to the reservoir. From P2, oil flows into
Port 1, out of Port 2 of the PFR valve,
through de-energized SOL5 to the hydraulic
reservoir.
PP LP
M SOL7
SOL1
LIFT/
AUX1
LOAD
HOLD C
Legend
P1 P1 1
3 1 2
Pressure
LIFT/
H/S AUX
2 1 LIFT Return
3 2
SOL5
1
Energized Solenoid
2 SOL3
P2 SOL12 2 PROP
AUX REL1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 PFR
1 3 T1
LIFT/ 2 4
2 1
AUX SOL8
SOL6
LIFT/
AUX SOL4 ATTACHMENT
AUX2 1 CB1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB2
TILT
2 1
P3
A1 A2
SOL11
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL9 A2
T PROP HI FLOW
REL2 2 SOL2 AUX. 2
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
W / HIGH SPEED AUX
Figure 8-21: Hi-Flow Auxiliary System - Serial No. 0100-1729
8-48 PDMM-0089 Issued: 6/24/02

Hi-Flow Auxiliary System

hi-flow aux functions. See Figure 8-22.
• When option A switch is closed, an input is
sent to the VM at JPC6-1. When option B
switch is closed, an input is sent to the VM
at JPC6-2. These inputs are sent to the
vehicle function controller located in the
VM.
• Only oil supplied by P1 is used for hi-flow
aux functions. Oil from P2 flows through
de-energized solenoids SOL8 and SOL5
back to the reservoir.
SOL7, energized SOL12 (Aux Dump), SOL6
(Aux Dir), and through to the appropriate
hi-flow aux solenoid and specific function.
PP LP
M SOL-7
SOL-1
LIFT/
AUX1
LOAD
HOLD
Legend
P1 P1 1
3 1 2 C
Pressure
LIFT/ 2 1 LIFT
Return
H/S AUX
3 2
SOL-5 2 SOL-3
P2 SOL-12 2 PROP
AUX REL-1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 2
1
T1
LIFT/ 3
2 1
AUX SOL-8
SOL-6
LIFT/
AUX2 CB-1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB-2
TILT
2 1
P3
A1 A2
SOL-11
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL-11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL-9 A2
T PROP HI FLOW
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
W / HIGH SPEED AUX
Figure 8-22: Hi-Flow Auxiliary System - Serial No. 1730-Up
PDMM-0089 Issued: 6/24/02 8-49

Steering
Steering
With the key switch ON, the deadman pedal
depressed, and the EPO switch closed, the
following happens:
• Relay K3 is energized, sending B+ to the VM
at JPC8-13 (B+KC). This supplies B+KC to
one side of the steering contactor coil.
• A coil driver inside the VM supplies a (–) to
the steering contactor coil.
• When the coil is energized, the steering
contactor tips close, supplying battery
voltage to the steer motor. With the steer
motor running, oil is sent through the
steering orbitrol, and back to the hydraulic
reservoir. When steering is requested, oil is
sent through the orbitrol to the hydraulic
steer motor to rotate (steer) the drive unit.
8-50 PDMM-0089 Issued: 6/24/02

Travel Circuit Components
Travel Circuit Components
Component Location Function
Traction Power Located in front of the lift Provides regulation of current to the
Amplifier amplifier. There are two traction motors. There is one amplifier
amplifiers for traction. for each traction motor.
Lift Power Amplifier Located under the cover, Provides regulation of current to the lift
adjacent to the steering tiller. motor.
Steer Position Located on a bracket above Sends feedback to the VM regarding the
Sensor the steerable wheel position of the steer wheel. This is
assembly. necessary to rotate each drive wheel in
the proper direction.
Multi Function Located on the top of the This is an interface between the operator
Control Handle operator console in the and the VM to execute the operator’s
center. requests. Requests are travel, lift/lower,
sideshift, tilt, hi-flow auxiliary
functions, and horn.
Speed Sensors Located on the side of the The speed sensors function as an
drive (traction) motors below interface between the traction motors
the brake. and the VM. They tell the VM present
speed. There is one sensor located on
the side of each traction motor. The
information from the sensors is used to
determine the speed of the vehicle and
can also be viewed on the operator
display.
Brake Assembly Located directly on top of both The brakes are located on top of each
drive motors. traction motor. The purpose of the brake
is to stop the vehicle when the
operator’s foot is removed from the
deadman pedal. Each brake
incorporates an electrical coil. The
brake is spring applied and electrically
released.
Horn Located to the left of the The horn is an electrical warning device
multi-function control that is operated by a request from the
handle. operator. The horn button, located in
the multi-function control handle,
sends a signal to the VM. The VM
processes this request and gives the
horn its negative by way of an internally
mounted coil driver.
EPO Located on the right of the The emergency power off disables all
operator display interface. functions of the truck. It does this by
removing B– from relay K3.
PDMM-0089 Issued: 6/24/02 8-51

Fuse Identification Chart
Component Location Function
ODI Located on the top of the The function of the ODI is to give the
operator console, in front of operator information with respect to the
the multi-function control operation of the vehicle. It also gives
handle. trained technicians information for
troubleshooting.
Pressure Located on the top of the The pressure transducer is an option that
Transducer lift/aux manifold. will tell the VM the weight on the forks.
It changes a mechanical signal
(pressure) to an electrical signal
(voltage). Note: The weight displayed is
for reference only.
Deadman Switch Located under the deadman The deadman switch is used to enable
(S2) pedal in the operator truck functions when the operator is in
compartment. the operator compartment. The
deadman switch is a micro-switch.
Testing can be found in the electrical
testing section.
VM Located under the operator Receives inputs and sends output signals
display interface. to the other components of the vehicle
to initiate truck functions.
NOTE: There are no serviceable parts or
Firmware in the VM.
Fuse Identification Chart

Use the following chart to help you locate
specific fuses on the truck, determine their
rating, and identify the corresponding circuits
that they are designed to protect.
Fuse Rating Circuits Protected

FU1 40A Power feed for steer motor
FU2 600A Power feed to traction circuits
FU3 500A Power feed to lift circuits
FU5 15A Power feed for key switch circuits
FU6 15A Strobe light (B–) or heaters (C/S)
FU7 15A Strobe light (B+) or heaters (C/S)
FU8 5A Fan (B–)
FU9 5A Fan (B+)
FU10 15A B– fused for VM
FU12 1.5A Warning light
FU13 1.5A Fan (B+)
8-52 PDMM-0089 Issued: 6/24/02

Hall Effect Switches
Hall Effect Switches

The limit switches and battery gate switches
used on this truck are Hall Effect switches.
These switches consist of a transistor that is +12VP
turned on when a magnet is positioned next to
the transistor. (Keep in mind that the magnet is
part of the switch assembly and can only be
seen if the switch is disassembled). DGND
See Figure 8-23 for an example of a typical Hall

Effect switch. Refer to Figure 8-24 for a
schematic representation of a Hall Effect
switch. 8
Figure 8-24: Example of Hall Effect Switch Schematic
Contactor Coils
The contactor coils used on this lift truck are all
36V coils (TPC, LPC, STR). These coils are
turned ON and OFF by coil drivers located
within the VM. The coil drivers are not
replaceable singularly and must be replaced by
way of the VM.
Solenoids
All of the solenoids used in the hydraulic
system are 36V with the exception of those that
are proportional. The voltage of the solenoid coil
can be verified by checking the metal tag
located under the securing nut on the end of
the solenoid coil.
8
Figure 8-23: Typical Hall Effect Switch
The switch is powered as follows:

• +6 to +12V is applied to the positive (+)
terminal
• battery negative is applied to the negative
(–) terminal
• When a magnet is not present, the
transistor is in an OFF state and the output
lead is in a high state.
• When a magnet is present, the transistor is
turned ON creating a path from the
negative (–) terminal to the 0 terminal.
Terminal “0” will now be a negative (–)
potential.
PDMM-0089 Issued: 6/24/02 8-53

BUS+/BUS–
BUS+/BUS– battery installed reaches the percentage on the

display. At this point in time, the display will
BUS+/BUS– are the communication lines that start to count down as the battery discharges.
the intelligent modules use to communicate
with one another. BUS+ is a digital, serial NOTE: As a battery becomes older or is
communication line. BUS– is a digital improperly maintained, it will not accept
communication line that is a mirror image of a 100% charge. Therefore the operator
BUS+. Using communication lines in this display will show less than 100% even
fashion limits noise problems associated with after a full recharging period.
long communication lines operating in a noisy
environment. See Figure 8-25. Battery Maintenance
8
Charge the truck battery when the specific
gravity (SG) reaches the point where the battery
5 Volts manufacturer recommends recharging.
BUS+ Configure the cut-out so that the battery
0 Volts reaches this level when lift cut-out occurs.
Adjust the setting in the Configure Mode on the
OD. See page 3-4. The cut-out setting may need
5 Volts to be changed, depending on the condition of
the battery, so that lift cut-out will occur when
BUS-
the battery SG is at the point recommended by
0 Volts
the battery manufacturer.
Figure 8-25: BUS+/– Communication Lines
Battery-State-of-Charge
Battery-State-of-Charge (BSOC) as displayed on
the operator display shows the amount of
usable energy that remains in the battery. The
value displayed is the percentage of energy in
the battery available for use. BSOC uses battery
voltage under load for this calculation.
When 0% is displayed on the Operator’s
Display, lift is prevented until the battery is
recharged or replaced with a fully charged
battery.
The battery should not be changed or charged
until the operator display reads 0 to 5%.
Recharging a battery that is not fully discharged
drastically shortens the life expectancy of the
battery. After the battery is charged, allow it to
cool down. Failure to allow sufficient cooling
time may also destroy the battery prematurely
due to overheating. If a battery is changed prior
to this point, the display may not reset. If the
display does not reset, it will continue to show
the percentage of the battery removed. This
percentage will stay on the display until the
8-54 PDMM-0089 Issued: 6/24/02

Battery Plugged In
Battery Plugged In
NOTE: All voltage readings are wrt TP4 (B–). See
Figure 8-26.
• B+ is seen at TP1 (B+), FU2 (600A) and
TPC-1, which is open.
• B+ is seen at FU1 (40A) and at steer
contactor STR-1, which is open.
• B+ is seen at FU3 (500A) and at lift
contactor LPC-1, which is open.
NOTE: All JPF1 connections are located on the
Contactor Fuse Panel.
• B+ is seen at JPF1-1 through FU9 (5A) to
TS1-1.
• B+ is seen at JPF1-3 and JPF1-10 through
FU7 (15A) to K1, which is open.
• B+ is seen at JPF1-8 and JPF1-9, through
FU5 (15A) out of the Contactor Fuse Panel
at JPF3-4, to open key switch S1-1.
• B+ is seen at JPF1-8 and JPF1-9, through
FU5 (15A) to the open tips of K2 and K3.
• B+ is seen at JPF1-9 and JPF1-9, out of the
Contactor Fuse Panel through JPF2-1 and
then at the VM at JPC8-7
(Battery_Sense_In).
PDMM-0089 Issued: 6/24/02 8-55

Battery Plugged In
A B C D
JPC7
S2
NC JPC8-9
DEADMAN
COM -5
DGND VEHICLE FU1_SENSE
SWITCH
NO
-16 MANAGER
ON_DEADMAN JPC10
2 12V
JPS2
-1
JPC7
-1
B+KB
-19
+12VP
A -2 -17
POSITION
STEER STEER_CHA
SENSOR
POSITION B
STEER
-3 -18
SENSOR STEER_CHB JPC8
C -4 -8 -17
MOTOR STEER_CHC B+KEY
SENSORS -13
B+KC
JPS11 JPC10
M1 BWI
-2 -8 -4
LEFT_TRAC_BWI1 B+KA
t˚ -3 -3 -5
MUX_TEMP1_LTM B+KA
M1 -7
-1 -24 BATTERY_SENSE_IN
DGND_P -11
-4 -9 EPO_SENSE
LEFT_TRAC_BWI2
BWI
JPS12 JPC10
M2 BWI
-2 -13
RIGHT_TRAC_BWI1
t˚ -3 -2
M2 MUX TEMP2 RTM
3 -1
-4
-23
-10
DGND_P
RIGHT_TRAC_BWI2
BWI
JPS8 JPC10
MP BWI
MOTOR SENSORS
-2 -14
LIFT_BWI1
t˚ -3 -1
MP MUX_TEMP3_LM
-1 -22
POWER AMPLIFIERS
DGND_P JPC4
-4 -15
LIFT_BWI2 -9
BWI BUS+
-10
BUS-
JPC6
MULTI-FUNCTION -15
POT_SUP_(TRAVEL)
CONTROL HANDLE
-10
TRAVEL TRAVEL_POT_INPUT
VR1 -13
TRAVEL_RETURN
-9
N/C
Legend:
4 LIFT/LOWER
VR2
-11
-8
LIFT_POT_INPUT
POT_SUP_(LIFT)
Positive Circuit
S3
HORN 2 1 -7
HORN_INPUT
S8
TILT UP 2 1 -3
CONTROL HANDLE
TILT_UP_INPUT
S9
TILT DN 2 1 -4
TILT_DN_INPUT Negative Circuit
S6
S/S RIGHT 1 -6
2
S/S_RIGHT_INPUT
S/S LEFT
2
S7
1
-5
S/S_LEFT_INPUT
BUS+ and BUS-
S4
OPTION A 2 1 -1
OPTION_A_INPUT
OPTION B 2
S5
1 -2
OPTION_B_INPUT
Power Supply
-14
DGND_P Voltage
-12
N/C
5 X Y
JPC8
-18 JPD2
STR STR_CONTACTOR JPC5 JPD1 UP
-1 -1 -5
CONTACTOR PANEL
-19 +12 VP
SPARE ADDR_LATCH -2 -2
X Y -20 -3 -3 -3 DN
DATA_LATCH
DISPLAY/INPUT KEYS
TPC TPC_CONTACTOR -4 -4
DISP_MISO
-14 -5 -5
ALARM_PWM -1 ENTER
B+ KC -6 -6
-21 SHIFT_CLOCK
-7 -7 -2
LPC LPC_CONTACTOR DATA_OUT
Y DGND -8 -8 -4
DISPLAY
X
JPS3 JPC10
-1 -4 -6
FEEDBACK
HE_SUPPLY1
LEFT -2 -12
SPEED
JPC8
(MD1) SPEED
SENSOR -6
GEAR_SENSE1 -6
-3 DGND
HE_DGND -1
JPS4 JPC10 -2
FEEDBACK
-1 -5 B-F -3
HE_SUPPLY2
SPEED
RIGHT -2 -11 -12

(MD2) SPEED GEAR_SENSE2
6 SENSOR -3 -7
HE_DGND
JPC9
-3
B+KA
JPB3 JPC10 2 1
(LEFT) -1
-2 -17 TILT_SOL SOL4 (LIFT_AUX1_SOL)
B1 LEFT_BRAKE1
2 1
-1 -20 -8 1 2
SOL6_OUT SOL6 (AUX_DIR_SOL)
B+KB SOL12 OPTION (SHT 2)
JPB2 2 1 (LIFT_AUX1_SOL)
-9 (P2 DUMP SOL)
(RIGHT) -2 -16 SOL7_OUT SOL7
HORN & BRAKES
B2 RIGHT_BRAKE2
-1 -21
-6 2 1 1
B+KB
LOAD_HLD_SOL SOL1
JPC8
1 -15 2 1
SOLENOID
-7
CONTROL
B+KA SOL5_OUT SOL5

H -16
2 2 1
HORN ENABLE -10
SOL8_OUT SOL8 (LIFT_AUX2_SOL)
2 1
-2
SOL9_OUT SOL9 (PROPORTIONAL RELIEF)
2 1
7 PROP_LWR_SOL
-5
SOL3
JPH1
-11 1 2
B+KA-P -1
SOL2
OPTIONAL
-12 -2 (SHT 2)
SIDE_SHIFT_OUT
A B C D
Figure 8-26: Battery Plugged In Schematic
8-56 PDMM-0089 Issued: 6/24/02

Battery Plugged In
E F G H
TS1-1
TS1-2
TS1-3
K1
FU9 (5A) JPF1-1
2
KEYSWITCH S1
2 1 JPF3-4 2 1
JPF3-2 FU7 (15A) -10
JPF2-5 2 1 -3
K3 K2 FU5 (15A)
JPF2-7 -8
T-1 2 1 -9
K3 K2 K1
JPF2-2
JPF2-8
JPF2-1
JPF2-6
JPF4-1
JPF5-1
JPF5-2
JPF5-4
JPF5-5
JPTL1
B+
TPC FU2
600A TP1
B+ 3
-1 B+K2
2 1
(LSFF)
F1
TRACTION POWER E1 A1 FU3 FU1
AMPLIFIER 500A 40A
(LEFT)
JPTL2 M1
-3
F2
BUS+ LA E2 A2
-6 BUS-
1 1 JP
M- LPC STR B+
-4 BUS- B- 2 2
-5 TERM
JPTR1 B+
-1
B+K2
-21
NODE SELECT
(RSFF) +
JP 4
F1 CONTACTOR B-
TRACTION POWER E1 MS
JPTR2 A1 FUSE
-3 AMPLIFIER PANEL
(RIGHT) -
BUS+
-6 M2
BUS-
F2
E2 A2
-4 BUS- RA
-5 TERM M-
B- TP4
JPL1 B+
-1
B+K2
JPL2
-3
BUS+
-6 D
BUS-
LIFT/AUXILIARY
POWER AMPLIFIER
5
JPF3
MP -1
-4 1
BUS-
-5
TERM PA A S21
M- EPO -3
2
B-
JPF5
-3 JPF1-5
-6
-11
FU10
JPF2 15A
-4 2 1 -12
-9
-10
-11
-12
JPF4-2
JPF1-13
TS2-1 H FU6
CAD
2 15A 1 -14
NOTE: This schematic is for Theory of Operation TS2-2
FU8
5A
only. Refer to the schematic located in the TS2-3
2 1 -7
Appendix when troubleshooting or

performing maintenance.
7
E F G H
PDMM-0089 Issued: 6/24/02 8-57

Turning Key Switch (S1) ON
Turning Key Switch (S1) ON SelfTest Checks

During the SelfTest portion of power-up, the
Start-up Sequence following components and circuits are checked
When the key switch is turned from OFF to ON, for correct operation.
the VM performs a series of system SelfTests. If Checks:
you press the ENTER button, the OD will show
• Voltage of the battery and whether or not it
the hour meters. During the start-up sequence,
is within min/max voltage range.
the following are displayed in the order and the
length of time indicated: • Calculates the Battery-State-of-Charge.
• Proper output of the VM power supply
Time voltage.
Identifier* Meaning Displayed
• No fused contactor tips (LPC, TPC, STR).
(seconds)
• Position of the Deadman Switch (S2); the
xxxx.xKH Key on Hours 3 PC contactor will not energize unless the
deadman pedal is released.
xxxx.xHD Hours on
3 • Operation of the horn (audible test only).
Deadman
• Power amplifier and traction motor
xxxx.xHL Hours spent
3 temperatures.
lifting
• Hydraulic pressure through the pressure
xxxxxxTM Distance transducer (optional).
3
Traveled
• Read the Speed Feedback Proxs.
SelfTest System Testing 4 • If a problem is detected, SelfTest will stop at
the point of the problem and display the
PASSED SelfTest passed 1
appropriate fault code on the operator
Please Message to display. See “Messages and Codes” on
complete operator page 6-9.
-----
daily
checklist
*The operator display will show the three

hour meters and distance traveled only if
you press the ENTER button.
8-58 PDMM-0089 Issued: 6/24/02

Key Switch Turned ON
Key Switch Turned ON the Node Select (JPTR1-2) on the right

Traction Power Amplifier
Figure 8-27. • With K3 energized, the tips of K3 close. This
supplies B+Key to the VM at JPC10-19
• B+ is supplied to the contactor fuse panel (B+KB) through T-1. From there B+KB is
at JPF1-8 and JPF1-9, through FU5 (15A) supplied to the left and right brakes at
then through JPF3-4 to the closed tips of JPC10-20 and JPC10-21. B+Key is also
key switch (S1). supplied to the VM at JPC8-13 (B+KC)
• B+ from key switch (S1) flows through the through JPF2-7. After this, it is found at
contactor fuse panel at JPF3-2 and JPC8-14 (which supplies contactor coils
energizes coils K1, K2 and K3. STR, TPC, LPC)
• Negative potential is supplied to Coil K3, • BUS+ generated by the VM at JPC4-9 is
through JPF3-1 and the closed Emergency supplied to the left Traction Power Amplifier
Power Off (EPO) switch (S21), then back to at JPTL2-3, right Traction Power Amplifier
TP4 (B–) through FU10 (15A). at JPTR2-3, and Lift/Aux Power Amplifier
• Negative potential is supplied to coils K1 at JPL2-3
and K2 through the contactor fuse panel • BUS– generated by the VM at JPC4-10 is
back to TP4 (B–) through FU10 (15A). supplied to the left Traction Power Amplifier
at JPTL2-6, right Traction Power Amplifier
• B+Key is supplied at JPF2-5 (leaving the
at JPTR2-6, and Lift/Aux Power Amplifier
contactor fuse panel to the VM) and at JPC
at JPL2-6
8-17 (B+Key). The VM converts B+Key to
+12V, which is monitored at JPC7-1 and
JPC5-1.
• Negative potential is supplied at JPF2-6
(leaving the contactor fuse panel) to the VM
at JPC8-11 (EPO-Sense).
• With K1 coil energized, the tips of K1 close.
This supplies B+Key to TS1-2 and TS1-3
from K1,
• With K2 coil energized, the tips of K2 close.
this supplies B+Key to JPF2-2 and JPF2-8
at the Contactor Fuse Panel and then at
JPC8-4 and JPC8-5 (B+KA). After this, it
can be found at JPC8-15 (horn), JPC9-3
(supply for SOL1,2,4,5,6,7,8,9,12), and
JPC9-11 (supply for SOL3)
B+ is also supplied to JPF5-1 then JPL1-1
(B+K2) which powers the Lift/Aux Power
Amplifier, JPF5-2 then JPTR1-1 which
powers the right Traction Power Amplifier,
JPF5-4 then JPTL1-1 which powers the left
Traction Power Amplifier, and JPF5-5 then
PDMM-0089 Issued: 6/24/02 8-59

A B C D
JPC7
S2
NC JPC8-9
DEADMAN
COM -5
SWITCH
NO
-16 MANAGER
ON_DEADMAN JPC10
2 12V
JPS2
-1
JPC7
-1
B+KB
-19
+12VP
A -2 -17
POSITION
STEER STEER_CHA
SENSOR
POSITION B
STEER
-3 -18
C -4 -8 -17
SENSORS -13
B+KC
JPS11 JPC10
M1 BWI
-2 -8 -4
LEFT_TRAC_BWI1 B+KA
t˚ -3 -3 -5
MUX_TEMP1_LTM B+KA
M1 -7
DGND_P -11
-4 -9 EPO_SENSE
LEFT_TRAC_BWI2
BWI
JPS12 JPC10
M2 BWI
-2 -13
RIGHT_TRAC_BWI1
t˚ -3 -2
M2 MUX TEMP2 RTM
3 -1
-4
-23
-10
DGND_P
RIGHT_TRAC_BWI2
BWI
JPS8 JPC10
MP BWI
MOTOR SENSORS
-2 -14
LIFT_BWI1
t˚ -3 -1
MP MUX_TEMP3_LM
-1 -22
POWER AMPLIFIERS
DGND_P JPC4
-4 -15
LIFT_BWI2 -9
BWI BUS+
-10
BUS-
JPC6
MULTI-FUNCTION -15
POT_SUP_(TRAVEL)
CONTROL HANDLE
-10
VR1 -13
TRAVEL_RETURN
-9
N/C
4 LIFT/LOWER
-11
LIFT_POT_INPUT
Legend:
VR2 -8
POT_SUP_(LIFT)
S3
HORN 2 1
S8
-7
HORN_INPUT Positive Circuit
TILT UP 2 1 -3
CONTROL HANDLE
TILT_UP_INPUT
S9
Negative Circuit
TILT DN 2 1 -4
TILT_DN_INPUT
S6
S/S RIGHT 1 -6
2
S/S_RIGHT_INPUT
S7
S/S LEFT
2 1
S4
-5
S/S_LEFT_INPUT BUS+ and BUS-
OPTION A 2 1 -1
OPTION_A_INPUT
S5
OPTION B 2 1
-14
-2
OPTION_B_INPUT Power Supply
-12
DGND_P
Voltage
N/C
5 X Y
JPC8
-18 JPD2
-1 -1 -5
CONTACTOR PANEL
-19 +12 VP
X Y -20 -3 -3 -3 DN
DATA_LATCH
DISPLAY/INPUT KEYS
DISP_MISO
-14 -5 -5
ALARM_PWM -1 ENTER
B+ KC -6 -6
-21 SHIFT_CLOCK
-7 -7 -2
Y DGND -8 -8 -4
DISPLAY
X
JPS3 JPC10
-1 -4 -6
FEEDBACK
HE_SUPPLY1
LEFT -2 -12
SPEED
JPC8
(MD1) SPEED
SENSOR -6
GEAR_SENSE1 -6
-3 DGND
HE_DGND -1
JPS4 JPC10 -2
FEEDBACK
-1 -5 B-F -3
HE_SUPPLY2
SPEED
RIGHT -2 -11 -12

6 SENSOR -3 -7
HE_DGND
JPC9
-3
B+KA
JPB3 JPC10 2 1
(LEFT) -1
B1 LEFT_BRAKE1
2 1
-1 -20 -8 1 2
B+KB SOL12 OPTION (SHT 2
-9 (P2 DUMP SOL
HORN & BRAKES
B2 RIGHT_BRAKE2
-1 -21
-6 2 1 1
B+KB
LOAD_HLD_SOL SOL1
JPC8
1 -15 2 1
SOLENOID
-7
CONTROL
B+KA SOL5_OUT SOL5

H -16
2 2 1
HORN ENABLE -10
2 1
-2
2 1
7 PROP_LWR_SOL
-5
SOL3
JPH1
-11 1 2
B+KA-P -1
SOL2
OPTIO
-12 -2 (SHT
SIDE_SHIFT_OUT
A B C D
Figure 8-27: Key Switch Turned ON Schematic
8-60 PDMM-0089 Issued: 6/24/02

E F G H
TS1-1
TS1-2
TS1-3
K1
FU9 (5A) JPF1-1
2
KEYSWITCH S1
2 1 JPF3-4 2 1
JPF3-2 FU7 (15A) -10
JPF2-5 2 1 -3
K3 K2 FU5 (15A)
JPF2-7 -8
T-1 2 1 -9
K3 K2 K1
JPF2-2
JPF2-8
JPF2-1
JPF2-6
JPF4-1
JPF5-1
JPF5-2
JPF5-4
JPF5-5
JPTL1
B+
TPC FU2
600A TP1
B+ 3
-1 B+K2
2 1
(LSFF)
F1
AMPLIFIER 500A 40A
(LEFT)
JPTL2 M1
-3
F2
BUS+ LA E2 A2
-6 BUS-
1 1 JP
M- LPC STR B+
-4 BUS- B- 2 2
-5 TERM
JPTR1 B+
-1
B+K2
-21
NODE SELECT
(RSFF) +
JP 4
F1 CONTACTOR B-
JPTR2 A1 FUSE
-3 AMPLIFIER PANEL
(RIGHT) -
BUS+
-6 M2
BUS-
F2
E2 A2
-4 BUS- RA
-5 TERM M-
B- TP4
JPL1 B+
-1
B+K2
JPL2
-3
BUS+
-6 D
BUS-
LIFT/AUXILIARY
POWER AMPLIFIER
5
JPF3
MP -1
-4 1
BUS-
-5
TERM PA A S21
M- EPO -3
2
B-
JPF5
-3 JPF1-5
-6
-11
FU10
JPF2 15A
-4 2 1 -12
-9
-10
-11
-12
JPF4-2
JPF1-13
TS2-1 H FU6
CAD
2 15A 1 -14
TS2-2
NOTE: This schematic is for Theory of Operation FU8
5A -7
2 1

7
E F G H
PDMM-0089 Issued: 6/24/02 8-61

8-62 PDMM-0089 Issued: 6/24/02

Deadman Pedal Depressed

Figure 8-28.
• With the deadman pedal (S2) depressed, a
circuit is completed to the VM between
JPC7-16 and JPC7-5.
• The VM energizes the coil drivers for the
LPC (at JPC8-21), TPC (at JPC8-20), and
STR (at JPC8-18) coils closing the related
contactor tips.
• With the TPC contactor tips closed, B+ is
supplied to the B+ terminals on the left and
right traction power amplifiers and to the
left (M1) and right (M2) traction motor
armatures (A1).
• With the LPC contactor tips closed, B+ is
supplied to the B+ terminal on the lift/aux
power amplifier and to the lift motor (MP)
field and armature.
• With the STR contactor tips closed, B+ is
supplied to the steer motor (MS) causing
the steer motor to run.
PDMM-0089 Issued: 6/24/02 8-63

A B C D
JPC7
S2
NC JPC8-9
DEADMAN
COM -5
SWITCH
NO
-16 MANAGER
ON_DEADMAN JPC10
2 12V
JPS2
-1
JPC7
-1
B+KB
-19
+12VP
A -2 -17
POSITION
STEER STEER_CHA
SENSOR
POSITION B
STEER
-3 -18
C -4 -8 -17
SENSORS -13
B+KC
JPS11 JPC10
M1 BWI
-2 -8 -4
LEFT_TRAC_BWI1 B+KA
t˚ -3 -3 -5
MUX_TEMP1_LTM B+KA
M1 -7
DGND_P -11
-4 -9 EPO_SENSE
LEFT_TRAC_BWI2
BWI
JPS12 JPC10
M2 BWI
-2 -13
RIGHT_TRAC_BWI1
t˚ -3 -2
M2 MUX TEMP2 RTM
3 -1
-4
-23
-10
DGND_P
RIGHT_TRAC_BWI2
BWI
JPS8 JPC10
MP BWI
MOTOR SENSORS
-2 -14
LIFT_BWI1
t˚ -3 -1
MP MUX_TEMP3_LM
-1 -22
POWER AMPLIFIERS
DGND_P JPC4
-4 -15
LIFT_BWI2 -9
BWI BUS+
-10
BUS-
JPC6
MULTI-FUNCTION -15
POT_SUP_(TRAVEL)
CONTROL HANDLE
-10
VR1 -13
TRAVEL_RETURN
-9
N/C Legend:
4 LIFT/LOWER
VR2
-11
-8
LIFT_POT_INPUT
HORN 2
S3
1 -7
POT_SUP_(LIFT)
Positive Circuit
HORN_INPUT
S8
TILT UP 2 1 -3
CONTROL HANDLE
TILT DN 2
S9
1 -4
TILT_UP_INPUT
Negative Circuit
TILT_DN_INPUT
S6
S/S RIGHT 1 -6
2
S7
-5
S/S_RIGHT_INPUT
BUS+ and BUS-
2 1
S/S LEFT S/S_LEFT_INPUT
S4
OPTION A 2 1 -1
OPTION B 2
S5
1 -2
OPTION_A_INPUT
Power Supply
-14
OPTION_B_INPUT
Voltage
DGND_P
-12
N/C
5 X Y
JPC8
-18 JPD2
-1 -1 -5
CONTACTOR PANEL
-19 +12 VP
X Y -20 -3 -3 -3 DN
DATA_LATCH
DISPLAY/INPUT KEYS
DISP_MISO
-14 -5 -5
ALARM_PWM -1 ENTER
B+ KC -6 -6
-21 SHIFT_CLOCK
-7 -7 -2
Y DGND -8 -8 -4
DISPLAY
X
JPS3 JPC10
-1 -4 -6
FEEDBACK
HE_SUPPLY1
LEFT -2 -12
SPEED
JPC8
(MD1) SPEED
SENSOR -6
GEAR_SENSE1 -6
-3 DGND
HE_DGND -1
JPS4 JPC10 -2
FEEDBACK
-1 -5 B-F -3
HE_SUPPLY2
SPEED
RIGHT -2 -11 -12

6 SENSOR -3 -7
HE_DGND
JPC9
-3
B+KA
JPB3 JPC10 2 1
(LEFT) -1
B1 LEFT_BRAKE1
2 1
-1 -20 -8 1 2
-9 (P2 DUMP SOL)
HORN & BRAKES
B2 RIGHT_BRAKE2
-1 -21
-6 2 1 1
B+KB
LOAD_HLD_SOL SOL1
JPC8
1 -15 2 1
SOLENOID
-7
CONTROL
B+KA SOL5_OUT SOL5

H -16
2 2 1
HORN ENABLE -10
2 1
-2
2 1
7 PROP_LWR_SOL
-5
SOL3
JPH1
-11 1 2
B+KA-P -1
SOL2
OPTION
-12 -2 (SHT 2
SIDE_SHIFT_OUT
A B C D
Figure 8-28: Deadman Pedal Depressed Schematic
8-64 PDMM-0089 Issued: 6/24/02

E F G H
TS1-1
TS1-2
TS1-3
K1
FU9 (5A) JPF1-1
2
KEYSWITCH S1
2 1 JPF3-4 2 1
JPF3-2 FU7 (15A) -10
JPF2-5 2 1 -3
K3 K2 FU5 (15A)
JPF2-7 -8
T-1 2 1 -9
K3 K2 K1
JPF2-2
JPF2-8
JPF2-1
JPF2-6
JPF4-1
JPF5-1
JPF5-2
JPF5-4
JPF5-5
JPTL1
B+
TPC FU2
600A TP1
B+ 3
-1 B+K2
2 1
(LSFF)
F1
AMPLIFIER 500A 40A
(LEFT)
JPTL2 M1
-3
F2
BUS+ LA E2 A2
-6 BUS-
1 1 JP
M- LPC STR B+
-4 BUS- B- 2 2
-5 TERM
JPTR1 B+
-1
B+K2
-21
NODE SELECT
(RSFF) +
JP 4
F1 CONTACTOR B-
JPTR2 A1 FUSE
-3 AMPLIFIER PANEL
(RIGHT) -
BUS+
-6 M2
BUS-
F2
E2 A2
-4 BUS- RA
-5 TERM M-
B- TP4
JPL1 B+
-1
B+K2
JPL2
-3
BUS+
-6 D
BUS-
LIFT/AUXILIARY
POWER AMPLIFIER
5
JPF3
MP -1
-4 1
BUS-
-5
TERM PA A S21
M- EPO -3
2
B-
JPF5
-3 JPF1-5
-6
-11
FU10
JPF2 15A
-4 2 1 -12
-9
-10
-11
-12
JPF4-2
JPF1-13
TS2-1 H FU6
CAD
2 15A 1 -14
TS2-2
5A -7
2 1

7
E F G H
PDMM-0089 Issued: 6/24/02 8-65

8-66 PDMM-0089 Issued: 6/24/02

Directional Control Moved

depressed, the following happens:
(See Figure 8-29.)
• As the control handle is moved, the VM
senses a voltage increase from VR1 (travel
potentiometer) at JPC6-10.
• The VM prepares for travel by sending a
signal to the left and right traction power
amplifiers through JPC4-9 (BUS+) and
JPC4-10 (BUS–). This directs the traction
power amplifier transistors, which control
the left (M1) and right (M2) drive motor
armature and field, to choose the proper
speed and direction
• When the key switch is turned ON, relay K2
is energized and supplies B+ power to the
left and right traction power amplifiers and
the node select terminal JPTR1-2 on the
right traction power amplifier (see “Key
Switch Turned ON” on page 8-59).
• As the transistors are pulsed, current flows
through the TPC contactor and drive motor
armatures (A1 to A2) to the power
amplifiers at M–, then through the
armature transistor and back to B– (TP4).
• The amount of current through each motor
is monitored by the current sensing devices
in the traction power amplifiers.
• Speed is monitored by the left (MD1) and
right (MD2) speed sensors.
• The VM sends a signal to the coil drivers
mounted inside the VM that supply B– to
the brake coils for the brakes (B1, B2). This
releases the brakes.
• Depressing the Emergency Power Off (EPO)
switch removes B– from solenoid K3 and all
of the contactor and brake coil drivers
located in the VM.
• The status of the EPO switch is sensed at
the VM at JPC8-11 through JPF2-6 on the
fuse contactor panel.
PDMM-0089 Issued: 6/24/02 8-67

A B C D
JPC7
S2
NC JPC8-9
DEADMAN
COM -5
SWITCH
NO
-16 MANAGER
ON_DEADMAN JPC10
2 12V
JPS2
-1
JPC7
-1
B+KB
-19
+12VP
A -2 -17
POSITION
STEER STEER_CHA
SENSOR
POSITION B
STEER
-3 -18
C -4 -8 -17
SENSORS -13
B+KC
JPS11 JPC10
M1 BWI
-2 -8 -4
LEFT_TRAC_BWI1 B+KA
t˚ -3 -3 -5
MUX_TEMP1_LTM B+KA
M1 -7
DGND_P -11
-4 -9 EPO_SENSE
LEFT_TRAC_BWI2
BWI
JPS12 JPC10
M2 BWI
-2 -13
RIGHT_TRAC_BWI1
t˚ -3 -2
M2 MUX TEMP2 RTM
3 -1
-4
-23
-10
DGND_P
RIGHT_TRAC_BWI2
BWI
JPS8 JPC10
MP BWI
MOTOR SENSORS
-2 -14
LIFT_BWI1
t˚ -3 -1
MP MUX_TEMP3_LM
-1 -22
POWER AMPLIFIERS
DGND_P JPC4
-4 -15
LIFT_BWI2 -9
BWI BUS+
-10
BUS-
JPC6
MULTI-FUNCTION -15
POT_SUP_(TRAVEL)
CONTROL HANDLE
-10
VR1 -13
TRAVEL_RETURN
Legend:
-9
N/C
4 LIFT/LOWER
VR2
-11
-8
LIFT_POT_INPUT
Positive Circuit
POT_SUP_(LIFT)
S3
HORN 2 1 -7
HORN_INPUT
TILT UP 2
S8
1 -3 Negative Circuit
CONTROL HANDLE
TILT_UP_INPUT
S9
TILT DN 2 1 -4
TILT_DN_INPUT
S/S RIGHT
2
S6
1 -6
S/S_RIGHT_INPUT
BUS+ and BUS-
S7
2 -5
1
OPTION A 2
S4
1 -1
OPTION_A_INPUT
Power Supply
OPTION B 2
S5
1 -2
OPTION_B_INPUT
Voltage
-14
DGND_P
-12
N/C
5 X Y
JPC8
-18 JPD2
-1 -1 -5
CONTACTOR PANEL
-19 +12 VP
X Y -20 -3 -3 -3 DN
DATA_LATCH
DISPLAY/INPUT KEYS
DISP_MISO
-14 -5 -5
ALARM_PWM -1 ENTER
B+ KC -6 -6
-21 SHIFT_CLOCK
-7 -7 -2
Y DGND -8 -8 -4
DISPLAY
X
JPS3 JPC10
-1 -4 -6
FEEDBACK
HE_SUPPLY1
LEFT -2 -12
SPEED
JPC8
(MD1) SPEED
SENSOR -6
GEAR_SENSE1 -6
-3 DGND
HE_DGND -1
JPS4 JPC10 -2
FEEDBACK
-1 -5 B-F -3
HE_SUPPLY2
SPEED
RIGHT -2 -11 -12

6 SENSOR -3 -7
HE_DGND
JPC9
-3
B+KA
JPB3 JPC10 2 1
(LEFT) -1
B1 LEFT_BRAKE1
2 1
-1 -20 -8 1 2
-9 (P2 DUMP SOL)
HORN & BRAKES
B2 RIGHT_BRAKE2
-1 -21
-6 2 1 1
B+KB
LOAD_HLD_SOL SOL1
JPC8
1 -15 2 1
SOLENOID
-7
CONTROL
B+KA SOL5_OUT SOL5

H -16
2 2 1
HORN ENABLE -10
2 1
-2
2 1
7 PROP_LWR_SOL
-5
SOL3
JPH1
-11 1 2
B+KA-P -1
SOL2
OPTIONA
-12 -2 (SHT 2)
SIDE_SHIFT_OUT
A B C D
Figure 8-29: Directional Control Moved (Sheet 1 of 2)
8-68 PDMM-0089 Issued: 6/24/02

E F G H
TS1-1
TS1-2
TS1-3
K1
FU9 (5A) JPF1-1
2
KEYSWITCH S1
2 1 JPF3-4 2 1
JPF3-2 FU7 (15A) -10
JPF2-5 2 1 -3
K3 K2 FU5 (15A)
JPF2-7 -8
T-1 2 1 -9
K3 K2 K1
JPF2-2
JPF2-8
JPF2-1
JPF2-6
JPF4-1
JPF5-1
JPF5-2
JPF5-4
JPF5-5
JPTL1
B+
TPC FU2
600A TP1
B+ 3
-1 B+K2
2 1
(LSFF)
F1
AMPLIFIER 500A 40A
(LEFT)
JPTL2 M1
-3
F2
BUS+ LA E2 A2
-6 BUS-
1 1 JP
M- LPC STR B+
-4 BUS- B- 2 2
-5 TERM
JPTR1 B+
-1
B+K2
-21
NODE SELECT
(RSFF) +
JP 4
F1 CONTACTOR B-
JPTR2 A1 FUSE
-3 AMPLIFIER PANEL
(RIGHT) -
BUS+
-6 M2
BUS-
F2
E2 A2
-4 BUS- RA
-5 TERM M-
B- TP4
JPL1 B+
-1
B+K2
JPL2
-3
BUS+
-6 D
BUS-
LIFT/AUXILIARY
POWER AMPLIFIER
5
JPF3
MP -1
-4 1
BUS-
-5
TERM PA A S21
M- EPO -3
2
B-
JPF5
-3 JPF1-5
-6
-11
FU10
JPF2 15A
-4 2 1 -12
-9
-10
-11
-12
JPF4-2
JPF1-13
TS2-1 H FU6
CAD
2 15A 1 -14
TS2-2
5A -7
2 1

7
E F G H
PDMM-0089 Issued: 6/24/02 8-69

Proportional Plugging
Proportional Plugging
When the truck is traveling in one direction and
the control handle is moved through neutral to
the opposite direction to stop the truck and/or
change directions, the process of plugging
occurs. “Proportional Plugging” means the
further the control handle is moved, the quicker
the truck stops and changes direction. In this
example, plugging occurs from the forks-first
direction to tractor-first.
• The VM senses that the truck is still moving
in the forks-first direction because of the
input from the traction power amplifiers.
• The VM senses the voltage from VR1 and
recognizes this is a request for tractor-first
travel.
• The VM will not change the polarity of the
fields during plugging.
• As the armature continues to rotate it is
converted into a generator. The generated
voltage is routed back to the battery that
has now become the load.
• This process continues until the truck is
almost stopped. After the truck has slowed
almost to a stop, proportional plugging will
stop and the traction system will be in drive
mode.
NOTE: If the EPO knob is depressed during
travel, the truck will reverse the fields of
the motor to stop the truck quickly.
8-70 PDMM-0089 Issued: 6/24/02

Torque On Demand
Torque On Demand
Torque on demand allows the truck to smoothly
climb out of potholes or other floor
obstructions. For this situation, assume the
truck is stopped with the drive tire resting in a
depression in the floor, the following occurs:
• A travel request is received from VR1, but
the obstruction prevents the drive motor
from turning.
• The speed request remains constant.
• The speed error signal increases the longer
the truck does not move.
• The Pulse Width Modulated (PWM) duty
cycle increases (more ON time). This keeps
the Power Transistor turned ON for a longer
period of time, increasing the current
through the drive motor armature.
• The VM sends a communication signal to
the traction power amplifier. The traction
power amplifier controls current through
the drive motor field windings. Drive motor
torque is proportional to the current level in
the field windings. More current gives
greater torque.
• The speed sensor can sense even the
smallest amount of drive motor rotation. If
the truck is driven against a solid object,
the speed sensor will sense that the drive
motor cannot rotate and will disable travel
after a short time. The travel controller
must be returned to neutral position before
attempting to travel again.
PDMM-0089 Issued: 6/24/02 8-71

Current Limiting
Current Limiting
The power amplifier continually adjusts the
PWM signal from commands given by the VM so
current limit is never exceeded. The following
process occurs many times per second:
• Drive motor armature current is monitored
by the power amplifiers.
• The “ON time” of the PWM signal is reduced
by the power amplifier and VM as needed so
that maximum current is never exceeded.
• The lowered duty cycle causes the power
amplifier to limit current to traction motor.
The VM monitors vehicle operation and will
control performance as required to ensure safe
vehicle operation and prevent damage to
various systems of the truck. The following
functions are monitored and truck performance
adjusted to suit:
• Thermal limitations
• Elevated height limits
8-72 PDMM-0089 Issued: 6/24/02

Thermal Cut-Back
Thermal Cut-Back
Temperature sensors on the power amplifiers
and drive motor monitor temperatures. The
output of the drive temperature sensor is fed
into the VM. The output of the power amplifier
temperature sensor is fed into the VM via the
BUS+/– communication lines. As the
temperature rises in the traction system, the
VM reduces the maximum current. However,
plugging strength (regenerative braking) is not
reduced.
NOTE: As the temperature of the drive motor
and/or power amplifier increases,
current is reduced in a stepped manner.
The VM adjusts the current of the traction
motor as follows:
• The temperature sensor measures the
traction motor temperatures and sends the
signal to the VM at JPC10-2, and JPC10-3.
• The VM reduces the maximum allowable
current as the temperature rises.
PDMM-0089 Issued: 6/24/02 8-73

Thermal Cut-Back
8-74 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual PC Loader Program
PC Loader Program 9:
PDMM-0089 Issued: 6/24/02 9-1

PC Loader Program EASi Pacer™ Lift Truck Maintenance Manual
Overview
Overview
The control system on the EASi Pacer™ Lift

Truck does not have a removable EPROM. The
software is installed directly in the VM using
the PC Loader program. The PC Loader Program
allows you to update software, set factory
defaults, and configure options on your EASi
Pacer™ Lift Truck via the following:
• Flash Memory Program
• Blank Primary Memory
• Set Factory Defaults
• Options
Vehicle Identification
The memory for the vehicle specific information
is stored in the Operator Display Card (ODC).
There is a backup copy stored in the VM. The
back up information is uploaded to the ODC if a
blank card is installed. A pre-programmed ODC
is only required if the VM and the ODC are
replaced at the same time. When this is done
the display is blank when the truck is first
keyed ON. The PC Loader program will then
have to be used to install the latest version of
software.
Requirements
The following hardware is required to install
and access PC Loader:
• Personal Computer (PC), IBM-compatible
• 9-pin Serial Cable.
! CAUTION
We recommend using a surge
protector (available from your
Raymond Dealer) to protect your PC
from possible electrostatic discharge
or voltage surge.
9-2 PDMM-0089 Issued: 6/24/02

PC Loader Installation
PC Loader Installation
This program is installed and accessed using
either DOS or a Windows-based application.
Installation using DOS

1. Place the disk in your PC floppy drive.
2. Type a:\install at the DOS prompt. (If your
3.5 in. disk drive is not designated as “a”,
substitute the proper drive letter in its
place.
3. The program will automatically install on
your PC’s hard drive.
Installation using Windows95/98

1. Place the disk in your PC floppy drive.
2. Click on the START button located in the
lower left corner of your screen. Select RUN.
3. At the prompt, type a:\install and click OK.
(If your 3.5 in. disk drive is not designated
as “a”, substitute the proper drive letter in
its place.)
Installation using Windows v3.1

1. Locate the Program Manager icon on the
main desktop screen and open.
2. Locate the menu bar at the top of the
screen. Click on FILE.
3. From the FILE menu, select RUN.
4. At the prompt, type a:\install and use your
mouse to click on the OK button. (If your
3.5 in. disk drive is not designated as “a”,
substitute the proper drive letter in its
place.)
PDMM-0089 Issued: 6/24/02 9-3

Connect PC To Lift Truck
Connect PC To Lift Truck

1. Turn the truck key switch OFF.
2. Connect the surge protector to the COMM 1
or COMM 2 port of your computer.
! CAUTION
We recommend using a surge
protector (P/N 154-010-801) to
protect your PC from possible
electrostatic discharge or voltage
surge.
NOTE: The COMM 1 or 2 ports on most PC’s

and laptops are located on the rear of
the unit and are 9-pin “male”
connections.
3. Connect a standard 9-pin serial cable to the
surge protector.
NOTE: A DTIC cable will not work. You must
use a 9-pin serial cable.
4. Connect the cable to JC1 on the VM
mounted under the Operator Display.
Starting PC Loader
Start PC Loader from either a DOS or a
Windows-based application.
Starting PC Loader from DOS:

1. Turn the truck key switch ON.
2. Make sure you are in the main directory on
your hard drive. Your DOS prompt should
be C:\>
If you are not in the main directory, type
cd\ at the prompt and press ENTER key.
This should return you to the main
directory.
3. Type c:\raymond\loadlite\loadlite.bat at
the DOS prompt.
4. The Main Menu screen should appear on
your PC screen. Select the feature you want
to use from the Main Menu. See Figure 9-1.
9-4 PDMM-0089 Issued: 6/24/02

Starting PC Loader
Starting PC Loader from

Windows95/98
2. After starting Windows, use your mouse to
click on the START button located in the
lower left corner of your screen. Then, use
your mouse to click on the RUN icon.
3. At the prompt, type
C:\raymond\loadlite\loadlite.bat and
use your mouse to click on the OK button.
4. The main menu screen should appear on
your PC screen. See Figure 9-1.
Starting PC Loader from Windows

v3.1
2. Locate the Program Manager icon on the
main desktop screen and open it by
double-clicking on it with your mouse.
3. Locate the menu bar at the top of the
screen. Click on FILE.
4. From the FILE menu screen, select RUN by
double-clicking on it with your mouse.
5. At the prompt, type
C:\raymond\loadlite\loadlite.bat and
use your mouse to click on the OK button.
6. The Main Menu screen should appear on
your PC screen. See Figure 9-1.
PDMM-0089 Issued: 6/24/02 9-5

Troubleshooting
9opening.tif
Figure 9-1: Main Menu Screen In PC Loader
Troubleshooting
Communication Error At Start-Up
If PC Loader cannot read the truck software
when you start PC Loader, you will see the
communication error screen in Figure 9-2.
9comm.tif
Figure 9-2: Communication Error Screen At Start-Up
1. Make sure the truck key switch is ON and

that the correct communication port is
selected (1 or 2). Check the cable
connection between the truck and the PC.
2. Cycle the key switch OFF and ON.
9-6 PDMM-0089 Issued: 6/24/02

Troubleshooting
3. Restart the PC Loader.

4. If you see the screen shown in Figure 9-3,
type E (for EASi Pacer™ Lift Truck) at the
prompt.
Figure 9-3: Truck Not Recognized Screen
Communication Error During Use

If you see the screen in Figure 9-4 while you are
using PC Loader, communication with the truck
software was lost.
Figure 9-4: Communication Error Screen During Use
Make sure the truck key switch is ON. Check

the cable connection between the truck and the
PC.
PDMM-0089 Issued: 6/24/02 9-7

Flash Memory Program
Dealer Mismatch Screen

If you see the message in Figure 9-5, the truck’s
software must be updated.
Figure 9-5: Dealer Mismatch Screen
To clear the screen, perform the following:

1. Close and restart PC Loader.
2. Update the truck software. See “Flash
Memory Program”.
3. If you see the message in Figure 9-5 at any
time after you update the software, call
your local authorized Raymond Dealer.

The Flash Memory program allows you to:
• identify the current version of software on
your truck
• update the current version of software with
a newer version
Flash Programming Screen

1. To access the Flash Programming screen,
type F at the main menu prompt. See
Figure 9-6.
9-8 PDMM-0089 Issued: 6/24/02

9Opening.tif
Figure 9-6: Main Menu Screen
2. Type the number of the software version

you want to load on the truck at the flash
programming prompt. See Figure 9-7.
NOTE: To exit this menu, select A to abort. This
will return you to the main menu.
9Flash.tif
Figure 9-7: Flash Programming Screen
3. After you enter the highlighted selection:

• the Flash Memory program updates the
software
• the truck restarts automatically (you do not
need to cycle the key switch)
• the screen returns to the main screen
PDMM-0089 Issued: 6/24/02 9-9

Blank Primary Memory

The Blank Primary Memory feature allows you
to clear the memory in a truck so the Operator
Display can be used in another truck.
NOTE: The primary memory of this truck is
located on the Operator Display.
1. To access Blank Primary Memory, type B at
main menu prompt. See Figure 9-8.
2. After selecting this feature, the Blank

Primary Memory screen appears. See
Figure 9-9.
9clearcau.tif
Figure 9-9: Clear Primary Memory Caution Screen
9-10 PDMM-0089 Issued: 6/24/02

3. If you type N, the action is cancelled. If you

type Y, the memory is cleared. The truck
will then automatically restart and a new
prompt appears on your screen. See
Figure 9-10.
! CAUTION
Before removing the Operator
Display, make sure you do not cycle
the power OFF/ON. Doing so will
rewrite the memory of the truck.
9clear2.tif
Figure 9-10: Blank Primary Memory Screen
4. Turn the truck OFF. It is now safe to

remove the Operator Display from the lift
truck.
PDMM-0089 Issued: 6/24/02 9-11

Set Factory Defaults
Set Factory Defaults

The “Set Factory Defaults” feature allows you to
configure the truck to the original factory
settings.
1. Type S at the Main Menu prompt. See
Figure 9-11.
2. The program will ask you to verify your

decision to restore the factory defaults.
Enter Y if you want to restore the settings.
Enter N if you want to exit to the Main
Menu screen. See Figure 9-12.
Figure 9-12: Factory Default Settings Screen
9-12 PDMM-0089 Issued: 6/24/02

Options
Options
The Options feature allows you to:
• enable and disable options on the truck like
sideshift, attachments, electric key, etc.
• check the software version on the truck
• check the serial number of the truck
• check the manufacture date of the truck
• check the model type of the truck
Options Menu
1. To enter the Options menu, type O at the
Main Menu prompt. See Figure 9-13.
9opening.tif
2. The Options Menu screen shows the

available options that are enabled/disabled
on the truck. See Figure 9-14.
PDMM-0089 Issued: 6/24/02 9-13

Options
9options.tif
Figure 9-14: Options Menu Screen
3. Use the UP or DOWN arrows to move

through the options items.
4. To change an option setting:
a. Type Y or N to change the highlighted
option.
b. When you finish changing the options,
type X to exit.
NOTE: The option settings for “EE Truck,”
“French” and “Spanish” are for
information only. They cannot be
configured and appear as grey letters.
c. The program will then ask you to verify
the settings that you have chosen. A
message, “Write This Data to the
Vehicle?”, will appear at the bottom of
your screen. Type Y to configure the
truck or N to exit. See Figure 9-15.
9-14 PDMM-0089 Issued: 6/24/02

Options
Figure 9-15: Options Menu Verification Screen
d. After changing the option settings, the

Main Menu appears.
PDMM-0089 Issued: 6/24/02 9-15

Options
9-16 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual Appendix
Appendix A
PDMM-0089 Issued: 6/24/02 A-1

Appendix EASi Pacer™ Lift Truck Maintenance Manual
Lubrication Equivalency Chart
Lubrication Equivalency 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 liter)
(all applications) Lubricant Oil 990-655/003 (1 gal/3.8 liters)
API Service GL-5
Lift Chains Oil 10W-30 Motor Oil 990-603/04 (1 qt./0.9 liter)

API Service 990-603/03
CE,CD,CC,SG,SF (5 gal/18.9 liters)
Hydraulic Reservoir Hydraulic ISO 46 990-616/04 (1 qt./0.9 liter)

(Non-CS trucks) Fluid Anti-Wear Hydraulic 990-616/01 (1 gal/3.8 liters)
(+50° F to +120° F) Fluid 990-616/02 (2 gal/7.6 liters)
(+10° C to +49° C) 990-616/03 (5 gal/18.9 liters)
Hydraulic Reservoir Hydraulic MIL-H-5606E 990-618/TX1 (1 gal/3.8 liters)

(CS trucks) Fluid 990-618/01 (1 gal/3.8 liters)
(-20° F to -0° F)
(-29° C to -18° C)
(confined to freezer)
Hydraulic Reservoir Hydraulic ISO 32 990-617/01 (1 gal/3.8 liters)

(CS trucks) Fluid 990-617/03 (5 gal/18.9 liters)
(-20° F to +70° F)
(-29° C to +21° C)
(in and out of freezer)
Hydraulic Reservoir Hydraulic ISO 46 990-615/01 (1 gal/3.8 liters)

(high performance/ Fluid Multi-Viscous 990-615/03 (5 gal/18.9 liters)
high temp conditions) Hydraulic Fluid
Mast Uprights, Grease NLGI Grade 2 990-620/01

Bearings, (etc.) (10 cartridges/case)
990-620/02 (5 gal/18.9 liters)
Mast Uprights, Grease NLGI Grade 2 990-652/01

Bearings, (etc.) w/Teflon (10 cartridges/case)
(CS trucks) 990-652/02 (5 gal/18.9 liters)
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 pt./0.47 liter)
DOT-5
A-2 PDMM-0089 Issued: 6/24/02

Thread Adhesives, Sealants, and Lubricants
Thread Adhesives, Sealants, and Lubricants

Loctite*
Application Raymond P/N
Number/Color
Thread-locking 1/4 in. and below 990-403 222/Purple
Thread-locking 1/4 to 3/4 in. contamination tolerant 990-536 243/Blue
Thread-locking 1 in. and under 990-544 271/Red
Thread-locking 1 in. and under, contamination tolerant 990-463 603/Green
Thread-locking 1 in. and over 990-571 277/Red
Thread-locking Cleaner/Primer 990-538 7075
Thread-locking Primer 990-533 T7471
Hydraulic Sealant, fittings up to 2 in. 990-552 569
Molybdenum Anti-Seize Compound (Molykote) 990-638 Silver
Gasket Cement 990-556 Permatex 300
Cover Plate Sealant 990-443 587/UltraBlue
Corrosion Inhibitor Coating 990-456/001
Silicone Sealant (cold storage) 990-445 Dow Corning III
Figure 9-16: 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-0089 Issued: 6/24/02 A-3

Component Specific Torque/Information Chart
Component Specific Torque/Information Chart

Thread-Locking
Component Sub-Component(s) Torque to:
Compound
Drive Wheels mounting bolts (qty 8) N/A 108 ft lbs (146 N•m)
Hydraulic Steer Motor sprocket set screws P/N 990-536 N/A
Lift Cylinders end caps P/N 990-571 200 ft lbs (271 N•m)
Overhead Guard mounting bolts N/A 181 ft lbs (245 N•m)
Sideshift Carriage lower hook nut N/A 110 ft lbs (149 N•m)
Solenoid Coils securing nut N/A 5 ft lbs (7 N•m)
Solenoid Valves N/A N/A 35-40 ft lbs (47-54 N•m)
Speed Feedback Sensor mounting bolt P/N 990-536 N/A
impeller shroud
P/N 990-536 N/A
mounting screws
power cable securing 45-55 in. lb
N/A
Steer Motor nuts (5.0-6.2 N•m)
mounting bolts (qty 4) Reference “Torque Chart -
P/N 990-536 Standard (Ferrous)” on
page A-5.
sensor mounting
P/N 990-536 N/A
Steer Position screws (qty 4)
Proximity Sensor bracket mounting bolts
P/N 990-536 N/A
(qty 2)
Steer Pump mounting bolts (qty 2) P/N 990-536 N/A
Steerable Wheel Assy mounting bolts (qty 6) P/N 990-536 55 ft lb (75 N•m)
A minimum pressure of 5 tons (4536 kg) is required to press on a new

Tire Replacement
tire. If the minimum pressure is not met, replace the hub.
A-4 Revised: 5/3/04 PDMM-0089 Issued: 6/24/02

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 9-17: Torque Chart - Standard
* NOTE: Use “oiled” values for bolts with thread-locking compound
PDMM-0089 Issued: 6/24/02 A-5

Torque Chart - Metric
Torque Chart - Metric

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
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
A-6 PDMM-0089 Issued: 6/24/02

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
PDMM-0089 Issued: 6/24/02 A-7

Decimal Equivalent Chart
To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 0.397
1/32 .031 .03 0.794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700
Figure 9-18: Decimal Equivalent Chart
A-8 PDMM-0089 Issued: 6/24/02

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 9-18: Decimal Equivalent Chart
PDMM-0089 Issued: 6/24/02 A-9

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 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26
Ounces to Grams Ounces x 28.35
Grams to Ounces Ounces x 0.035
Ounces to Kilograms Ounces x 0.028
Kilograms to Ounces Kilograms x 35.27
A-10 PDMM-0089 Issued: 6/24/02

To Convert... Multiply...
Pounds to Kilograms Pounds x 0.454
Kilograms to pounds Kilograms x 2.2
Pounds per Square Inch (PSI) to Kilopascals Pounds per Square Inch x 6.894
(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 0.0704
Square Centimeter (kg/cm2)
Kilograms per Square Centimeter (kg/cm2) to Kilograms per Square Centimeter (kg/cm2) x
Pounds per Square Inch (PSI) 14.2
Inch Pounds (in. lbs.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lbs.) Newton Meters x 8.85
Foot Pounds (ft lb) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft lb) Newton Meters x 0.737
Miles per Hour to Kilometers per Hour Miles per Hour x 1.609
Kilometers per Hour to Miles per Hour Kilometers per Hour x 0.6214
Fahrenheit to Celsius (°F - 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) + 32
PDMM-0089 Issued: 6/24/02 A-11

A-12 PDMM-0089 Issued: 6/24/02

Electrical Schematics
Appendix A
Electrical Schematics
PDMM-0089 Issued: 6/24/02 A-13

A B C D
JPC7
S2
NC JPC8-9
DEADMAN
COM -5
SWITCH
NO
-16 MANAGER
ON_DEADMAN JPC10
2 12V
JPS2
-1
JPC7
-1
B+KB
-19
+12VP
A -2 -17
POSITION
STEER STEER_CHA
SENSOR
POSITION B
STEER
-3 -18
C -4 -8 -17
SENSORS -13
B+KC
JPS11 JPC10
M1 BWI
-2 -8 -4
LEFT_TRAC_BWI1 B+KA
t˚ -3 -3 -5
MUX_TEMP1_LTM B+KA
M1 -7
DGND_P -11
-4 -9 EPO_SENSE
LEFT_TRAC_BWI2
BWI
JPS12 JPC10
M2 BWI
-2 -13
RIGHT_TRAC_BWI1
t˚ -3 -2
M2 MUX TEMP2 RTM
3 -1
-4
-23
-10
DGND_P
RIGHT_TRAC_BWI2
BWI
JPS8 JPC10
MP BWI
MOTOR SENSORS
-2 -14
LIFT_BWI1
t˚ -3 -1
MP MUX_TEMP3_LM
-1 -22
POWER AMPLIFIERS
DGND_P JPC4
-4 -15
LIFT_BWI2 -9
BWI BUS+
-10
BUS-
JPC6
MULTI-FUNCTION -15
POT_SUP_(TRAVEL)
CONTROL HANDLE
-10
VR1 -13
TRAVEL_RETURN
-9
N/C
4 LIFT/LOWER
VR2
-11
-8
LIFT_POT_INPUT
POT_SUP_(LIFT)
S3
HORN 2 1 -7
HORN_INPUT
S8
TILT UP 2 1 -3
CONTROL HANDLE
TILT_UP_INPUT
S9
TILT DN 2 1 -4
TILT_DN_INPUT
S6
S/S RIGHT 1 -6
2
S/S_RIGHT_INPUT
S7
2 -5
1
S4
OPTION A 2 1 -1
OPTION_A_INPUT
S5
OPTION B 2 1 -2
OPTION_B_INPUT
-14
DGND_P
-12
N/C
5 X Y
JPC8
-18 JPD2
-1 -1 -5
CONTACTOR PANEL
-19 +12 VP
X Y -20 -3 -3 -3 DN
DATA_LATCH
DISPLAY/INPUT KEYS
DISP_MISO
-14 -5 -5
ALARM_PWM -1 ENTER
B+ KC -6 -6
-21 SHIFT_CLOCK
-7 -7 -2
Y DGND -8 -8 -4
DISPLAY
X
JPS3 JPC10
-1 -4 -6
FEEDBACK
HE_SUPPLY1
LEFT -2 -12
SPEED
JPC8
(MD1) SPEED
SENSOR -6
GEAR_SENSE1 -6
-3 DGND
HE_DGND -1
JPS4 JPC10 -2
FEEDBACK
-1 -5 B-F -3
HE_SUPPLY2
SPEED
RIGHT -2 -11 -12

6 SENSOR -3 -7
HE_DGND
JPC9
-3
B+KA
JPB3 JPC10 2 1
(LEFT) -1
B1 LEFT_BRAKE1
2 1
-1 -20 -8 1 2
-9 (P2 DUMP SOL)
HORN & BRAKES
B2 RIGHT_BRAKE2
-1 -21
-6 2 1 1
B+KB
LOAD_HLD_SOL SOL1
JPC8
1 -15 2 1
SOLENOID
-7
CONTROL
B+KA SOL5_OUT SOL5

H -16
2 2 1
HORN ENABLE -10
2 1
-2
2 1
7 PROP_LWR_SOL
-5
SOL3
JPH1
-11 1 2
B+KA-P -1
SOL2
OPTIONAL
-12 -2 (SHT 2)
SIDE_SHIFT_OUT
A B C D
9P31001 1a.eps
Figure A-19: EASi Pacer™ Lift Truck Electrical Schematic (Sheet 1 of 2)
A-14 PDMM-0089 Issued: 6/24/02

E F G H
TS1-1
TS1-2
TS1-3
K1
FU9 (5A) JPF1-1
2
KEYSWITCH S1
2 1 JPF3-4 2 1
JPF3-2 FU7 (15A) -10
JPF2-5 2 1 -3
K3 K2 FU5 (15A)
JPF2-7 -8
T-1 2 1 -9
K3 K2 K1
JPF2-2
JPF2-8
JPF2-1
JPF2-6
JPF4-1
JPF5-1
JPF5-2
JPF5-4
JPF5-5
JPTL1
B+
TPC FU2
600A TP1
B+ 3
-1 B+K2
2 1
(LSFF)
F1
AMPLIFIER 500A 40A
(LEFT)
JPTL2 M1
-3
F2
BUS+ LA E2 A2
-6 BUS-
1 1 JP
M- LPC STR B+
-4 BUS- B- 2 2
-5 TERM
JPTR1 B+
-1
B+K2
-21
NODE SELECT
(RSFF) +
JP 4
F1 CONTACTOR B-
JPTR2 A1 FUSE
-3 AMPLIFIER PANEL
(RIGHT) -
BUS+
-6 M2
BUS-
F2
E2 A2
-4 BUS- RA
-5 TERM M-
B- TP4
JPL1 B+
-1
B+K2
JPL2
-3
BUS+
-6 D
BUS-
LIFT/AUXILIARY
POWER AMPLIFIER
5
JPF3
MP -1
-4 1
BUS-
-5
TERM PA A S21
M- EPO -3
2
B-
JPF5
-3 JPF1-5
-6
-11
FU10
JPF2 15A
-4 2 1 -12
-9
-10
-11
-12
JPF4-2
JPF1-13
TS2-1 H FU6
CAD
2 15A 1 -14
TS2-2
FU8
2 5A 1 -7
TS2-3
E F G H
1P31001 1b.eps
EASi Pacer™ Lift Truck Electrical Schematic (Sheet 2 of 2)
PDMM-0089 Issued: 6/24/02 Revised: 5/3/04 A-15

A B C D
NOTES;
1. FOR POWER DISTRIBUTION DIAGRAM, SEE 223-001-002.
2. FWD REFERS TO THE FORKS-FIRST DIRECTION.
LPC CONTACTOR POWER DISCONNECT- LIFT
3. LEFT AND RIGHT SIDE ARE REFERENCED TO OPERATORS POSITION FACING THE FORKS.
2
STR CONTACTOR POWER DISCONNECT- STEER
TPC CONTACTOR POWER DISCONNECT- TRACTION
DA5 DIODE ASSY FOR SS AND 2 H.S. FUNCT. (ATTACH MTD)
S1 KEYSWITCH
FU8 FUSE 5 AMP ON FUSE/RELAY PCB
S2 DEADMAN SWITCH
S3 SWITCH HORN
S4 SWITCH OPTION A CONTROL
FU5 FUSE 15 AMP ON FUSE/RELAY PCB HANDLE
S5 SWITCH OPTION B
S6 SWITCH SIDE SHIFT RIGHT (OPT.)
FU12 FUSE 1.5 AMP INLINE FUSE FOR FLASHING LIGHT
S7 SWITCH SIDE SHIFT LEFT (OPT.)
FU2 FUSE 600 AMP DRIVE MOTOR FUSE ON CONTACTOR PANEL
S8 SWITCH TILT UP
FU3 FUSE 500 AMP LIFT MOTOR FUSE ON CONTACTOR PANEL
S9 SWITCH TILT DOWN
FU1 FUSE 40 AMP STR MOTOR FUSE ON CONTACTOR PANEL
S10 & S15 SWITCH FOR WORKING LIGHTS (OPT.)
FU13 FUSE 1.5 AMP INCLINE FUSE FOR FAN (OPTION)
S11 SWITCH HIGH SPEED/MAST LIMIT (OPT.)
H HORN
S12 SWITCH LIFT LIMIT (OPT.)
H2 TRAVEL ALARM (OPT.)
S18 SWITCH MAST TILT (OPT.)
3 JP3 CONNECTOR ON STROBE LIGHTS

S36
S21
SWITCH FAN (OPT.)
SWITCH EPO
JP48 CONNECTOR ON OVER THE MAST CABLE (CARRIAGE SIDE) S22 BATTERY GATE SWITCH (OPT.)
JPA1 CONNECTOR ON ATTACHMENT CARD TO VM SOL1 THRU 12 SOLENOIDS
JPA2 CONNECTOR ON ATTACHMENT CARD ATTACHMENT SOLENOIDS SPL5 & 6 SPLICES FOR WORKING LIGHTS (OPT.)
JPA3 CONNECTOR ON ATTACHMENT CARD TO BATTERY GATE SWITCHES TP1,TP4 & TP5 TY-POINTS
JPB+ CONNECTOR ON BATTERY VM VEHICLE MANAGER
JPB- CONNECTOR ON BATTERY TS1 TERMINAL STRIP, FUSE/RELAY CARD
JPB1 CONNECTOR ON BUMP DETECTOR TS2 TERMINAL STRIP, FUSE/RELAY CARD
JPB2 CONNECTOR ON RIGHT BRAKE TS3 TERMINAL STRIP, EE ENCLOSURE (OPT)
JPB3 CONNECTOR ON LEFT BRAKE
2 HIGH SPEED ATTACHMENT & 1 LOW SPEED
JPD1 CONNECTOR ON OPERATOR DISPLAY MOUNTED ON CARRIAGE OR ATTACHMENT
JPD2 CONNECTOR ON OPERATOR DISPLAY TO OVERLAY
1 2
JPC10 CONNECTOR VM TO BRAKES, MOTOR SENSORS B+KA FROM SOL 6
SOL12
JPC11 CONNECTOR VM TO WEIGHT SENSOR
TO SOL 7
4 JPC12
JPC6
CONNECTOR VM TO LIFT LIMIT & SPEED LIMIT SWITCHES
CONNECTOR VM TO MULTI-FUNCTION CONTROL HANDLE JP48 JPH2
-1 -1
JPC1 CONNECTOR VM TO LOADER MODULE/SMARTI OPTION
JPC9 CONNECTOR VM TO HYD. MANIFOLD 1 2
-2 -2
JPC3 NOT USED SOL10
JPC4 CONNECTOR VM TO TRACTION POWER AMP (LEFT)
1 2
JPC2 NOT USED -3 -3
JPC7 CONNECTOR VM TO OPTIONAL FEATURES, DEADMAN, & STEER POSITION SENSOR SOL11
JPC8 CONNECTOR VM TO CONTACTOR PANEL & HORN

JPC5 CONNECTOR VM TO DISPLAY -4 -4
JPF1 CONNECTOR FUSE/RELAY CARD TO B+/B-

1 2
JPF2 CONNECTOR FUSE/RELAY CARD TO VM
-5 -5
JPF3 CONNECTOR FUSE/RELAY CARD TO S1,EPO SOL2
JPF4 CONNECTOR FUSE/RELAY CARD TO ATTACHMENT CARD

JPF5 CONNECTOR FUSE/RELAY CARD TO TRACTION AND LIFT PA'S ALL SOLENOIDS ARE OVER-THE-MAST
CARRIAGE MOUNTED CABLE ASSEMBLY
5 JPF6
JPF7
CONNECTOR ON EE ENCLOSURE (OPT)
CONNECTOR ON EE ENCLOSURE (OPT)
JPH1
-2 -1
JP48
JPH1 CONNECTOR FOR SIDE SHIFT OPTION
-1
JPH2 CONNECTOR ON OVER THE MAST CABLE
JPL1 CONNECTOR LIFT POWER AMP 1 2
DA5 -2
JPL2 CONNECTOR LIFT POWER AMP SOL10
JPTL1 CONNECTOR TRACTION POWER AMP (LEFT)
JPTL2 CONNECTOR TRACTION POWER AMP (LEFT) 1 2
-3
SOL11
JPTR1 CONNECTOR TRACTION POWER AMP (RIGHT)
JPTR2 CONNECTOR TRACTION POWER AMP (RIGHT)
-4
JPS1 CONNECTOR VM TO SMARTi/EMS MODULE
JPS2 CONNECTOR STEER POSITION SENSOR
1 2
JPS3 CONNECTOR LEFT TRACTION MOTOR SPEED SENSOR -5
SOL2
JPS4 CONNECTOR RIGHT TRACTION MOTOR SPEED SENSOR
JPS5 CONNECTOR HIGH SPEED LIMIT SWITCH
6 JPS6 CONNECTOR LIFT LIMIT SWITCH SOLENOIDS 2 & 10 ON CARRIAGE

SOLENOID 11 ON ATTACHMENT
JPS7 NOT USED
JPS8 CONNECTOR LIFT MOTOR BWI & TEMP SENSOR
FU12 FU7
JPS10 NOT USED 1.5A 15A
1 2 JP3 TS1-2
JPS11 CONNECTOR LEFT TRACTION MOTOR BWI & TEMP SENSOR -1
B+
ROTATING LIGHT
JPS12 CONNECTOR RIGHT TRACTION MOTOR BWI & TEMP SENSOR 2 1
STROBE
JPS13 CONNECTOR FOR BATTERY GATE SWITCHES (OPT) OR
STROBE OR
ROTATING
JPS14 CONNECTOR FOR BATTERY GATE SWITCHES (OPT) LIGHT FU6
JPWL1 CONNECTOR ON RIGHT WORKING LIGHT JP3 TS2-2 15A
-2
JPWL2 CONNECTOR ON LEFT WORKING LIGHT B-
2 1
JPWL3 CONNECTOR ON REVERSE WORKING LIGHT
JPWL4 INTERCONNECTION TO JPL2
JPWL5 INTERCONNECTION TO JPL1
K1 KEYSWITCH RELAY- OPTIONS FU13
1.5A FU7
1 2 TS1-2 15A
K2 KEYSWITCH RELAY- SOLENOIDS,ATTACHMENTS,HORN 2 1
B+
K3 KEYSWITCH RELAY- BRAKES,CONTACTORS,POWERAMPS
7 M1 LEFT DRIVE MOTOR FAN ACCESSORY
CIRCUIT
FU6
M2 RIGHT DRIVE MOTOR TS2-1 15A
2 1
B-
MP LIFT PUMP MOTOR
1 2
MS STEER PUMP MOTOR
S36
A B C D
1P31001 2a.eps
Figure A-20: EASi Pacer™ Lift Truck Optional Features Electrical Schematic (Sheet 1 of 2)
A-16 PDMM-0089 Issued: 6/24/02

.
E F G H
BATTERY GATE SWITCHES
S22B S22A
JPS1
-7
JPC1
-1
(JPC8-15)
2
JPS13 (RIGHT)
BUS-
JPS14 (LEFT)
B+KA
+VS
+VS
-2 H
TXD_OUT
OUT
OUT
GND
GND
-3
RXD_IN
FLASH/SMARTI/EMS
-4
SMARTI/EMS (OPT)
-6
BUS+
+
+
0
0
-
-
-5 -5
DGND JPC8 TRAVEL
-2 -3 -1 -2 -3 -6 -22 H2 ALARM/LIGHT
NC
-7
BOOT
-8
NC
-8 -5 -3 -9 -9
+12VF
BOTTLER'S
JPA3
ATTACHMENT TILT + +VS
CARD OPTION REVISIONS
0
(OPTIONAL)
S18
VEHICLE MANAGER
OUT
3
(OPTIONAL FEATURES) - GND
JPC12 JPS5
JPA1 JPC7 -1 -1 + +VS
-1 -15
BATTERY GATE
-6 -2 0
-2 -4 MAST
+12VP S11
OUT LIMIT SWITCH
-3 -13
ATTACH_SW1
-14 -3 -3 - GND
-4
ATTACH_SW2
-5 -12
PRESS_OPT_IN
ATTACHMENTS
-6 -9
SOL12_EN
JPA2 -20
-7 JPC12
-8 SOL10_EN JPS5
AUX_DUMP_SOL -8 -10 -1 -1 + +VS
SOL11_EN
+12VP
LIMIT SWITCH
-9 -7
HIGH SPEED
DGND
HI_SPEED_LIMIT
-6 -2 0
OUT S11
HIGH SPEED
LIMIT SWITCH
4
-3
B+KA
-3 -3 - GND
DGND
-9
HS AUX1_SOL
JPC12 JPS6
-4 -1 + +VS
-10 +12 VP
HS AUX2_SOL
LIFT LIMIT
-5 -2 0
SWITCH
LIFT_LIMIT LIFT
OUT S12 LIMIT SWITCH
-4 -2 -
B+KA -3 GND
JPF4-1
DGND
-5
JPF4-2 B-F
JPC11
JPB1 JPC7 -4
-3 -11 RED
BUMP_IN +12VP
BUMP
-2 -19
DETECTOR
BUMP_TEST_OUT -3
GRN PRES.
WEIGHT
5
WEIGHT SENSOR
BUMP DETECTOR
PRESSURE_IN SENSOR
SENSOR
-1 -3 #1
+12 VP -2
BLK
DGND
-4 -6
DGND
-1
DGND SHLD
JPWL3
-1
FU9
5A
1
S10
2
JPWL5
-1
JPWL1
-1 6
1 2 TS1-1 JPWL4 JPWL2
-1 -1
B+ WORK
LEFT LIGHTS REV
2 1 1 1 RIGHT 1
S15
FU6
15A
JPWL4 JPWL2
1 2 TS2-2
-2 -2 2 2 2
B-
JPWL5 JPWL1
-2 -2
JPWL3
-2
TS2-1
E F G H
1P31001 2b.eps
EASi Pacer™ Lift Truck Optional Features Electrical Schematic (Sheet 2 of 2)
PDMM-0089 Issued: 6/24/02 A-17

A B C D
X Y
STR-2/ STR
TP-5
TS1-1
X Y
TPC TS1-2
TS1-3
JPF6
TS3-13 -13
STR-X LPC
TS3-9 -9 X Y
TPC-X
TS3-10 -10
LPC-Y K2
TS3-11 -11 K3
LPC-X
TS3-8 -8
TPC-Y
3
TS3-12 -12
STR-Y
TS3-1 -1
TS3-2 -2
OPTIONS
TS3-3 -3
-14
TS3-4 -4
FU-T1
TS3-5 -5
T-1
TS3-6 -6
OPTIONS
TS3-7 -7
JPF2 JPF7 JPF2

-1 -17 -1
-5 -20 -5
-7 -22 -7
-2 -18 -2
4 -8
-6
-23
-21
-8
-6
-4 -19 -4
-9 -24 -9
-10 -25 -10
-11 -26 -11
-12 -27 -12
JPF7 JPF1
-2 -7
-5 -13
-6 -14
TP4
-1 -5
-3 -11
-4 -12
5
JPF3 JPF3
-2 -12 -2
-1 -11 -1
-4 -14 -4
-3 -13 -3
JPF5 JPF5
-1 -7 -1
-2 -8 -2
-4 -9 -4
-5 -10 -5
6 JPF4 JPF7 JPF4

-1 -15 -1
-2 -16 -2
TS2-1
FU6
TS2-2 2 15A 1
FU8
TS2-3 2 5A 1
A B C D
1P31001 3a.eps
Figure A-21: EASi Pacer™ Lift Truck“EE” Contactor Enclosure (Sheet 1 of 2)
A-18 PDMM-0089 Issued: 6/24/02

E F G H
2
"EE" CONTACTOR ENCLOSURE
FU9 (5A) JPF1-1

2 1
K1 FU7 (15A)
-10
2 1 -3
FU5 (15A)
-8
2 1 -9
K3 K2 K1
TPC-2
TO
TRACTION POWER
AMP (B+)
TPC FU2
600A TP1 B+
TP1
2 1
FU3 FU1
500A 40A
4
1 1
LPC STR
2 2
JP
B+
STR-2
JP
B-
+
5
MS
TP4
FU10
2 15A 1
E F G H
1P31001 3b.eps
EASi Pacer™ Lift Truck“EE” Contactor Enclosure (Sheet 2 of 2)
PDMM-0089 Issued: 6/24/02 A-19

Standard Auxiliary Function
PP LP
M SOL7
SOL1
LIFT/
LOAD
AUX1
HOLD C
3 1 2
P1 P1 2
LIFT/ 1
LIFT
H/S AUX
3 2 2
SOL5
P2 2
SOL3
1
DUMP PROP
PLUG LOWER
1 REL1
1 3
P2 P2 PFR
1 3 T1
LIFT/ SOL8 2 4 SOL4
2 1
AUX LIFT/ SOL6 TILT
AUX2 AUX
1 DIR CB1
3
1 2 2 1
T2
M 3
3 4 4 3 CB2
TILT
2 1
P3
A1 A2
2
P1 P2
SR SOL2
1
SIDESHIFT
2 1 A1
AP 2 4 3
REL2 A2
SIDE
SHIFT
T 1
Figure A-22: Serial Numbers 0100-1729 with Standard Aux Function
PP LP
M SOL-7
SOL-1
LIFT/
LOAD
AUX1
HOLD C
3 1 2
P1 P1 2
LIFT/ 1
LIFT
H/S AUX
3 2 2
SOL-5
P2 2
SOL-3
1
DUMP PROP
PLUG LOWER
1 REL-1
1 3
P2 P2 2
1
T1
LIFT/ 3 SOL-4
2 1
LIFT/ AUX
AUX2 DIR CB-1
3
1 2 2 1
T2
M 3
3 4 4 3 CB-2
TILT
2 1
P3
A1 A2
2
P1 P2
SR SOL-2
1
SIDESHIFT
2 1 A1
AP 2 4 3
REL-2 A2
SIDE
SHIFT
T 1
Figure A-23: Serial Numbers 1730 and Up with Standard Aux Function
A-20 PDMM-0089 Issued: 6/24/02

High Speed Auxiliary Function

PP LP
M SOL7
SOL1
LIFT/
LOAD
AUX1
HOLD C
3 1 2
P1 P1 1
LIFT/ 2 1 LIFT
H/S AUX
1
3 2
SOL5 2 SOL3
P2 SOL12 2 PROP
AUX REL1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 PFR
1 3 T1
LIFT/ 2 4
2 1
AUX SOL8
SOL6
LIFT/
AUX SOL4 ATTACHMENT
AUX2 1 CB1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB2
TILT
2 1
P3
A1 A2
SOL11
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL9 A2
T PROP HI FLOW
REL2 2 SOL2 AUX. 2
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
Figure A-24: Serial Numbers 0100-1729 with High Speed Aux Function
PP LP
M SOL-7
SOL-1
LIFT/
LOAD
AUX1
HOLD C
3 1 2
P1 P1 1
LIFT/ 2 1 LIFT
H/S AUX
1
3 2
SOL-5 2 SOL-3
P2 SOL-12 2 PROP
AUX REL-1
1
DUMP LOWER
DUMP 2
1 3
P2 P2 2
1
T1
LIFT/ 3
2 1
AUX SOL-8
SOL-6
LIFT/
AUX2 CB-1
3 4 4 3
T2 FUNCTION
M 3
1 2 1 2 CB-2
TILT
2 1
P3
A1 A2
SOL-11
2
H/S AUX1
2 1
A1
SR 4 3
1 A2
HI FLOW
SOL-11
AUX. 1
H/S AUX2
AP 1 A1
2 1
4 3
SOL-9 A2
T PROP HI FLOW
SIDESHIFT
2 1 A1
4 3
A2
SIDE ATTACHMENT
SHIFT PRIMARY
FUNCTION
Figure A-25: Serial Numbers 1730 and Up with High Speed Aux Function
PDMM-0089 Issued: 6/24/02 A-21

A-22 PDMM-0089 Issued: 6/24/02

Attachment Configurations
Appendix A
Attachment Configurations
PDMM-0089 Issued: 6/24/02 A-23

Overview
Overview
The EASi Pacer™ Lift Truck is designed to
handle a variety of attachment configurations.
In most cases, the physical configuration of the
truck is done at the factory.
This means that different solenoids are used for
different functions, depending on the
attachment. The physical configuration of your
truck may not match the standard electrical
schematic in the Appendix.
It is important to make sure that you have
activated or deactivated the appropriate menu
selections. The PC Loader software program is
used to toggle different functions ON or OFF.
If you do not have your EASi Pacer™ Lift Truck
configured properly, the attachment will not
function properly.
See Table A-1 to determine the proper
configuration for your application and
attachment. The last column in the table refers
to customized schematics which represent the
specific electrical configuration of the
associated configuration.
A-24 PDMM-0089 Issued: 6/24/02

Overview
Table A-1: Attachment Configurations

Sideshift Sideshift HSA #1 HSA #2
PC Loader See
Function on on on on Setting Config Mode Schem.
SOL2? SOL11? SOL10? SOL11?
Standard Y-
N N N Sideshift: “YES” Sideshift: “ON” A
Sideshift Tractor
1 Low Speed Y* -
N N N Sideshift: “YES” Sideshift: “ON” A
Aux Tractor
1 High Speed Y-
N N N Attachment: “YES” HSA#1 Menu: Setup B
Aux Carriage
Standard
Y- Y- Sideshift: “YES” Sideshift: “ON”
Sideshift & 1 N N C
Carriage Carriage Attachment: “YES” HSA#1 Menu: Setup
High Speed Aux
Standard Sideshift: “ON”
Y- Y- Y- Sideshift: “YES”
Sideshift & 2 N HSA#1 Menu: Setup C
Carriage Carriage Carriage Attachment: “YES”
High Speed Aux HSA#2 Menu: Setup
Standard Sideshift: “ON”
Y- Y- Y- Sideshift: “YES”
Sideshift & 2 N HSA#1 Menu: Setup D
Carriage Carriage Attach Attachment: “YES”
High Speed Aux HSA#2 Menu: Setup
1 Low Speed
Y*- Y- Sideshift: “YES” Sideshift: “ON”
Aux & 1 High N N C
Carriage Carriage Attachment: “YES” HSA#1 Menu: Setup
Speed Aux
1 Low Speed Sideshift: “ON”
Y* - Y- Y- Sideshift: “YES”
Aux & 2 High N HSA#1 Menu: Setup C
Carriage Carriage Carriage Attachment: “YES”
Speed Aux HSA#2 Menu: Setup
1 Low Speed
Y* - Y- Sideshift: “YES” Sideshift: “ON”
Aux and 1 High N N C or D
Attach Attach Attachment: “YES” HSA#1 Menu: Setup
Speed Aux
1 Low Speed Sideshift: “ON”
Y* - Y- Y- Sideshift: “YES”
Aux and 2 High N HSA#1 Menu: Setup C or D
Attach Attach Attach Attachment: “YES”
Speed Aux HSA#2 Menu: Setup
2 High Speed Y- Y- HSA#1 Menu: Setup
N N Attachment: “YES” C or D
Aux Carriage Carriage HSA#2 Menu: Setup
2 High Speed Y- Y- HSA#1 Menu: Setup
N N Attachment: “YES” C or D
Aux Attach Attach HSA#2 Menu: Setup
2 Speed
Y- Y- HSA#1 Menu: Setup
Sideshift & 1 N N Attachment: “YES” C
Carriage Carriage HSA#2 Menu: Setup
High Speed Aux
2 Speed
Y- Y- HSA#1 Menu: Setup
Sideshift & 1 N N Attachment: “YES” C or D
Attach Attach HSA#2 Menu: Setup
High Speed Aux
* SOL2 is used to control hydraulic fluid to the low speed attachment instead of the sideshifter.
PDMM-0089 Issued: 6/24/02 A-25

Attachment Schematic A
Attachment Schematic A
JPC7
S2
NC
COM
DEADMAN
-5
DGND
SWITCH
NO
-16
ON_DEADMAN
JPS2 JPC7
12V -1 -1
+12VP
A -2 -17
STEER
POSITION
STEER_CHA
SENSOR
POSITION B -3 -18
STEER_CHB
STEER
SENSOR
C -4 -8
STEER_CHC
VEHICLE
MANAGER
JPH1
B+KA FROM SOL 9
-1
JPC9
(223-001-001 SHT 1, D-7)
1 2
-2 -12
SOL2 SIDE_SHIFT_OUT
LOCATED ON TRACTOR
STANDARD SIDE SHIFT ONLY
Figure 1-26: Standard Sideshift Attachment
A-26 PDMM-0089 Issued: 6/24/02

Attachment Schematic B
Attachment Schematic B
JPC7
S2
NC
COM
DEADMAN
-5
DGND
SWITCH
NO
-16
ON_DEADMAN
JPS2 JPC7
12V -1 -1
+12VP
A -2 -17
STEER
POSITION
STEER_CHA
SENSOR
POSITION B -3 -18
STEER_CHB
STEER
SENSOR
C -4 -8
STEER_CHC
VEHICLE
MANAGER
ATTACHMENT
CARD
JPA1 JPC7
-1 -15
BATTERY GATE
-2 -4
+12VP
-3 -13
JPA2 ATTACH_SW1
1 2 -14
B+KA FROM SOL 6 TO SOL 7 -8 -4
ATTACH_SW2
SOL12 AUX_DUMP_SOL
-5 -12
(223-001-001 SHT 1, D-6) PRESS_OPT_IN
-6 -9
ATTACHMENTS
SOL12_EN
-7 -20
SOL10_EN
LOCATED ON TRACTOR -8 -10
SOL11_EN
-9 -7
DGND
-3
B+KA
1 2
-9
SOL10 HS AUX1_SOL
LOCATED ON TRACTOR
-4
JPF4-1 B+KA
-5
JPF4-2 B-F
SINGLE HSA ONLY
Figure 1-27: Single HSA Attachment
PDMM-0089 Issued: 6/24/02 A-27

Attachment Schematic C
Attachment Schematic C
JPC7
S2
NC
COM
DEADMAN
-5
DGND
SWITCH
NO
-16
ON_DEADMAN
JPS2 JPC7
12V -1 -1
+12VP
A -2 -17
STEER
POSITION
STEER_CHA
SENSOR
POSITION B -3 -18
STEER_CHB
STEER
SENSOR
C -4 -8
STEER_CHC
VEHICLE
MANAGER
ATTACHMENT
CARD
JPA1 JPC7
-1 -15
BATTERY GATE
-2 -4
+12VP
JPA2 -3 -13
1 2 ATTACH_SW1
B+KA FROM SOL 6 TO SOL 7 -8 -14
-4
SOL12 AUX_DUMP_SOL ATTACH_SW2
(223-001-001 SHT 1, D-6) -5 -12
PRESS_OPT_IN
-6 -9
ATTACHMENTS
SOL12_EN
-7 -20
SOL10_EN
LOCATED ON TRACTOR -8 -10
SOL11_EN
-9 -7
DGND
JP48 JPH2
-1 -1 -3
B+KA
1 2
-2 -2 -9
SOL10 HS AUX1_SOL
1 2
-3 -3 -10
SOL11 HS AUX2_SOL
-4 -4
-4
JPF4-1 B+KA
1 2 -5
JPF4-2 B-F
-5 -5
SOL2
ALL SOLENOIDS ARE OVER-THE-MAST

CARRIAGE MOUNTED CABLE ASSEMBLY
JPH1
B+KA FROM SOL 9 JPC9
-1
(223-001-001 SHT 1, D-7)

-2 -12
SIDE_SHIFT_OUT
1 OR 2 HSA AND/OR SIDE SHIFT
Figure 1-28: 1or 2 HSA and/or Sideshift Attachments
A-28 PDMM-0089 Issued: 6/24/02

Attachment Schematic D
JPC7
S2
NC
COM
DEADMAN
-5
DGND
SWITCH
NO
-16
ON_DEADMAN
JPS2 JPC7
12V -1 -1
+12VP
A -2 -17
STEER
POSITION
STEER_CHA
SENSOR
POSITION B -3 -18
STEER_CHB
STEER
SENSOR
C -4 -8
STEER_CHC
VEHICLE
MANAGER
ATTACHMENT
CARD
JPA1 JPC7
-1 -15
BATTERY GATE
-2 -4
+12VP
-3 -13
JPA2 ATTACH_SW1
1 2 -4 -14
B+KA FROM SOL 6 TO SOL 7 -8 ATTACH_SW2
SOL12 AUX_DUMP_SOL -12
-5
(223-001-001 SHT 1, D-6) PRESS_OPT_IN
-6 -9
ATTACHMENTS
SOL12_EN
-7 -20
SOL10_EN
-8 -10
LOCATED ON TRACTOR SOL11_EN
-9 -7
DGND
JP48 JPH2
-1 -1 -3
B+KA
1 2
DA5 -2 -2 -9
SOL10 HS AUX1_SOL
1 2
-3 -3 -10
SOL11 HS AUX2_SOL
-4 -4
-4
JPF4-1 B+KA
1 2 -5
JPF4-2 B-F
-5 -5
SOL2
SOLENOIDS 2 & 10 ON CARRIAGE OVER-THE-MAST

SOLENOID 11 ON ATTACHMENT CABLE ASSEMBLY
JPH1
B+KA FROM SOL 9 JPC9
-1
(223-001-001 SHT 1, D-7)

-2 -12
SIDE_SHIFT_OUT
1 OR 2 HSA AND/OR SIDE SHIFT

(WITH DIODE MODULE)
Figure 1-29: 1 or 2 HSA and/or Sideshift w/Diode Attachments
PDMM-0089 Issued: 6/24/02 A-29

A-30 PDMM-0089 Issued: 6/24/02

EASi Pacer™ Lift Truck Maintenance Manual Index
Index I:
A Charts
Decimal Equivalent . . . . . . . . . . . . . . . . . A-8
Abbreviations List . . . . . . . . . . . . . . . . . . . . . . 1-5 Electrical Connector . . . . . . . . . . . . . . . 5-15
Active Maintenance Mode . . . . . . . . . . . . . . . 3-4 Torque
Adhesives, Thread . . . . . . . . . . . . . . . . . . . . . .A-3 Component Specific . . . . . . . . . . . . . A-4
Alarm Test . . . . . . . . . . . . . . . . . . . . . 6-136, 6-137 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Analog Tests . . . . . . . . . . . . . . . . . . . . 6-67 to 6-88 Standard - Brass . . . . . . . . . . . . . . . A-7
Antistatic Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Standard (Ferrous) . . . . . . . . . . . . . A-5
Armature Current Checking Hydraulic Oil Level, see Oil
Traction Motor #1 Test . . . . . . . . . . . . . 6-68 Cleaning, Motor . . . . . . . . . . . . . . . . . . . . . . . 7-60
Traction Motor #2 Test . . . . . . . . . . . . . 6-69 Codes
Attachment Configurations . . . . . . . . . . . .A-23 CAN Bus . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Auxiliary Functions . . . . . . . . . . . . . . . . . . . 8-40 Power Amplifier . . . . . . . . . . . . . . . . . . . . 6-8
Auxiliary Functions, Troubleshooting . . 5-19 Summary Tables . . . . . . . . . . . . . . . . . . . 6-5
Axle Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Codes and Messages . . . . . . . . . . . . . 6-9 to 6-66
Cold Storage Conditioning . . . . . . . . . . . . . 7-58
Component Locator Photos . . . . . . . 7-3 to 7-10
B Configure Mode . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Configure Mode Settings . . . . . . . . . . . . . . 3-10
Battery Contactor Coils . . . . . . . . . . . . . . . . . . . . . . . 8-53
Discharge Indicator Test . . . . . . . . . . . 6-76 Contactor Fuse Panel . . . . . . . . . . . . . . . . . 7-53
Maintenance . . . . . . . . . . . . . . . . . . . . . . 8-54 Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
Safety . . . . . . . . . . . . . . . . . . . . . . . . 2-7 to 2-11 LPC Test . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
State of Charge, Theory . . . . . . . . . . . . 8-54 STR Test . . . . . . . . . . . . . . . . . . . . . . . . . 6-118
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Testing Resistance . . . . . . . . . . . . . . . . 7-55
Bearings, Motor . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Tip Inspection . . . . . . . . . . . . . . . . . . . . . 7-55
Bleeding Hydraulic System . . . . . . . . . . . . 7-70 TPC Test . . . . . . . . . . . . . . . . . . . . . . . . . 6-116
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Control Handle . . . . . . . . . . . . . . . . . . . . . . . 7-27
Air Gap Adjustment . . . . . . . . . . . . . . . . 7-45 Replacement . . . . . . . . . . . . . . . . . . . . . . 7-29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Control Module Installation . . . . . . . . . . . 7-31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Conversions, Standard/Metric . A-10 to A-11
Removal and Installation . . . . . . . . . . . 7-46 Current Limiting . . . . . . . . . . . . . . . . . . . . . . 8-72
Stromag Two-Stage . . . . . . . . . . . . . . . . 7-48 Cylinders, Lift . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Brakes
Traction Motor #1 Test . . . . . . . . . . . . 6-135
D
Brush Wear Indicator
Tests . . . . . . . . . . . . . . . . . . .6-99, 6-101, 6-103 Deadman
BUS+/BUS- . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54 Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63
Switch Test . . . . . . . . . . . . . . . . . . . . . . . 6-90
Decimal to Fraction Conversion . . . . . . . . A-8
C Default Passwords, see Passwords
Design, Manual . . . . . . . . . . . . . . . . . . . . . . . . 1-4
CAN Bus Troubleshooting . . . . . . . . . . . . . 5-10 Digital Input Tests, see Tests
Chain, Steering . . . . . . . . . . . . . . . . . . . . . . . 7-24 Digital Output Tests, see Tests
Directional Control . . . . . . . . . . . . . . . . . . . . 8-67
Discharge Indicator Test . . . . . . . . . . . . . . 6-76
Display, Operator . . . . . . . . . . . . . . . . . . . . . 7-25
PDMM-0089 Issued: 6/24/02 I-1

Index EASi Pacer™ Lift Truck Maintenance Manual
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . 7-33 Hydraulic Components . . . . . . . . . .7-69 to 7-81

Drive Motor, see Motors Hydraulic Fluid, see Oil
Hydraulic Oil, Selecting, see Oil
E Hydraulic Schematics . . . . . . . . . . . . . . . . A-20
Hydraulic System
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Electric Motor Tests . . . . . . . . . . . . . . . . . . . 7-61
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Electrical
Troubleshooting . . . . . . . . . . . . . . . . . . . 5-18
Components . . . . . . . . . . . . . . . . . . . . . . 7-51
Connector Locator Chart . . . . . . . . . . 5-15
System, Troubleshooting . . . . . . . . . . . 5-2 J
Electrostatic Discharge . . . . . . . . . . 5-3, 9-2, 9-4
ESD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Precautions . . . . . . . . . . . . . . . . . . . . . . . 2-12
K
F
Kit, Antistatic . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Fault Codes
Communications . . . . . . . . . . . . . . . . . . . 6-6 L
Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Function Controller . . . . . . . . . . . . . . . . 6-7
Learn Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Lift System . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
LED Diagnostics, Power Amplifier . . . . . . . 6-8
MTX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Lift Amp Temp Test . . . . . . . . . . . . . . . . . . . . 6-86
Operator Controls . . . . . . . . . . . . . . . . . . 6-6
Lift Amplifier Test . . . . . . . . . . . . . . . . . . . . 6-134
Power Amplifier . . . . . . . . . . . . . . . . . . . . 6-8
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Lift Motor
Summary Tables . . . . . . . . . . . . . . . . . . . 6-5
Current Test . . . . . . . . . . . . . . . . . . . . . . . 6-84
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Temp Test . . . . . . . . . . . . . . . . . . . . . . . . . 6-85
Traction System . . . . . . . . . . . . . . . . . 6-5, 6-7
Lift Motor, see Motors
Field Current
Lift/Aux Pump, see Pumps
Lift/Lower
System Overview . . . . . . . . . . . . . . . . . . . 8-23
Fluids, see Oil
Troubleshooting . . . . . . . . . . . . . . . . . . . 5-23
Fraction to Decimal Conversion . . . . . . . . A-8
(w/Hi-Flow Aux) . . . . . . . . . . . . . . . . . . . 8-32
Fuse Panel, Contactor . . . . . . . . . . . . . . . . . 7-53
(w/Standard Aux) . . . . . . . . . . . . . . . . . . 8-24
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Lift/Lower Pot Test . . . . . . . . . . . . . . . . . . . . 6-80
FU1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
Lift/Lower Pot Tests . . . . . . . . . . . . . . . . . . . 6-82
Identification Chart . . . . . . . . . . . . . . . 8-52
Lists
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . 1-5
G Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Locator Photos, Component . . . . . . .7-3 to 7-10
Grounded Motor Test . . . . . . . . . . . . . . . . . 7-62 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
See also Oil
H Lubrication Equivalency Chart . . . . . . . . . A-2
Hall Effect Switches, see Switches M

Handle
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Maintenance
Replacement . . . . . . . . . . . . . . . . . . . . . . 7-29 180 Day/500 HD . . . . . . . . . . . . . . . . . . . 4-9
Hi-Flow Auxiliary System . . . . . . . . . . . . . 8-48 360 Days/1500 HD . . . . . . . . . . . . . . . . 4-13
Horn Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138 90 Day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
I-2 PDMM-0089 Issued: 6/24/02

Maintenance Minder™ . . . . . . . . . . . . . . . . . 4-3 Operator Display

Maintenance Mode . . . . . . . . . . . . . . . . . . . . . 3-4 Troubleshooting . . . . . . . . . . . . . . . . . . . 5-32
Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Operator Display Card . . . . . . . . . . . . . . . . 7-25
Static . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Options Menu . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Map, Navigating the Manual . . . . . . . . . . . . 1-2 P
Mast
Bearing Caps . . . . . . . . . . . . . . . . . . . . . . 7-93
Page Revision Record . . . . . . . . . . . . . . . . . . . . v
Complete Removal . . . . . . . . . . . . . . . . . 7-86
Passwords
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 7-90
Changing a Password . . . . . . . . . . . . . . 3-8
Installation After Complete
Default . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Removal . . . . . . . . . . . . . . . . . . . . . . . 7-88
Entering a Password . . . . . . . . . . . . . . . 3-6
Installation After Partial Removal . . . 7-85
PC Loader Program . . . . . . . . . . . . . . 9-1 to 9-15
Partial Removal . . . . . . . . . . . . . . . . . . . . 7-84
Blank Primary Memory . . . . . . . . . . . . 9-10
Quad
Connect PC to Lift Truck . . . . . . . . . . . 9-4
Hose and Bracket Adjustment . . 7-81
Flash Memory Program . . . . . . . . . . . . . 9-8
Hose Replacement . . . . . . . . . . . . . 7-79
Installation . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Shimming . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Message and Code Summary Tables . . . . 6-5
Requirements . . . . . . . . . . . . . . . . . . . . . . 9-2
Messages and Codes . . . . . . . . . . . . . 6-9 to 6-66
Set Factory Defaults . . . . . . . . . . . . . . . 9-12
Summary List . . . . . . . . . . . . . . . . . . . . . . 6-2
Starting PC Loader . . . . . . . . . . . . . . . . . 9-4
Modes of Operation
Troubleshooting . . . . . . . . . . . . . . . . . 9-4, 9-6
Configure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Pin-Out Matrix . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Configure Mode Settings . . . . . . . . . . . 3-10
Navigation Instructions . . . . . . . . . . . . . 8-2
Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Plugging, Proportional . . . . . . . . . . . . . . . . 8-70
Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3-4
Power Amplifier LED Diagnostics . . . . . . . 6-8
Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Power Supply +12VDC Test . . . . . . . . . . . 6-87
See also Passwords
Press Sensor Voltage Test . . . . . . . . . . . . . 6-88
Module, Control . . . . . . . . . . . . . . . . . . . . . . . 7-31
Pressure
Motor
Auxiliary System Adjustment . . . . . . 7-72
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Hydraulic Adjustment . . . . . . . . . . . . . 7-72
Grounded Test . . . . . . . . . . . . . . . . . . . . 7-62
Lift Hydraulic System, Setting . . . . . 7-73
Open Circuit Tests . . . . . . . . . . . . . . . . . 7-61
Pressure Relief Valve . . . . . . . . . . . . . . . . . . 7-73
Temperature
Proportional Plugging . . . . . . . . . . . . . . . . . 8-70
Traction Motor #1 Test . . . . . . . . . 6-72
Pumps
Traction Motor #2 Test . . . . . . . . . 6-73
Lift/Aux . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63 Q
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Overheated . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Quad Mast
Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Hose and Bracket Adjustment . . . . . 7-81
Troubleshooting . . . . . . . . . . . . . . . . . . . 5-30 Hose Replacement . . . . . . . . . . . . . . . . . 7-79
O R
Oil Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Checking Hydraulic Oil Level . . . . . . . 7-70
Selecting Hydraulic Oil . . . . . . . . . . . . . 7-70
Open Circuit Motor Test, see Tests
PDMM-0089 Issued: 6/24/02 I-3

S Steer Chain Adjustment . . . . . . . . . . . . . . . 7-24

Steer Motor, see Motors
Safety Steer Position Sensor Test . . . . . . . . . . . . 6-109
Battery Safety . . . . . . . . . . . . . . . . 2-7 to 2-11 Steer Pump, see Pumps
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Steerable Wheel Assembly . . . . . . . . . . . . . 7-16
General Rules . . . . . . . . . . . . . . . . . 2-3 to 2-6 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
Jacking Safety . . . . . . . . . . . . . . . . . . . . 2-14 Steering and Controls . . . . . . . . . . .7-11 to 7-32
Static Precautions . . . . . . . . . . . . . . . . . 2-12 Stromag Two-Stage Brake, see Brake
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Surge Protector . . . . . . . . . . . . . . . . . . . . . 9-2, 9-4
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Switches
Scheduled Maintenance . . . . . . . . . . 4-1 to 4-13 Battery Gate Test . . . . . . . . . . . . . . . . . 6-111
180 Day/500 HD . . . . . . . . . . . . . . . . . . . 4-9 Control Handle Tests . . . . . . . . . . . . . . 6-112
360 Day/1500 HD . . . . . . . . . . . . . . . . 4-13 EPO Test . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
90 Day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Hall Effect . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 High Speed Limit Test . . . . . . . . . . . . . . 6-92
Operator’s Daily Checklist . . . . . . . . . . 4-6 Horn Test . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
Schematics Lift Limit Mast . . . . . . . . . . . . . . . . . . . . . 6-97
Attachment Configurations . . . . . . . . A-23 Sideshift Left Test . . . . . . . . . . . . . . . . . . 6-96
Customized . . . . . . . . . . . . . . . . . . . . . . . A-25 Sideshift Right Test . . . . . . . . . . . . . . . . 6-95
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . A-13 Tilt Down Test . . . . . . . . . . . . . . . . . . . . . 6-94
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . A-20 Tilt Up Test . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Schematics, see Schematics Symbols List . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Symptom Tables
Seals, Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Electrical Functions . . . . . . . . . . . . . . . . 5-30
SelfTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58 Hydraulic Functions . . . . . . . . . . . . . . . 5-19
Setting Lift System Pressure Travel Functions . . . . . . . . . . . . . . . . . . . 5-28
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . 7-73
Shimming, Mast Bearings . . . . . . . . . . . . . 7-99
Shorts to Frame Test . . . . . . . . . . . . . . . . . . . 5-6
Sideshift
Functions, Troubleshooting . . . . . . . . 5-22
(w/Hi-Flow Aux) . . . . . . . . . . . . . . . . . . . 8-46
(w/Standard Aux) . . . . . . . . . . . . . . . . . 8-44
Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Aux Dump Test . . . . . . . . . . . . . . . . . . 6-139
Auxiliary Direction Test . . . . . . . . . . . 6-124
High Speed Aux1 Test . . . . . . . . . . . . 6-128
High Speed Aux2 Test . . . . . . . . . . . . 6-129
Lift/Aux1 Test . . . . . . . . . . . . . . . . . . . 6-125
Lift/Aux2 Test . . . . . . . . . . . . . . . . . . . 6-126
Load Hold Test . . . . . . . . . . . . . . . . . . . 6-119
P2-Dump Test . . . . . . . . . . . . . . . . . . . . 6-123
Proportional Lower Test . . . . . . . . . . 6-121
Proportional Relief Test . . . . . . . . . . . 6-127
Sideshift Test . . . . . . . . . . . . . . . . . . . . 6-120
Tilt Test . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Specifications, Vehicle . . . . . . . . . . . . . . . . . 3-2
Speed Sensor Tests . . . . . . . . . . . . .6-105, 6-107
Standard/Metric Conversions . . A-10 to A-11
Start-up Sequence . . . . . . . . . . . . . . . . . . . . 8-58
Static Maintenance Mode . . . . . . . . . . . . . . 3-4
Static Precautions . . . . . . . . . . . . . . . . . . . . 2-12
I-4 PDMM-0089 Issued: 6/24/02

T Traction Power Amp Temperature . . 6-75

Theory of Operation
Tests Attachment Configurations . . . . . . . . A-23
+12VDC Power Supply . . . . . . . . . . . . . 6-87 Auxiliary Functions . . . . . . . . . . . . . . . 8-40
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-137 Battery Maintenance . . . . . . . . . . . . . . 8-54
Analog . . . . . . . . . . . . . . . . . . . . . . 6-67 to 6-88 Battery Plugged In . . . . . . . . . . . . . . . . 8-55
Aux Dump Solenoid . . . . . . . . . . . . . . 6-139 Battery State of Charge . . . . . . . . . . . . 8-54
Auxiliary Direction Solenoid . . . . . . . 6-124 BUS+/BUS- . . . . . . . . . . . . . . . . . . . . . . . 8-54
Battery Gate Switches . . . . . . . . . . . . 6-111 Contactor Coils . . . . . . . . . . . . . . . . . . . 8-53
Brakes . . . . . . . . . . . . . . . . . . . . . 6-135, 6-136 Current Limiting . . . . . . . . . . . . . . . . . . 8-72
Brush Wear Indicators . .6-99, 6-101, 6-103 Deadman Pedal Depressed . . . . . . . . 8-63
Control Handle Switches . . . . . . . . . . 6-112 Directional Control . . . . . . . . . . . . . . . . 8-67
Deadman Switch . . . . . . . . . . . . . . . . . . 6-90 Electrical Schematics . . . . . . . . . . . . . . A-13
Digital Input Tests . . . . . . . . . . 6-89 to 6-113 Hall Effect Switches . . . . . . . . . . . . . . . 8-53
Digital Output Tests . . . . . . . 6-115 to 6-139 Hi-Flow Auxiliary System . . . . . . . . . . 8-48
Discharge Indicator . . . . . . . . . . . . . . . . 6-76 Lift/Lower System . . . . . . . . . . . . . . . . . 8-23
EPO Switch . . . . . . . . . . . . . . . . . . . . . . . 6-91 Lift/Lower (w/Hi-Flow Aux) . . . . . . . . 8-32
High Speed Aux1 Solenoid . . . . . . . . 6-128 Lift/Lower (w/Standard Aux) . . . . . . 8-24
High Speed Aux2 Solenoid . . . . . . . . 6-129 Pin-Out Matrix . . . . . . . . . . . . . . . . . . . . . 8-5
High Speed Limit Switch . . . . . . . . . . . 6-92 Proportional Plugging . . . . . . . . . . . . . . 8-70
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138 SelfTest Checks . . . . . . . . . . . . . . . . . . . 8-58
Horn Switch . . . . . . . . . . . . . . . . . . . . . . 6-113 Sideshift (w/Hi-Flow Aux) . . . . . . . . . 8-46
Lift Amp Temp . . . . . . . . . . . . . . . . . . . . . 6-86 Sideshift (w/Standard Aux) . . . . . . . . 8-44
Lift Amplifiers . . . . . . . . . . . . . . . . . . . . 6-134 Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Lift Limit Mast Switch . . . . . . . . . . . . . 6-97 Start-up Sequence . . . . . . . . . . . . . . . . 8-58
Lift Motor Current . . . . . . . . . . . . . . . . . 6-84 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
Lift Motor Temp . . . . . . . . . . . . . . . . . . . 6-85 Thermal Cut-Back . . . . . . . . . . . . . . . . 8-73
Lift/Aux1 Solenoid . . . . . . . . . . . . . . . . 6-125 Tilt (w/Hi-Flow Aux) . . . . . . . . . . . . . . . 8-42
Lift/Aux2 Solenoid . . . . . . . . . . . . . . . . 6-126 Tilt (w/Standard Aux) . . . . . . . . . . . . . 8-40
Lift/Lower Pot . . . . . . . . . . . . . . . . 6-80, 6-82 Torque on Demand . . . . . . . . . . . . . . . . 8-71
Load Hold Solenoid . . . . . . . . . . . . . . . 6-119 Travel Circuit Components . . . . . . . . 8-51
LPC Contactors . . . . . . . . . . . . . . . . . . . 6-117 Thermal Cut-back . . . . . . . . . . . . . . . . . . . . 8-73
Open Motor Circuit . . . . . . . . . . . . . . . . 7-61 Thread Adhesives, Sealants,
P2-Dump Solenoid . . . . . . . . . . . . . . . . 6-123 and Lubricants . . . . . . . . . . . . . . . . . . . . . A-3
Press Sensor . . . . . . . . . . . . . . . . . . . . . . 6-88 Throttle Pot Test . . . . . . . . . . . . . . . . . . . . . . 6-77
Proportional Lower Solenoid . . . . . . . 6-121 Throttle Pot Test (solid state
Proportional Relief Solenoid . . . . . . . 6-127 control handle) . . . . . . . . . . . . . . . . . . . . 6-78
Shorts to Frame . . . . . . . . . . . . . . . . . . . . 5-6 Tilt
Sideshift Left Switch . . . . . . . . . . . . . . . 6-96 Functions, Troubleshooting . . . . . . . . 5-21
Sideshift Right Switch . . . . . . . . . . . . . 6-95 (w/Hi-Flow Aux) . . . . . . . . . . . . . . . . . . . 8-42
Sideshift Solenoid . . . . . . . . . . . . . . . . 6-120 (w/Standard Aux) . . . . . . . . . . . . . . . . . 8-40
Speed Sensor . . . . . . . . . . . . . . . 6-105, 6-107 Tire/Wheel Assemblies . . . . . . . . . . . . . . . . 7-15
Steer Position Sensor . . . . . . . . . . . . . 6-109 Torque Charts
Steering Fuse . . . . . . . . . . . . . . . . . . . . . . 6-98 Component Specific . . . . . . . . . . . . . . . . A-4
STR Contactors . . . . . . . . . . . . . . . . . . . 6-118 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Throttle Pot . . . . . . . . . . . . . . . . . . . 6-77, 6-78 Standard (Brass) . . . . . . . . . . . . . . . . . . . A-7
Tilt Down Switch . . . . . . . . . . . . . . . . . . 6-94 Standard (Ferrous) . . . . . . . . . . . . . . . . . A-5
Tilt Solenoid . . . . . . . . . . . . . . . . . . . . . . 6-122 Torque On Demand . . . . . . . . . . . . . . . . . . . 8-71
Tilt Up Switch . . . . . . . . . . . . . . . . . . . . . 6-93 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
TPC Contactors . . . . . . . . . . . . . . . . . . . 6-116 Traction Amplifier Tests . . . . . . . . . 6-130, 6-132
Traction Amplifiers . . . . . . . . . 6-130, 6-132 Traction Motor, see Motors, Drive
Traction Power Amp Temp . . . . . . . . . 6-74 Travel Circuit Components . . . . . . . . . . . . 8-51
PDMM-0089 Issued: 6/24/02 I-5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 9-6
Auxiliary Functions . . . . . . . . . . . . . . . 5-19
CAN Bus . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Electrical System . . . . . . . . . . . . . . . . . . . 5-2
Hydraulic Functions . . . . . . . . . . . . . . . 5-19
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Lift/Lower Functions . . . . . . . . . . . . . . 5-23
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Operator Display . . . . . . . . . . . . . . . . . . 5-32
Overheated Motor . . . . . . . . . . . . . . . . . . 5-4
Pin-Out Matrix . . . . . . . . . . . . . . . . . . . . . 8-5
Sideshift Functions . . . . . . . . . . . . . . . . 5-22
Symptom Tables
Electrical Functions . . . . . . . . . . . 5-30
Hydraulic Functions . . . . . . . . . . . 5-19
Travel Functions . . . . . . . . . . . . . . . 5-28
Tilt Functions . . . . . . . . . . . . . . . . . . . . . 5-21
Wiring Problems . . . . . . . . . . . . . . . . . . . 5-14
Valve, Relief, Setting Pressure . . . . . . . . . 7-73

Vehicle
Identification . . . . . . . . . . . . . . . . . . . . . . . 9-2
Manager . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Specifications . . . . . . . . . . . . . . . . . . . . . . 3-2
Voltage Surge . . . . . . . . . . . . . . . . . . . . . . . 9-2, 9-4
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Wheels
Drive Wheel/Tire . . . . . . . . . . . . . . . . . . 7-15
Steerable Wheel/Tire . . . . . . . . . . . . . . 7-16
Wiring Problems, Troubleshooting . . . . . 5-14
I-6 PDMM-0089 Issued: 6/24/02

PDMM-0089 Printed in the USA

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Maintenance Manual

EASi Pacer™ Lift Truck

Model Serial No.

PDMM-0089 Issued: 6/24/02

To locate a dealer, go to www.raymondcorp.com.

© 2004 The Raymond Corporation.

How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

PDMM-0089 Issued: 6/24/02 iii

Messages, Codes and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

PC Loader Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

iv PDMM-0089 Issued: 6/24/02

Page Revision Record

Page Revision Record

PDMM-0089 Issued: 6/24/02 Revised: 5/3/04 v

Page Revision Record

vi PDMM-0089 Issued: 6/24/02

How to Use This Manual 1:

PDMM-0089 Issued: 6/24/02 1-1

Map of the Manual

Map of the Manual

How To Use This

1-2 PDMM-0089 Issued: 6/24/02

Map of the Manual

MAP2: Map of the Manual (Continued)

Component Alphabetical List of

PDMM-0089 Issued: 6/24/02 1-3

1-4 PDMM-0089 Issued: 6/24/02

Abbreviations & Symbols

Term/Symbol Definition Term/Symbol Definition

PDMM-0089 Issued: 6/24/02 1-5

Abbreviations & Symbols

Term/Symbol Definition Term/Symbol Definition

qt. quart or quarts

RA Right Traction Power

SAE Society of Automotive

TPC Traction Power Control

wrt with respect to

1-6 PDMM-0089 Issued: 6/24/02

PDMM-0089 Issued: 6/24/02 2-1

Throughout this manual, you will see two kinds

2-2 PDMM-0089 Issued: 6/24/02

Do NOT attempt to operate this lift truck until

Know the truck’s controls and what they do.

Do NOT operate this truck if it needs repair or if

PDMM-0089 Issued: 6/24/02 2-3

Operate this truck only from the operator’s

Before working on this truck, always turn the

Do NOT wear watches, rings, or jewelry when

Follow the scheduled lubrication, maintenance,

2-4 PDMM-0089 Issued: 6/24/02

Follow the safety and repair instructions exactly

Do NOT use an open flame near the truck.

Do NOT use gasoline or other flammable liquids

Clean up any hydraulic fluid, oil, or grease that

PDMM-0089 Issued: 6/24/02 2-5

Use and park this truck indoors. Do NOT