Maintenance Manual
Model 9600 and 9700 Swing-Reach ® Lift Truck
 With The ACR System ™

Model Serial Numbers

9600 960-09-00001 and Up
9700 970-09-00001 and Up

1089040B Re-Issued: 15 Jun 2010

Replaces 1089040A Issued: 01 Sep 2009

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9700 Swing-Reach ® Lift Truck With The  

 This publication, 1089040B, applies to the Model 9600 and 9700
 ACR System , Model 9600, S/N 960-09-00001 and up, Model 9700, S/N 970-09-00001 and up, and
to all subsequent releases of this product until otherwise indicated in new editions or bulletins.
Changes occur periodically to the information in this publication.

For revision information, see “Page Revision

Revision Record”
Record” on page
page v .

If you need assistance with your lift truck, or to order

o rder additional copies of this manual, contact your
local authorized Raymond dealer.

 To locate your local authorized Raymond dealer,

dealer, go to www.raymondcorp
www.raymondcorp.com.
.com.

©2010 The Raymond Corporation.

 The following terms are trademarks of The Raymond Corporation:

Corporation: iPort, iAlert , iControl , Raymond ,
Swing-Reach , Maintenance Minder , and  Auto Power Off . All other brand and product names are
trademarks or registered trademarks of their respective companies.

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Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Table of Contents

Table of Contents

Page Revision Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v  . v 

Service Bulletin List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Product Improvement Notice List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
How to Use ThisThis Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
 Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
 Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Blocking and Lifting Safety Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Systems Overview.
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Lift Truck Specifications

Installation Instructions .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 3-4
3-3
FlashWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Operator Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Scheduled Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Minder ™ Tool  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial 90 Day/250 Deadman Hour (HD) Maintenance . . . . . . . . . . . . 4-5
Every 180 days or 500 Deadman
Deadman Hours (HD) . . . . . . . . . . . . . . . . . . . 4-6
Every 360 Days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Chain Maintenance
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Electrical Connector Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Circuit Card Connectors
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
 Troubleshooting Communication Error Codes (5x Series) Series) . . . . . . . . . 5-19
 Wire Guidance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
 Troubleshooting Steering Fault Codes (G Series) Series) . . . . . . . . . . . . . . . 5-23
Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-24
Symptom Tables: Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Symptom Tables: Travel Problems
Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Symptom Tables: Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . 5-34
Messages, Codes,
Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Messages and Codes Summary List . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Publication: 1089040, Re-issued: 15 Jun 2010 i

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Table of Contents Model 9600/9700 Swing-Reach ® Maintenance Manual

Electrical Inputs/Test Sum Summarymary List . . . . . . . . . . . . . . . . . . . . . . 6-35

 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
Component
Compo nent Procedu
Procedures res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Special Tools, Decals, and Chassis Chassis . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Lift/Lower Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Decals and Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Steering and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Steer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
EPO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Drive and
and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Drive Tire Pressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Battery Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

 Wiring and Harness

Power CablesHarn . .ess
. . Connectors
. . . . . . . . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 7-42
7-50
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Guidance Manager Firmware Replacement Replacement . . . . . . . . . . . . . . . . . . . 7-56
Mini-Mast Height Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Rotate Position Feedback Pot (VR6) . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
 Traverse Position Feedback Pot (VR5) . . . . . . . . . . . . . . . . . . . . . . . 7-64
Slack Chain Switch Adjustment
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Hydraulic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Lift/Lower Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Lift Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
Load Handler Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
 Traverse Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
Main Lift Cylinders (9700) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Main Lift Cylinders (9600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Main Lift Cylinder Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
Flow Limiters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
Mast, Chain, Hose, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
Main Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Main Lift Chains (9600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92
Main Lift Chains (9700) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
 Telescopic Removal and Mast Bearing Replacement (9700) . . . . . . . 7-96
Main Mast Lateral Bearing Adjustment (9700) . . . . . . . . . . . . . . . . . 7-98
Main Mast Lateral Bearing Adjustment (9600) . . . . . . . . . . . . . . . . . 7-99
Operator Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
 Telescopic Removal and Mast Puck/Bearing Replacement (9600) . 7-102
Height Encoder Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 7-103
Mini-Mast and Load Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104

ii Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Table of Contents

Load Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107

 Traverse Gear Shaft
Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110
Load Handler Lift Chain
Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112
Mini-Mast Pucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-113
Fork Height and Lift ChainChain Adjustment . . . . . . . . . . . . . . . . . . . . . 7-115
 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Functional Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
 Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Component Specific Service/Torque Chart . . . . . . . . . . . . . . . . . . . . . A-4
 Torque Chart - Hydraulic
Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
 Torque Chart - Straight
Straight Thread Face Seal O-Rings O-Rings . . . . . . . . . . . . . . . A-9
 Torque Chart - Standard
Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
 Torque Chart - Standard
Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
 Torque Chart - Metric
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Publication: 1089040, Re-issued: 15 Jun 2010 iii

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Table of Contents Model 9600/9700 Swing-Reach ® Maintenance Manual

iv Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Page Revision Record

Page Revision Record

 This section is a record of all revised pages in this manual. Whenever a page is revised, this section
is updated and included in the revision package.

Pages are revised due to technical and non-technical changes described as follows:
• Technical
Technical changes
changes – These
These changes
changes are identif
identified
ied by a vertica
verticall line (change
(change b
bar)
ar) in the
the left
margin next to the change. Pages affected by technical changes are identified with
“Page Revised: dd/mmm/yyyy” in the footer. These pages are also available on the Raymond  
iNet.
• Non-techni
Non-technical
cal changes
changes – These change
changess consist of
of typogr
typographica
aphicall and grammati
grammatical
cal corrections
corrections,,
paragraph renumbering, repagination, etc. Non-technical changes are not identifed with a
change bar, however,
however, affected pages are identifed with “Revised: dd/mmm/yyyy” in the footer.

Document Revision History 

1089040A Original Issue . . . . . . . 01 Sep 2009
1089040B
10890 40B Re-issue
Re-issue . . . . . . . . . . . 15 Jun 2010
2010
(technical changes identified by change bars)

Publication: 1089040, Re-issued: 15 Jun 2010 v

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Service Bulletin List Model 9600/9700 Swing-Reach ® Maintenance Manual

Service Bulletin List

 The following Service Bulletins have been incorporated into this manual.

Use the blank rows below to log Service Bulletins when they are added to this manual.

Document Number Subject Date

vi Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Product Improvement Notice List

Product Improvement Notice List

 The following Product Improvement Notices have been incorporated into this
this manual.

Use the blank rows below to log Product Improvement Notices when they are added to this manual.

Document Number Subject Date

SWR-09-R003 Power Amplifier Cooling Fan Kit Available 21 Dec 2009

SWR-10-R001 TM S/W V2.2 and CM S/W V1.8 26 Jan 2010

Publication: 1089040, Re-issued: 15 Jun 2010 vii

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Product Improvement Notice List Model 9600/9700 Swing-Reach ® Maintenance Manual

viii Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 1. How to Use This Manual

Sect
Sectio
ion
n 1. Ho
How
w to Us
Use
e Th
This
is M
Man
anua
uall

Publication: 1089040, Re-issued: 15 Jun 2010 1-1

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Section 1. How to Use This Manual Model 9600/9700 Swing-Reach ® Maintenance Manual
Map of the Manual

Map of the Manual

MAP.WMF 

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 

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


1-2 Publication: 1089040, Re-issued: 15 Jun 2010

https://www.forkliftpdfmanuals.com/
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 1. How to Use This Manual
Manual Design

Manual Design • Section 7: Component Procedures gives

step-by-step procedures to remove, install,
and adjust serviceable components.
 This manual is designed with the following Components are grouped by truck system.
objectives in mind:  To find a component procedure, you may
• provid
providee ttech
echnic
nical
al cov
covera
erage
ge for exp
expecte
ected
d use one of two methods:
levels of user expertise
• List
Look
Lookofup
upComponent
the
the comp
compon
onen
entt na
name
me in
Proceduresin on
th
the
e
• antici
anticipat
pate
e your
your needs
needs and reduce
reduce your
your
decisions regarding maintenance pa
page
ge 7-
7-2
2.
• reduce
reduce page
page flipp
flipping
ing throug
through
h a “one-s
“one-stop
top • Look
Look up
up the
the comp
compononen
entt na
name
me in
in th
the
e
shopping” approach Index (
 (pa
page
ge I-
I-1
1).
• Section 8: Theory of Operation explains
 The two-line running page
page header at the top of signal flow within the electrical and
each page tells you: hydraulic systems for various conditions
• th
the
e nam
nameeo
off the
the ma
manu
nual
al of truck operation. This section also
(Model 9600/9700 Swing-Reach ®  contains a detailed connection point table
Maintenance Manual ) (Pinout Matrix) designed to assist in
testing and troubleshooting the truck.
• th
thee curr
curren
entt sect
sectio
ion
n ti
titl
tle
e
(for example, this page How to Use This • Appendix contains reference information
Manual ) such as torque values, lubricants, and
• th
thee cur
curre
ren
nt top
topic
ic standard/metric conversions.
(for example, this page Manual Design ) • Index lists subjects alphabetically.

 This manual consists of the following sections:

• Section 1: How to Use This Manual 
explains the manual format and design as
 well as abbreviations and symbols used.
• Section 2: Safety explains warning and
caution notes, general safety rules, and
safety rules for batteries, static, jacking,
and welding.
• Section 3: Systems Overview includes
general lift truck specifications,
installation, FlashWare, Modes of
Operation, and configuration information.
• Section 4: Scheduled Maintenance 
outlines the recommended schedule of
preventive services to keep the lift truck
 working most efficiently.
• Section 5: Troubleshooting guides the
user from fault symptoms to specific
checks and tests in order to isolate a bad
component.
• Section 6: Messages, Codes, and Tests
lists fault codes and firmware-based
inputs and electrical tests designed to
diagnose problems and repair the truck.

Publication: 1089040, Re-issued: 15 Jun 2010 1-3

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Section 1. How to Use This Manual Model 9600/9700 Swing-Reach ® Maintenance Manual
Abbreviations and Symbols

 Abbreviations and
Symbols
 These abbreviations, acronyms, and symbols are used in this manual.
manual.

 Term/Symbol Definition  Term/Symbol Definition

 A   Ampere E UL Electric Truck Type
 AC  Alternating Current  Certification Rating with
 AGND  Analog Ground safeguards against inherent
 AH hours on Load Handler  fire and electrical shock
amp  Ampere or amplifier  hazards
 ANSI  American National Standards
Standards EE UL Electric Truck Type
Institute Certification Rating where
 API  American Petroleum Institute electrical equipment is
approx. approximately  completely enclosed
assy  assembly  Elev. Ht. Elevated Height 
aux  auxiliary  Emerg Emergency 
 AWG  American Wire Gauge
Gauge EOA  End-of-Aisle
EPO Emergency Power Off 
BSOC Battery State-of-Charge ESD Electrostatic Discharge
ESDS Electrostatic Discharge
C Celsius or Centigrade Sensitive
CAN Controller Area Network 
CB Counterbalance valve F  Fahrenheit 
CCW  Counterclockwise FF  Forks First 
cfg configuration ft. foot or feet 
CM Carriage Manager  ft. lb. foot pound(s)
CMB Carriage Manager Boot Block  FU Fuse
cm centimeter 
COP Computer Operating Properly  GA  gauge
CS Cold Storage gal. gallon or gallons
CV  Check Valve GM Guidance Manager 
CW  Clockwise gm gram(s)
CYL  Cylinder  Gnd ground

DC Direct Current  HA  Heading Angle or hours on

DdManH Deadman Pedal Hours Load Handler 
DFW  Distance From Wire HD hours with Deadman switch
DGND Digital Ground activated
diam. diameter  HL  hours lifting
Dir  Direction HT  hours traveling
DMM Digital MultiMeter  Ht  Height 
DOT  US Department of HTR  Heater 
 Transportation
DVM Digital Voltmeter  IC Integrated Circuit 
in. inch or inches
lb.
in. lb. inch pound(s)

 JP jack and pin connector 

1-4 Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 1. How to Use This Manual
Abbreviations and Symbols

 Term/Symbol Definition  Term/Symbol Definition

K  thousand P pump or lift contactor 

KH hours with key switch ON PAL  Lift Power Amp Software
kg kilogram(s) PALB Lift Power Amp Boot Block 
km/cm2 kilograms per square PALVCL  Lift Power Amp Veh
Vehicle
icle Control
centimeter  Language
km/h kilometers per hour  PAT   Traction Power Amp Software
kPa  kiloPascal(s) PATB  Traction Power Amp Boot
Block 
l liter(s) PATVCL   Traction Power Amp Vehicle
Vehicle
lb. pound or pounds Control Language
LPA  Lift Power Amplifier  pot  Potentiometer 
LED Light Emitting Diode Press Pressure
LiftH Lift Hours Prop Proportional
LH Load Handler or Left-Hand Prox  Proximity 
LHC Load Handler Contactor  psi pounds per square inch
L/L  lift/lower  PWM Pulse Width Modulation
LHM Load Handler Motor  P/N Part Number 
LM Lift Motor 
LME Lift Motor Encoder  qt. quart 
LMT  Lift Motor Temperature sensor  qty. quantity 
LPA  Lift Power Amplifier 
LPC Lift Power Contactor  RAM Random Access Memory 
LR  LPA precharge resistor  RCH Reach
LWR  Lower  REL  relief 
RF  Radio Frequency 
m meter(s) ROM Read Only Memory 
mA  milliampere RPIN Raymond  Product
 Product
mm millimeter  Improvement Notice
MM Maintenance Minder ™ rpm revolutions per minute
mph miles per hour  R/R  reach/retract 
MS steer motor  RSB Raymond  Service
 Service Bulletin

N/A  Not Applicable or Not Available S Switch

N/C Normally Closed SA  Steer Amplifier 
NLGI National Lubricating Grease SAE Society of Automotive
Institute Engineers
Nm Newton Meter  S/N Serial Number 
N/O Normally Open SOL  Solenoid
NVM Non-Volatile Memory  spec specification
SPL  Splice
OACH Overall Collapsed Height  STR  Steer Contactor 
OD Operator Display  SWM Supplier Wireless Module
OSHA  Occupational Safety and
Health Association
OTM over-the-mast 
oz. ounce(s)

Publication: 1089040, Re-issued: 15 Jun 2010 1-5

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Section 1. How to Use This Manual Model 9600/9700 Swing-Reach ® Maintenance Manual
Abbreviations and Symbols

 Term/Symbol Definition

 TA   Traction Power Amplifier 

temp temperature
 TF   Tractor First 
 TM  Tractor Manager, Traction
Motor, or Total distance
traveled
 TMB  Tractor Manager Boot Block 
 TME  Traction Motor Encoder 
 TMT   Traction Motor Temperature
sensor 
 TP  Tie Point 
 TPA   Traction Power Amplifier 
 TPC  Traction Power Contactor 
 TS  Terminal Strip

UL  Underwriters Laboratories

UNC Unified Coarse thread
UNF  Unified Fine thread

 V   Volts
 Volts
 VDC  Volts
 Volts Direct Current 
 ver..
 ver  version
 VR   variable resistor 

 wrt with respect to

 Xducer Transducer 

@ at 
™ trademark 
© copyright 
+ plus or positive
 –  minus or negative
± plus or minus
° degrees
°F  degrees Fahrenheit 
°C degrees Celsius
< less than
> greater than
% percent 
= equals

1-6 Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 2. Safety

Sect
Sectio
ion
n 2. Sa
Safe
fety 
ty 

Publication: 1089040, Re-issued: 15 Jun 2010 2-1

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Section 2. S
Saafety Model 9600/9700 Swing-Reach ® Maintenance Manual
Definitions

Definitions
 Throughout this manual, you will see two kinds
of safety reminders:

 Warning means a potentially hazardous

situation exists which, if not avoided,
could result in death or serious injury.

Caution means a potentially hazardous

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

2-2 Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 2. Safety
General Safety

General Safety  Operate this lift truck only from the operator’s
position.
8b15007d.eps

Do not  operate
 operate or work on this lift truck unless
 you are trained, qualified, and authorized to do
so, and you have read the Owner Manual and
the Operator Manual.
8b15004d.eps

Before working on this lift truck, always turn

the key switch to OFF and disconnect the lift
truck’s battery connector (unless this manual
tells you otherwise).
8b15009d.eps

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

8b15005d.eps

Do not  wear
 wear watches, rings, or jewelry when
 working on the lift truck.
 jewelry.eps

Do not  operate
 operate this lift truck if it needs repair or
if it is in any way unsafe.
8b15006d.eps

Follow the scheduled lubrication, maintenance,

and inspection steps.
schedmnt.eps

Publication: 1089040, Re-issued: 15 Jun 2010 2-3

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Section 2. S
Saafety Model 9600/9700 Swing-Reach ® Maintenance Manual
General Safety
Follow exactly the safety and repair instructions  Always operate and park this lift truck indoors.
in this manual. Do not  take
 take “shortcuts.” 8b15001d.eps

8b15008d.eps

Do not  wash
 wash this lift truck with a hose.
Do not  use
 use an open flame near the lift truck. 8b15010d.eps

8b15002d.eps

Do not  add
 add to or modify this lift truck until you
Do not  use
 use gasoline or other flammable liquids contact your local Raymond dealer to receive
for cleaning parts.  written manufacturer approval.
8b15003d.eps 8b15011d.eps

Clean up any hydraulic fluid, oil, or grease that

has leaked or spilled on the floor.
spills.eps

2-4 Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 2. Safety
Battery Safety

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

 without arm shields), and a rubber apron.
25l6s016.eps

 As a battery is being charged,

char ged, an
explosive gas mixture forms within and
around each cell. If the area is not
correctly ventilated, this explosive gas
can remain in or around the battery for
several hours after charging. Make sure
there are no open flames or sparks in Make sure that a shower and eyewash station
the charging area. An open flame or are nearby in case of an accident.
spark can ignite this gas, resulting in 04g6s059.eps

serious damage or injury.

Battery electrolyte is a solution of

sulfuric acid and water. Battery acid
causes burns. If any electrolyte comes in
contact with your clothing or skin, flush
the area immediately with cold water. If
the solution gets on your face or in your  A battery gives off explosive gases. Never  
eyes, flush the area with cold water and smoke, use an open flame, or use anything that
get medical help immediately. gives off sparks near a battery.
23l6s012.eps

Read, understand, and follow procedures,

recommendations, and specifications in the
 battery and battery charger
charger manufacturer’s
manuals.
25L6S014.EPS

Keep the charging area well-ventilated to avoid

hydrogen gas concentration.
04g6s058.eps

 Wear personal protective equipment to protect

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

Publication: 1089040, Re-issued: 15 Jun 2010 2-5

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Section 2. S
Saafety Model 9600/9700 Swing-Reach ® Maintenance Manual
Battery Safety
 Turn the key switch OFF before  disconnecting
 disconnecting Keep plugs, terminals, cables, and receptacles
the battery from the lift truck at the battery in good condition to avoid shorts and sparks.
connector. Do not break live circuits at the 8c04076s.tif 

 battery terminals. A spark often occurs at the

point where a live circuit is broken.
8b15009d.eps

Keep filler plugs firmly in place at all times

Do not  lay
 lay tools or metal objects on top of the except when checking the electrolyte level,
 battery. A short circuit or explosion could  when adding water to the cells, or when
result. checking the specific gravity.
04g6s057.eps

Make sure the vent holes in the filler plugs are

open to permit the gas to escape from the cells.
09g6s047.tif 

 Vent
 Vent
Hole

Keep batteries clean. Corrosion causes shorts

to the frame and the possibility of sparks.
27y7S013.tif 

Do not  permit
 permit cleaning solution, dirt, or any
foreign matter to enter the cells.

Make sure you install the correct size battery. A

smaller or lighter weight battery could seriously
affect lift truck stability. See the lift truck’s
specification plate for more information.
8b15012d.eps

2-6 Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 2. Safety
Battery Safety
Never  plug
 plug a battery charger into the lift truck’s
 battery connector.
connector. Plug the battery charger only
into the battery connector from the battery.
8b15013d.eps

Publication: 1089040, Re-issued: 15 Jun 2010 2-7

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Section 2. S
Saafety Model 9600/9700 Swing-Reach ® Maintenance Manual
Static Precautions

Static Precautions Figur

Figuree 2-2.
2-2.
9600_2139.jpg
ES
ESD
D Grou
Ground
nd - O
Ope
perat
rator
or Comp
Compartm
artment 
ent 

Electronic circuit boards can contain

ESD Ground Jack 
Electrostatic Discharge Sensitive (ESDS)
devices.

Static charges can accumulate from normal

operation of the lift truck as well as movement
or contact between non-conductive materials
(plastic bags, synthetic clothing, synthetic soles
on shoes, styrofoam coffee cups, and so forth.)

 Accumulated static electricity can be

discharged to a circuit board or component by • Handle
Handle cir
circui
cuitt bo
board
ards
s by the edges
edges only
only..
touching the parts. Electrostatic Discharge  Avoid touching the edge connectors.
(ESD) is also possible through the air when a • If you
you are
are remo
removi
ving
ng o
orr in
inst
stal
alli
ling
ng
charged object is placed close to another static-sensitive components, place them
surface at a different electrical potential. Static on a correctly grounded anti-static mat.
discharge can occur without seeing or feeling it.
• To tran
transpo
sport
rt stat
static
ic sens
sensiti
itive
ve comp
compone
onents
nts,,
including failed components being
 Whenever working
follow these on or near ESDS
precautions. ESDS devices, returned, place the components in an
anti-static bag or box (available from your
• Wear an ESD
ESD wris
wristt strap
strap.. Th
The
e wr
wrist
ist strap
strap local authorized Raymond dealer).
should be equipped with a 1 megohm
resistor to dissipate static charges slowly.  Test the wrist strap and related accessories
• Connec
Connectt the
the wrist
wrist str
strap
ap p
plug
lug to tthe
he grou
ground
nd  before each use to make sure they are working
Figur
 jack on the lift truck. See Figuree 2-
2-1
1 and correctly.
Fi
Figu
gure
re 2-
2-2
2. If you cannot use the ground
 jack, connect the ground clip to an Figur
Figure
e 2-
2-3
3 shows the components of the
unpainted, grounded surface on the lift Raymond anti-static field service kit,
truck frame. P/N 1-187-059. The kit includes
includes a wrist
wrist strap,
ground cord, and static-dissipative work
Fig
Figure
ure 2-1.
2-1. ESD Ground
Ground Jac
Jackk - Ele
Electr
ctrica
icall Comp
Compartm
artment 
ent 
9600_2252.jpg surface (mat). Follow the instructions packaged
 with the kit.

ESD Ground Jack 

2-8 Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 2. Safety
Static Precautions
Fig
Figure
ure 2-3.
2-3. Anti-S
Anti-Stat
tatic
ic Kit
Kit with
with Wrist
rist Strap
Strap and Mat 
2mat2.tif 

 Wrist straps (P/N 1-187-058/001) are available

in quantities of 25.

 A wrist strap tester (P/N 1-187-060/100) is also

wrist
available. also

Contact your local Raymond dealer for

information.

Publication: 1089040, Re-issued: 15 Jun 2010 2-9

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Section 2. S
Saafety Model 9600/9700 Swing-Reach ® Maintenance Manual
 Jacking Safety

 Jacking Safety  Figu

Figure
re 2
2-4
-4..
8c04078s.tif 
Jack
Jackin
ing
g and
and Bl
Bloc
ocki
king
ng Bas
Basel
eleg
eg

Some maintenance procedures require the lift

truck to be jacked up. To safely jack the truck:
1. Lower the carria
carriage
ge an
and
d forks
forks com
completel
pletely
y to

the floor. Remove any load.

2. Place
Place aall
ll co
contr
ntrols
ols iin
n neutr
neutral.
al.
3. Block
Block the wheels
wheels to preve
prevent
nt movemen
movementt of
the vehicle.
4. Turn the
the key switch
switch OFF
OFF and disco
disconne
nnect
ct
the battery connector. 0.5 in. (13 mm)
5. If possible,
possible, stabilize
stabilize th
the
e top of th
the
e mast off floor max.
 with an overhead chain
chain hoist.
8. To jack the tractor : Place the jack in the
6. Place
Place the ja
jack
ck under
under the desig
designat
nated
ed designated jacking position. Do not  jack
 jack
Figu
 jacking points. See Figure
re 2-
2-4
4 and under the removable bumper. See
Fi
Figu
gure
re 2-
2-5
5. Figur
Figuree 2-
2-5
5. Jack one side of the lift truck
so that the drive tire is off the floor no
more than 2 in. (50 mm). Block that side of
the lift truck in place. Then jack up the
Use extreme care when the lift truck is other side of the lift truck in the same
jacked up. Never block the lift truck manner.. Block that side in place.
manner
between the carriage and the floor. Figu
Figure
re 2
2-5
-5.. Jack
Jackin
ing
g and
and Bl
Bloc
ocki
king
ng Tra
Tract
ctor 
or 
Keep hands and feet clear while jacking  jacksafe.JPG

the lift truck. After the lift truck is

jacked, place solid blocks or jack stands
beneath it to support it. Do not  rely
 rely on
the jack alone to support the lift truck.

7. To jack the baseleg: Place the jack in the

designated jacking position. See
Figur
Figuree 2-
2-4
4. Jack the lift truck up just high
enough to raise the load wheel off the floor,

no more
 block thanthe
under 0.5baseleg
in. (13 as
mm). Place a
shown.

Do not
jack here

2-10 Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 2. Safety
Blocking and Lifting Safety

Blocking and Lifting Blocking Load Handler

Safety  Figu
Figure
re 2-7
2-7..
2912_001.tif 
Bl
Bloc
ocki
king
ng Loa
Load
d Hand
Handle
ler 
r 

Blocking the Carriage

Do not block against the platform floor;

use the edge of the platform. Do not
block the carriage against the floor.

Fi
Figu
gure
re 2-6.
2-6. Bloc
Blocki
king
ng Carr
Carria
iage 
ge 
8C11031Hr.TIF 

Lifting Motors
Secure a hoist to the traction motor with 2
straps cross-wrapped as shown in FiguFigure
re 2-
2-8
8.
Figu
Figure
re 2-8.
2-8. Li
Lift
ftin
ing
g Tract
ractio
ionn M
Mot
otor 
or 
liftingmotor.jpg

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ed: 15 Jun 2010 2-11
 

Section 2. S
Saafety Model 9600/9700 Swing-Reach ® Maintenance Manual
Welding Safety

 Welding
 Welding Safety  • Check
Check for
pa
page
ge 5-
for sho
5-3
shorts
rts to frame
frame as
as descr
describe
ibed
d on
3. If you detect any shorts, correct
them before you weld.
• Clea
Clean
n the
the a
are
rea
a to be weld
welded
ed..
• Protect
Protect all lif
liftt truc
truck
kccomp
ompone
onents
nts from
from
Flame cutting or welding on painted heat, weld spatter, and debris.
surfaces can produce potentially • At
Atta
tach
ch the
the grou
ground
nd cab
cable
le as
as close
close to
to the
the
harmful fumes, smoke, and vapors.  weld area as possible.
Before doing flame cutting or welding,
• Do not wel
weld
d near
near electri
electrical
cal compone
components
nts..
remove the coating from the area where
the operation(s) will occur.
occur. • If yo
youu must
must weld
weld near
near the
the b
bat
atte
tery
ry
compartment, remove the battery from the
Coating removal can occur by lift truck.
mechanical methods, chemical methods, • Disconn
Disconnect
ect all electri
electrical
cal cir
circui
cuitt card
cards
s
or a combination of methods. Do flame  before welding. When you are finished
cutting and/or welding operations only  welding, reconnect all circuit cards
cards and do
in well-ventilated areas, using local ground tests and electrical inspections
exhaust if necessary.
necessary.  before operating the lift truck.

Before working on this lift truck, make sure:

• Fire
Fire prot
protect
ectio
ion
n equip
equipmen
mentt is ne
near
arby
by..
• You kno
knoww where
where the
the ne
near
arest
est eyewa
eyewash
sh
station is.
04g6s059.eps

Disconnect the battery before you

attempt to inspect, service, or repair the
lift truck.
8b15009d.eps

2-12 Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview

Sect
Sectio
ion
n33.. Sy
Syst
stem
emss O
Ove
vervi
rview 
ew 

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ed: 15 Jun 2010 3-1
 

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Introduction

Introduction
 This manual provides information for
maintenance and repair of the Model
9600/9700 Swing-Reach ® lift truck by
Raymond.

 This manual contains the most current and

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

For the latest information on your Raymond  lift

 lift
truck, contact your local authorized Raymond
dealer.

3-2 Publication: 1089040, Re-issued: 15 Jun 2010

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Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Lift Truck Specifications

Lift Truck Specifications

 This lift truck is rated for performance by load
center, load weight, and load height with forks
and/or platform elevated.

Review the specification plate located on the lift

truck’s left mast upright for detailed load
capacity and load center information. See
Figu
Figure
re 3-
3-11.

Due to continuous product improvement,

specifications are subject to change without
notice or obligation.
Figuree 3-1.
Figur 3-1. Lift Tr
Truck
uck Speci
Specifica
fication
tion Plate 
Plate 
SPECTAG.WMF 412-852_C.EPS

Nominal battery voltage

Nominal battery width

Serial number Corporation
Raymond Corp
P.O. Box 130
Greene, New York 13778

Model Serial Number Battery Volts Nominal Width (in./mm)

Maximum battery
Raymond model (l(lb
b./kg)  weight for this lift
Truck Weight Battery Weight b./kg)
(l(lb Battery Max. Rated Capacity
With Maximum Battery Maximum (A.H.)
truck 
 Approximate weight Without Battery Minimum Hour Rate Att achment
of lift truck with Power rating of
battery installed, HORIZONTAL MOTION OF BATTERY MUST NOT EXCEED 0.5 INCHES/ 12.7MM.
ATTACH RESTRAINT TO BATTERY COMPARTMENT AS REQUIRED.
VERTICAL battery 
minus load and LOAD
CENTER
in. mm
operator B 23.6 IN. 600 mm

CAPACITY CAPACITY Hour rating of battery 

MAXIMUM DIM. DIM. DIM. MAXIMUM DIM. DIM. DIM.
C APACITY A C D CAPACITY A C D

 Approximate weight lb. in. i n. i n. kg mm mm mm Minimum battery

of lift truck minus B
 weight for this lift
battery,, load, and
battery truck 
D
operator C
A
  R
  O  O
  F  L  O

Battery weight must

Maximum load be between the
capacity for this lift MANUFACTURED TO COMPLY WITH MANDATORY REQUIREMENTS OF ANSI/ITSDF B56.1 PART III EFFECTIVE ON THE DATE minimum and
OF MANUFACTURE FOR TYPE E INDUSTRIAL TRUCKS WHEN EQUIPPED WITH TYPE EO BATTERY.

truck  GIVE MODEL AND SERIAL NUMBER IN ALL CORRESPONDENCE.

412-852
maximum weight

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ed: 15 Jun 2010 3-3
 

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Installation Instructions

Installation Instructions  Assembly Procedure

Procedure

Inspect the units as received for damage in

transit. You should have the following:
• Mast
Mast assem
assembly
bly and diagon
diagonal
al support
support arms • Perform
Perform this
this proce
procedur
dure
e with
with a
on a pair of skids • minimum of two
Do not  permit
 permit technicians.
observers to stand
• Tractor
Tractor assemb
assembly,
ly, wit
with
h 2 bat
batter
tery
yggate
ates,
s,
glass mast guard (if so equipped), side nearby.
covers, and parts carton on a skid • Do not  allow
 allow distractions during
setup of the lift truck.
• Full
Full b
bod
ody
y ha
harn
rnes
ess
s and
and te
teth
ther 
er 
• Wear
Wear glove
gloves,
s, safe
safetyty glass
glasses,
es,
• Cable cl
clamps steel-toed safety boots, and a safety
• Misc
Miscel
ella
lane
neou
ous
s har
hardw
dwar
are
e helmet (hard hat).
• Lif
Liftt Refe
Referen
rence
ce Prox
Prox s
swit
witch
ch and bracke
bracket 
t  • Place
Place the
the mast
mast and tract
tractor
or skids
skids in
in
an open area where it is safe to
 work.
Equipment Required • Unasse
Unassemblmbled
ed lift
lift truck
truck compon
components
ents
are heavy,
heavy, unstable, and difficult to
In addition to normal tools, you should have the
handle. Use extreme caution when
following available at the installation site:
• A hoist
hoist or cran
cranee with
with a capaci
capacity
ty of
of 5 tons
tons lifting and assembling the lift truck.
• Do not  stand
 stand the mast up if the
(4540 kg) for a Model 9600 mast, or 10 mini-mast is not centered
tons (9000
(9000 kg) for a Model 9700
9700 mast. side-to-side in the main carriage.
Ceiling clearance must be greater than the
lift truck’s collapsed height dimension. If
• Do not  remove
 remove the steel banding
securing the main carriage or the
erecting a Model 9700 mast by means of
two lift trucks and a structural tubing
mini-mast, nor the wood stringers in
the lower traverse rack, until the
lifting bar, the lift trucks should have a
capacity of 8000 lbs. (3632 kg) each.
main mast is upright.
1. Cut and
and disca
discard
rd th
the
e bandin
banding g on the
the
• A 3000
3000 llb.
b. (136
(1362
2 kg)
kg) ca
capac
pacity
ity lift
lift truck
truck for
tractor. Carefully
Carefully set aside the tractor side
handling the tractor 
covers, glass mast guard (if so equipped),
• Hoist
Hoist sli
sling
ngs
s of suita
suitabl
ble
e capa
capaci
city 
ty  and parts carton. Remove forks from
• Three
Three leng
lengths
ths of heav
heavy
y ch
chain
ain of suit
suitabl
able
e tractor skid.
capacity  2. Remove
Remove diago
diagonal
nal suppo
support
rt arms from
from the
• Two wooden
wooden suppor
supportt b
bloc
locks
ks 3
3.5
.5 in. (9 cm)
cm) mast skid.
 wide by 2 in. (5 cm) high by 12 in. (30 cm) 3. Static
Static str
straps
aps might
might have
have been
been removed
removed
to 20 in. (51 cm) long for placement under prior to shipment or might have been
 baselegs repositioned so as not to protrude below
the mast. If they are not already installed,
install two static straps at the base of the
mast. Position static straps at a 45° angle
to the floor
flo or..
4. Cut and
and discard
discard the bandin
banding g secu
securing
ring the
mast to its skid(s). Do not remove banding
securing the mini-mast or the banding
securing the carriage to the mast until the
mast is standing upright.

3-4 Publication: 1089040, Re-issued: 15 Jun 2010

https://www.forkliftpdfmanuals.com/
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Installation Instructions
5. Cut and
and discard
discard the cable
cable ties
ties securing
securing the
the Figure
Figure 3-3. 9600 Mast
Mast EErecti
rection
on Using
Using Lif
Liftt Tr
Truck 
uck 
over-the-mast hoses and cables. Do not cut
1750_003.tif 

the cable ties securing the hose and cable

slap pads to the hoses and cable on the
outboard side of the cylinders. These
remain on the lift truck.

6. Use two
two lift
lift trucks
trucks of suitable
suitable capacity
capacity to
lift the mast off the skid(s). Remove and
discard skid(s). Carefully lower mast to
floor.
7. Model 9600: Attach two 5-ton
5-ton hoist
hoist straps
straps
around the main mast and telescopic
crossties.
NOTE: Model 9600 alternate method: Position
the lifting truck as shown in Figure
Figure 3-3-2
2 
and secure a heavy chain around the
fork carriage of the lifting truck and the
mast crosstie. Slowly and carefully raise
the mast erect. See Figur
Figuree 3-
3-3
3. Lift very
slowly at the point where the weight of
the mast goes forward of the pivot point. 8. Model
Model 9700:
9700: Attach
Attach two
two 10-ton
10-ton hoist
hoist
straps around the second main mast and
Figuree 3-2. 9600 Mast
Figur Mast Erecti
Erection,
on, Al
Alterna
ternate
te Method 
Method 
1750_005.tif 
telescopic crossties. See Figu
Figure
re 3-4
3-4..
Figure
Figure 3-4.
3-4. 9700 Mast Strapped
Strapped to Hoist 
Hoist 
3052_009.tif 

Note Routing
of Straps

On a Model 9700 mast, do not  wrap

 wrap
hoist strap around the uppermost
crosstie, only the main mast and
telescopic crossties.

NOTE: Model 9700 alternate method: Insert a

length of suitable structural tubing
through the 6 in. (15 cm) hole in the

lifting
Model flange. Thislower
9700 mast flangecrosstie.
is a partSee
of the

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ed: 15 Jun 2010 3-5
 

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Installation Instructions
Figu
Figure
re 3-
3-5
5. If you are using two lift structural tubing to the fork carriage
c arriage of
trucks to erect the mast, a 160 in. (407 the lift trucks.
cm) length is recommended for the 9. Raise the mast
mast and
and carria
carriage
ge section
section erect
tubing. See Table
See Table 3-1
3-1 for
 for specifications and hold in a level position. Block the back
on structural tubing. edge of the mast with wooden blocks. See
Figure
Figure 3-
3-66.
Table
able 3-1.
3-1. Str
Struct
uctura
urall Tubi
Tubing
ng Speci
Specific
ficati
ations
ons
Figur
Figuree 3-6.
3-6. Mast
Mast Blocke
Blocked 
d 
Structural OD/  Wall
 Wall 1750_007.tif 

 ASTM
 Tubing Type Size  Thickness

5 in. Round 5 in. 0.5 in. A500

 Type ERW  Grade B
or C

5 in. Round 5.6 in. 0.62 in.  A53 Type

Schedule nominal nominal E Grade
160 B

5 in. XXS 0.75 in.  A53 Type

Round nominal  A Grade
 A or B

Square 4x4 in. 0.5 in. A500

Grade B
or C

Fig
Figure
ure 3-5.
3-5. 9700
9700 Mast
Mast Liftin
Lifting
g Flange 
Flange 
1750_027.tif 

10. Pull hydraulic

hydraulic hoses and wire guidance
guidance
cable (if so equipped) out the hole near the
left side of the base of the mast. Pull
over-the-mast cables out the hole in the
top of the base of the mast near the right
side. Pull Model 9600 work light cable (if
Lifting Flange so equipped) out the cutout in the back of
the mast approx. 4 ft. (1.2 m) from the
floor on the right side.
Figure
Figure 3-7
3-7.. Pulling
Pulling Hydrauli
Hydraulicc Hoses
Hoses Through
Through Mast 
Mast 
7k24122s.tif 

 Attach and secure 10-ton hoist straps

around the structural tubing on both sides
of the mast.
If you are lifting the mast with lift trucks
instead of a hoist, chain or clamp the

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Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Installation Instructions
11. Install
Install Lift
Lift R
Referen
eference
ce P
Prox
rox sw
switch
itch and Figure 3-10. Mast-Tractor
Mast-Tractor Mounting Bolts, Lower 
Lower 
 bracket.
7k24106s.tif 

12. Using a lift truck, position

position the tractor
tractor in Locating Pin
alignment with the mast. See Figu
Figure
re 3-
3-8
8.
Fig
Figure
ure 3-8.
3-8. Mating
Mating Trac
Tractor
tor to Mas
Mast 
t 
1750_008.tif 

Mounting
Bolts

Diagonal support arms weigh approx.

60 lb. (27 kg)
13. Connec
Connectt the over-th
over-the-m
e-mast
ast cable
cable
16. Install
Install the
the diagonal
diagonal support
support arms.
arms. Secure
Secure
connectors to the correct tractor cable clevis pins with snap rings, flat side of the
connectors at the mast-to-tractor cable
ring to the inside of the tractor. See
connection panel. See Figur
Figuree 3-
3-9
9.
Figure
Figure 3-1
3-111.
Figuree 3-9. Mast to Tract
Figur Tractor
or Cable
Cable Connect
Connections
ions
9600_2194.jpg
Figure 3-11. Support Arm Installation
Installation to Tractor 
7k24103s.tif 

14. Mate the tractor

tractor to the mast, engaging
engaging th
the
e 17. Apply
Apply thread-
thread-lock
locking
ing compou
compound nd
locating pins in the tractor with the holes (P/N 990-571)
990-571) to upper mounting
mounting bolt
in the mast frame. threads. Thread the upper mounting bolt,
15. From the battery
battery compart
compartment,
ment, thread 4 tighten,
tighten, and torq
torque
ue to 70 ft. lb. (95 Nm).
Nm).
mounting bolts and washers through the  Tighten jam nuts against crosstie and
top of the tractor frame into the mast. support arm. See FiFigu
gure
re 3-
3-12
12..
 Thread 7 mounting bolts and washers
washers into
the bottom of the tractor frame into the
mast. Using a torque wrench, torque to
350 ft. lb. (475 Nm). See Figur
Figuree 3-
3-10
10..

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ed: 15 Jun 2010 3-7
 

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Installation Instructions
Figure 3-12. Support Arm Installation
Installation to Mast 
Mast  Guidance Filter Card at JW1 (if so
equipped). Connect standard cables to
9600_2188.jpg

interconnection points.
22. Connect
Connect the
the hydraulic
hydraulic hoses at the
the bottom
bottom
of the battery compartment. Make sure the
O-ring is in place on the male fitting. See
Figu
Fi gure
re 3-
3-13
13..
Figure 3-13. Hydraulic Hose
Hose Connection
7k24093s.tif 

Upper Mounting Bolt

To
Torque
rque tto
o 70 ft. lb.
(95 Nm)  Jam
Nuts
Cross-Tie

23. If they
they are
are not already
already in place, install
install
 battery rollers. Install a fully charged
Support Arm  battery, using a suitable battery
installation device. Install battery gates.
24. Make
Make sure the
the ground
ground wire
wire to the
the bottom
bottom
18. Install
Install the battery
battery spacer
spacer,, if used. of the seat is installed. See Figure
Figure 3-1
3-144.
19
19.. Remov
Remove
e hoist
hoist st
stra
rap.
p. Figure 3-14. Operator Seat
Seat Ground Wire 
1750_026.tif 

20. Cut and

and di
discar
scard
d the s
steel
teel b
band
anding
ing
securing the carriage to the mast. Remove
the bolt securing the mini-mast. Cut and
discard the cable ties and wooden
stringers that center the mini-mast in the Ground Wire
lower traverse rack. Remove the blocking
 between mini-mast and mini-mast lift
cylinder.

Use correct electrostatic discharge

precautions. See “Static Precautions” on
page
page 2-
2-8.
8.
25. Instal
Installl the glass
glass mast
mast guard
guard,, if so
21. Feed the
the electrica
electricall cables,
cables, and
and ca
cables
bles ffor
or equipped. Make sure brackets are
the travel light (if so equipped), installed with mounting screws on the
end-of-aisle sensor (if so equipped), and tractor side of the glass, so that the glass
 wire guidance sensor (if so equipped) from lines up with the back of the operator
the mast through the tractor opening and
connect to the Tractor Manager and Wire compartment, without any “ledge” or “jog.”

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Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Installation Instructions
 This is important for the mounting of the
the
Supplemental Operator Display.
26. Install
Install the
the Su
Supplemen
pplemental
tal Operat
Operator
or Di
Display
splay
on the glass or mesh mast guard.
27. Remove plastic
plastic w
wrapp
rapping
ing from control
control
handles and arms.
28. Bleed
Bleed the
the hydrau
hydraulic system.. See “Bleeding
lic system
the Hydraulic
Hydraulic System”
System” on page 7-74
7-74..
29. Grease
Grease stee
steerin
ring
g ring
ring gea
gearr.
30. Grease the traverse
traverse racks and areas
areas on the
top and bottom of the carriage where the
sliders ride.
31
31.. In
Inst
stal
alll the
the fork
forks.
s.
32
32.. In
Insta
stall
ll cov
cover
ers.
s.
33. Run Wire
Wire Guida
Guidance
nce L
Learn
earn.. Ref
Refer
er to
page 3-34
3-34..
34. Per
erfform Test
rm Test O62 – Lower Sol [Lower
Solenoid
Soleno id (SOL1)]
(SOL1)] (page 6-153
6-153)).
35. Install
Install optional
optional equipment
equipment such
such as lights,
lights,
fan, and so on. If so equipped, set Lift
Limit with Bypass heights per customer
requirements. See “Configuration and
 Truck Setup Options” on page 3-12.

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ed: 15 Jun 2010 3-9
 

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

FlashWare

FlashWare the screen. The software package is a

self-extracting executable file. Read the
“Readme” file in the software package for the
Overview  latest detailed installation instructions.

FlashWare is used on many different model Connecting PC to Truck 

trucks with different “Manager” configurations.
 The 9600/9700 uses the same “Vehicle  There are two methods available to connect the
Manager” for the Tractor and Carriage Manager. PC to a manager:
Unique software is loaded into the device and a
• USB to USB - this method requires the
harness/jumper configuration is used to
correct drivers to be installed on the PC.
identify the component. Refer to “Schematics”
 Typically, this type of connection is much
on pag
pagee A-1
A-199.
faster than a serial connection. With the
key switch OFF, connect cable P/N
FlashWare allows you to update software, view,
610-809/210 to a USB port on the PC and
and configure options on the lift truck through
the P3 connector on the manager. See
the following features:
Figu
Figure
re 3-
3-15
15..
• Update
Update Vehicle
ehicle ((Trac
Tractor
tor)) Manag
Manager
er S
Soft
oftwar
ware
e
• Serial to Serial - this method requires a
• Clear
Clear Prim
Primary
ary Mem
Memory
ory (tr
(truck
uck iden
identif
tifica
icatio
tion
n surge protector (P/N 154-010-801) to be
data from CM) connected in series with the cable to
• Reset
Reset Facto
Factory
ry De
Defa
fault
ult Sett
Settin
ings
gs protect the PC. 
PC. With
 With the key switch OFF,
OFF,
connect a standard 9-pin serial cable to a
• BSOC
BSOC Cali
Calib
bra
rati
tion
on
serial port on the PC and the J9 connector
• Clear
Clear Man
Manage
agers
rs (Tractor
(Tractor and Carria
Carriage)
ge) on the manager. See Figu
Figure
re 3-
3-15
15..
• Vi
View/
ew/Upd
Update
ate Carria
Carriage
ge M
Mana
anager
ger Sof
Softwa
tware
re Figure 3-15. Truck FlashWare
FlashWare Connections
• Vi
View/
ew/Ins
Instal
tall/U
l/Upda
pdate
te Power
Power Amp Softwa
Software
re
1750_026.tif 

• Upda
Update
te Carr
Carria
iage
ge Mana
Manage
gerr Softw
Softwar
are
e Serial connector (J9) USB connector (P3)

• In
Insta
stall
ll Clea
Cleare
red
d (Ne
(New)
w) Mana
Manage
ger 
r 

For more detailed FlashWare information, click

on Help and select Help Topics from the menu
 bar.

FlashWa
FlashWare
re can be
IBM-compatible installed
PC. The PC on any
communicates with
the truck software via a serial (9 pin) or USB
port.

Installing FlashWare on PC
If you are a customer service technician, obtain Manager Connection
FlashWare from your Raymond dealer.
 The Tractor Manager is the primary FlashWare
FlashWare
If you are a Raymond dealer technician, obtain connection point. However, when it is necessary
nece ssary
FlashWare
FlashWa re from the iNet software download to communicate with or clear a Carriage
site. Manager,, the PC must be connected directly to
Manager
the Carriage Manager.
Manager.

 To install FlashWare

FlashW
installation arefollow
file and on thethe
PC,
PCinstructions
, double-clickon
the

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Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
FlashWare
Tractor Manager 3. From
From the me
menu
nu bar,
bar, click
click “Con
“Connec
nectt to
 Truck”, then select “All Other Trucks”. The
The
Connect FlashWare to the Tractor Manager to:  Truck Setup screen is displayed.
• enab
enable
le/d
/dis
isab
able
le op
opti
tion
ons
s • If the PC is conn
connecte
ected
d tto
o a correct
correctly
ly
• update
update TM, CM, LPA,
LPA, and
and TPA sof
softwa
tware
re functioning Tractor Manager, the Truck
Setup screen is displayed.
• clear manager   Figure 3-17. Truck Setup
Setup Screen
• re
rese
sett fac
facto
tory
ry defa
defaul
ults
ts 9600FW_3-16.jpg

• instal
installl TM softwa
software
re into
into a b
blan
lank
k manag
manager 
er 

Carriage Manager

Connect FlashWare directly to the Carriage

Manager to:
• instal
installl CM softwa
software
re into
into a b
blan
lank
k manag
manager 
er 
• clear CM

Starting FlashWare
FlashWare
1. With the key
key switch
switch ON,
ON, double-c
double-click
lick the
the
FlashWare
FlashW are icon on the main desktop
screen or navigate via Start > Programs >
FlashWare.
FlashW are. The truck opening screen
Figur
appears. See Fig ure
e 3-
3-16
16..
Figure 3-16. Truck Opening
Opening Screen
Screen • If the PC is conn
connecte
ectedd tto
o a correct
correctly
ly
9600FW_3-15.jpg

functioning Carriage Manager or a

 blank manager,
manager, the VM
VM Software
Software screen
is displayed. See Figu
Figure
re 3-
3-18
18..
Figure 3-18. VM Software
Software Screen
9600FW_3-17.jpg

NOTE:  When entering or using FlashWare,

FlashWare, it is
normal for Code 57 to display.
2. From
From th
the
e menu
menu bar
bar, click
click
“Communications”, then select the
applicable connection type:
• COMx
COMx (9-p
(9-pin
in Se
Seri
rial
al))
• COMx ((U
USB)
NOTE: “x” numbers will vary depending on the
computer configuration.

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ed: 15 Jun 2010 3-11
 

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

FlashWare

Configuration and Truck Setup

Options
 The Truck Setup Screen allows you to:
• enab
enable
le o
opt
ption
ions
s that
that were
were a
add
dded
ed to
to the
the
truck since shipment from the factory 
• check
check the
the seri
serial
al numb
numberer,, mo
model
del number
number,,
software model number, Elevated Ht,
 V
 Vehicle
ehicle Manager version, and hour meters
of the truck. See Fig
Figur
ure
e 3-
3-19
19..
Figure 3-19. Truck Setup
Setup Screen
9600FW_3-16.jpg

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Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
FlashWare
To Change an Option Setting: Figure 3-20. Extended M Dimension
9600_steerCoils.svg
Dimension

 The list box near the middle of the window

window
shows the Truck Options.

Select the required check box. To disable an

option, deselect the check box. See Figur
Figure
e 3-
3-19
19..
 When the options are correctly configured, click
the “SEND Changes to Truck” button.
NOTE: Options displayed in red require M
authorization codes. When these options
are selected, a pop up window appears
L Deadman Pedal Travel/Lift Interlock - used
requesting the authorization code.
 when the customer wants to have both
Contact your local Raymond dealer for
deadman pedals depressed prior to allowing
the correct forms and procedure for
travel or lift/lower
li ft/lower..
obtaining the authorization code.
Lift Limit w/Bypass  - limits lift at up to 4
Options include (but are not limited to): programmable lift heights and is equipped with
NOTE: Unless otherwise specified, all options a bypass switch.
require an authorization code.
Travel Speed Limited due to Aux Mast Ht. -
Electronic Key - requires the operator to enter used to interrupt travel when the mini-mast is
a code before operation is allowed. raised above the programmed height.

Lift Limit w/o Bypass - limits lift height Travel Cut-Out @24 in. - used to interrupt
 without a bypass switch. travel when the vehicle’s elevated height is
above 24 in. (51 cm).
Lower Limit w/Bypass - limits lower height
and is equipped with a bypass switch. Battery Gate Interlock - used to interrupt
travel until the battery gate is correctly
Sidegate Interlock - requires both sidegates to installed. Authorization Code not required.
 be lowered to allow travel and lift/lower
functions. Authorization Code not required. Attachment, set weight - used when an
optional attachment has been installed.

Travel Alarm/Light
to function when the -lift
allows
truckthe
is alarm
movingoraslight Max Speed 5.6 mph - used to limit maximum
configured. Authorization Code not required. travel speed to 5.6 mph (9.0 km/h).

Lift/Lower Alarm - allows the alarm to function Out-of-Aisle Lift Inhibit - used to interrupt
 when the lift truck is lifting/lowering as
as main lift and limit travel speed when the truck
configured. Authorization Code not required. is not located in a rail or wire guided aisle.

Extended M >44 - Refer to Fig

Figure
ure 3-2
3-20
0. Used Rail Guidance - allows the rail guidance
 when dimension “M” exceeds 44 in. (112 cm). function to operate when the vehicle is correctly
equipped.

Wire Guidance - allows the wire guidance

function to operate when the vehicle is correctly
equipped.

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ed: 15 Jun 2010 3-13
 

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

FlashWare
Forks: Floor Lowered Height - used when Attachment Weight (lbs) - used to set the
truck has a floor lowered height to adjust the attachment weight after the  Attachment, set
height display correctly.  Authorization Code not weight  option
 option has been enabled.
required.
 Vehicle
 Vehicle (T
(Tractor)
ractor) Manager Software
Adjustable Unnested Speed - used to select

 what speed
1.6 km/h)]
km/h) [0,allowed
] is 0.5, or when
1 mphthe
th(0, 0.8, handler
e load or ler is
hand  Tractor Manager software management can be
performed in the VM Software dialog box:
not nested.
• Identi
Identify
fy the curren
currentt ve
versi
rsion
on of softwar
software
e
iPort Basic - used to select iPort  Basic.
 Basic. installed in the truck 
• Update
Update the curren
currentt vers
version
ion of softwa
software
re
iAlert - used to select iAlert  as
 as part of the iPort    with a newer version
Premium package. • Upload
Upload the curren
currently
tly instal
installed
led version
version of
software
iControl - used to select iControl  as
 as part of the
iPort  Premium
 Premium package. NOTE: If installing a new or cleared
c leared manager,
refer to “Install Cleared (New) Manager”
Customer Interlock 1-Platform  - used for on pag
page e 3-1
3-19
9.
optional inputs (see Table
(see Table 3-2
3-2).
). 1. Clic
Click
k the Vehicle Manager Software 
the
 button on Truck Setup Screen.
Customer Interlock 2-Platform - used for
(see Table 3-2
optional inputs (see Table 3-2).
). 2. Select the softwa
software
re version
version to loa
load.
d. See
See
Fi
Figu
gure
re 3-
3-21
21..
Customer Interlock 3-Tractor - used for
(see Table 3-2
optional inputs (see Table 3-2).
). Figure 3-21. VM Software Dialog Box 
9600FW_3-20.jpg

Customer Interlock 4-Tractor - used for

optional inputs (see Table
(see Table 3-2
3-2).
).

Customer Output-Tractor - used for optional

customer outputs (see “Configuration” on
page
page 3-
3-15
15).
).

Customer Output-Platform - used for optional

customer outputs (see “Configuration” on
page
page 3-
3-15
15).
).

End of Aisle Sense - used to select the type of

magnet system that has been installed into the
floor for the End-of-Aisle system.  Authorization
Code not required.
3. Clic
Click
k the Load VM With Selected
the
Elevated Height (inches) - used to set the forks Software Version button. The new
maximum elevated height. software is then installed in the truck.
4. To display
display softwa
software
re versions
versions in th
the
e truck,
truck,
Aux Mast Lift Ht (inches) - used to set the see “Version” under “Program Mode” on
height of the Aux (mini) mast. page
page 3-
3-22
22..
5. Load updates
updates to FlashWare
FlashWare and install
install
Platform Width (inches) - used to set the software to the truck as needed to make
platform width. sure a matching set of TM/CM software is
installed.

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Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
FlashWare
NOTE: Check the software model number table
in FlashWare Help for the current
matching set.
Do not cycle the key switch, or the
6. When the installation
installation is complete,
complete, click primary memory will be restored to the
EXIT to return to the Truck Setup screen. current truck configuration.

Clear Primary Memory  4. Remove

Remove the
the Carria
Carriage
ge Ma
Manag
nager
er..

On this truck, the Clear Primary Memory Configuration

feature removes truck specific information from
the Carriage Manager.
Manager.  Truck configuration can be reviewed in the
Configuration window.
NOTE:  The Carriage Manager can be replaced
 without losing truck identity. A copy of
Click Configuration on the main Truck Setup
the truck identity is stored in both the
screen. See Figure
Figure 3-1
3-19
9. The Configuration
 Tractor Manager and Traction Power
dialog box appears. See Figure
Figure 3-2
3-24
4.
 Amplifier. If two of the three memory
storage locations agree, the truck Figure 3-24. Configuration Dialog Box 
assumes that identity. If all three 39600FW_3-23.jpg

memory locations disagree, a code AV is

displayed and a programmed Carriage
Manager and Tractor Manager must be
installed.
1. Click
lick the Clear Primary Memory on the
the
 Truck Setup screen.
2. After selecting
selecting this
this feature,
feature, the Clear
Primary Memory dialog box appears. See
Fig
Figure
ure 3-2
3-222.
Figure 3-22. Clear Primary
Primary Memory Dialog Box 
9600FW_3-21.jpg

Reset Factory Defaults

Use this feature to reset vehicle configuration,

including Superword and Password.
NOTE: Record customer-specific
configurations; e.g. speed, acceleration,
3. If No is selected, the action is cancelled. If lift, and coast from the Truck Config
Yes is selected, a new dialog box appears. screens before  resetting
 resetting defaults.
See Figur
Figuree 3-
3-23
23.. Click OK.
Figure 3-25. Configuration Reset
Reset Dialog Box 
Figure 3-23. Remove Cleared
Cleared Memory Dialog Box 
Box  39600FW_3-24.jpg

9600FW_3-22.jpg

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ed: 15 Jun 2010 3-15
 

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

FlashWare
BSOC Calibration 1. Clic
Click
k the Clear Vehicle Manager button
the
on the right side of the Truck Setup
5 is the factory default and specifies the average screen. See Fi
Figur
gure
e 3-1
3-19.
9.
 voltage that is considered as 0% BSOC. 2. The Erase
Erase Vehicle
Vehicle Manager
Manager Softwar
Software
e dialog
dialog
 box is displayed. See Figur
Figure
e 3-2
3-26.
6.
Making this number smaller (down to 1) lowers
Figure 3-26. Erase Vehicle
Vehicle Manager Software Dialog Box 
the average
resulting in voltage considered
increasing the timeas
to 0% BSOC,
reach 0%
39600FW_3-25.jpg

BSOC, by using more battery capacity.

Making this number higher (up to 9) increases

the average voltage considered as 0% BSOC,
resulting in decreasing the time to reach 0%
BSOC, by using less battery capacity.

If BSOC is lowered such that the battery

is depleted to below Specific Gravity
1.120, the battery can be permanently
damaged.

Customer Outputs - Tractor and Platform

3. Click ERASE. Memory is cleared and the
 This option controls the 48V
48V output available at manager can now be programmed as a
the Tractor and Platform Customer Output  Tractor Manager or a Carriage Manager
Manager..
connectors (PCO1 and 2). Functionality is
enabled by selecting one of the following
Customer options.
Clear Carriage Manager
• None  NOTE: To clear a Carriage Manager, it must first
be programmed as a Tractor Manager.
• 3 mph Limit  -
 - activates an external device
 when travel speed is <3 mph in the 1. Connect
Connect directly
directly to the Carriage
Carriage Manag
Manager
er
tractor-first direction and at 0 mph. This and start FlashWare.
FlashWare. See “Starting
setting is designed to activate an optional FlashWare”
FlashW are” on page
page 3-11
3-11..
camera. 2. At the
the VM Software
Software s
screen,
creen, click to open
open
• Lift Hours  -
 - can be used to capture lift the Model103B folder and select VM
hours when using a wired third party software to be loaded. See Figur
Figure
e 3-2
3-27.
7.
 warehouse management system. This
setting records lift/lower hours.
• Wire Guidance Status  -
 - can be used to
record when the system is in the auto or
manual guidance mode.

Clear Vehicle Manager (Tractor

Manager)
 The Clear Vehicle
Vehicle Manager feature provides the
ability to purge existing memory and software
from the manager so that it may be used in a
different model truck.

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Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
FlashWare
Figure 3-27. VM Software Screen
Screen - Folder Selection
Selection  This feature is used to view/update Carriage
39600FW_3-26.jpg
Manager software and view/install/update
Power Amplifier software.
NOTE: If installing a new or cleared manager,
refer to “Install Cleared (New) Manager”
on pag
page e 3-1
3-19
9.
1. Click Carriage Manager/Power Amp
Software button in the main Truck Setup
screen.
2. When the Carriage
Carriage Manager/Pow
Manager/Powerer Amp
Amp
Screen appears, follow prompts on the
screen to Load/Upload software. See
Figure
Figure 3-2
3-28.
8.

3. Click
lick the Load VM With Selected
the
Software Version button. When load is
complete, the Truck Setup screen is

displayed.
4. From
From the Tr
Truck
uck Setup
Setup screen, selectt Clear
screen, selec
Vehicle Manager and follow the prompts.

Carriage Manager/Power Amp

Software
NOTE: Refer to the Software Release Reference
Guide posted on iNet for current
software version information.
Figure 3-28. Software on CAN connection
connection Screen
Screen
9600FW_3-27.jpg

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ed: 15 Jun 2010 3-17
 

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

FlashWare
Programming the Carriage Manager

Select Carriage Manager in the device window,

then select desired software version in the
software window. Click LOAD with selected
software version. See Figur
Figure
e 3-2
3-29.
9.

Figure 3-29. Carriage Manager

9600FW_3-28.jpg
Manager Software Selection
Selection

Programming the Traction Power Amplifier

Select Traction Power Amplifier in the device

 window, then select desired software version in
the software window. Click LOAD with selected
software version. See Figur
Figuree 3-2
3-29.
9.
Figure 3-30. Traction
Traction Power Amplifier Software Selectio
Selectionn
9600FW_3-29.jpg

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3-18 Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
FlashWare
Programming the Lift Power Amplifier

Select Lift Power Amplifier in the device

 window, then select desired software version in
the software window. Click LOAD with selected
software version. See Fi
Figur
guree 3-2
3-29.
9.

Figure 3-31. Lift Power Amplifier

9600FW_3-30.jpg
Amplifier Software Selection
Selection

RECONNECT (Re-read Truck) NOTE: If FlashWare cannot communicate with

the manager, verify B+ and B– to the
 This feature is used to re-establish manager. Verify FlashWare program and
communication with the vehicle. cables are functioning properly by
testing on another manager. If you are
still unable to communicate with the
SAVE Settings to File manager, replace it.
 This feature is used to store the vehicle’s 2. At the
the VM Software
Software screen,
screen, click
click to
to open
open
current configuration for future reference. the Model103B folder and select the
correct software to be loaded.
SEND Changes to Truck  3. Click
lick the Load VM With Selected
the
Software Version button. When load is
 This feature is used to transmit desired option complete, the Truck Setup screen is
and height-related changes to the vehicle. displayed.
4. Exit FlashW
FlashWare.
are. Cycle
Cycle key
key switch
switch and
and run
run
Install Cleared (New) Manager Learn. See “Le
“Learn”
arn” on page 3-23.

 This feature is used to load Tractor Manager or

Carriage Manager software in a cleared (new)
manager.
1. Connec
Connectt directl
directly
y to the manage
managerr bein
being
g
installed and start FlashW
FlashWare.
are. See
“Starting FlashWa
FlashWare”
re” on page 3-11.

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Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Operator Displays

Operator Displays
 The lift truck has two Operator Displays. The
Primary Operator Display is in the right control
arm, as viewed by the operator when seated.

See Figu
Fi
locatedgure
re the
on 3-32
3-32.. The
left Supplemental
side Display
of the mast guard, asis
 viewed by the operator when facing the the tractor
to drive standing up. See FigFigure
ure 3-
3-33
33..

Operator Display 
Figure 3-32. Operator Display 
9600_062.eps

Numeric Weight Pallet Icon

(l(lb
b/kg)

2.3  Numeric SpSpeed

Numeric Height
75 in  1400 lb  (mp
(m ph or km/h)
(in/mm) mph 

Height Icon Speed Bar

3/6/09  11:45 am 

Drive Wheel Position

Primary Display
Truck Lifting and Manual Steering Selected

Numeric Battery 1396 lb  2.3 

State of Charge 80%  mph 
(BSOC) Fork/Load
Handler
BSOC Icon Position

Date 3/6/09  1:55 pm  Time

Seeking Wire/Rail Icons Traverse Position

GuideWire/Rail Icons Platform Icon

Primary Display
Truck Traveling
Traveling and with Automatic Steering
(Wire Guided Mode) Selected

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3-20 Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Operator Displays

Supplemental Display 
Figure 3-33. Supplemental
Supplemental Display 
Display 
S80411A.EPS

Drive Wheel
Direction LEDs

Guide Wire/
Rail LEDs
Seeking Wire/
Rail LEDs
Forks Nested
LED

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Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Modes of Operation

Modes of Operation  Version

 Version
 The version of software resident in the
the following
Overview of Modes devices is displayed:
• CM - Car
Carri
riag
age
e Man
Manag
ager
er soft
softwa
ware
re
 This lift truck has several modes of operation.
 The main distinction is between Run Mode and • CMB - Carria
Carriage
ge Manage
Managerr Boot
Boot Block*
Block***
**
Program Mode. Run Mode is the normal • TM - Tra
Tract
ctor
or Ma
Mana
nage
gerr sof
softw
twar
are
e
 working mode for the lift truck. Program Mode • TMB
TMB - Trac
Tractor
tor Mana
Manage
gerr Boot
Boot B
Blo
lock
ck**
****
permits configuration, calibration, and
• GM - Guid
Guidan
ance
ce Mana
Manage
ger*
r*
diagnostic testing.
• PAT
PAT - Tra
Tract
ction
ion Po
Powe
werr Amp
Amp sof
softw
twar
are
e
Run Mode • PATB
PATB - Trac
Tractio
tion
n Powe
Powerr Amp
Amp Boot
Boot Bloc
Block**
k****
• PATV
PATVCL
CL - Tra
Tract
ctio
ion
n Powe
Powerr Amp
Amp VC
VCL*
L***
 When you power the lift truck on normally, the • PAL
PAL - Lift
Lift Po
Powe
werr A
Amp
mp softw
softwar
are
e
on-board firmware performs a number of
internal self-tests and enters the default mode • PALB
PALB - Lift
Lift Pow
Power
er A
Amp
mp Boo
Boott Block
Block**
****
of operation, Run Mode. Run Mode is the • PALV
PALVCL
CL - Lif
Liftt Pow
Power
er Amp
Amp V
VCL
CL**
**
normal working mode. In Run Mode, the
Operator Display shows the default display. *Guidance Manager change requires firmware
chip to be replaced to change version.
Program Mode **VCL = Vehicle Control Language. This is
Raymond specific software for the amp.
Use Program Mode for configuration,
calibration, and diagnostic testing on the lift
***Boot Block software cannot be changed in
truck. You need a password in order to enter
the field.
“Passwords”
Program Mode. See “Pass words” on page
page 3-24
3-24..
NOTE:  When using FlashWare,
FlashWare, the amp VCL
Program Mode is divided into six categories: file and software are located in the same
• Serial # file.
• Version
Hour Meters and Distance Indicator
• Hr Mtrs
• Config  The Operator Display shows the following
following
• Lear n (Superword required) accumulated totals:
• Maint (Superword required) • KH : Total hours the key switch has been
turned ON
 When Program Mode is exited, the electronic • HD : Total hours on deadman
key prompt is displayed (if enabled) or the truck • HL : Total hours spent lifting and lowering
performs Selftest and enters Run Mode.
• TM : Total distance traveled (miles or
kilometers, depending on Units specified
Serial # in Config)
 The serial number displayed must match the • HT : Total hours spent traveling
serial number on the tractor and mast • HA : Total hours on Load Handler 
specification plates. This field cannot be
changed from Program Mode.

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3-22 Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Modes of Operation
Config
Use Configure Mode to adjust various lift truck Disconnecting wires or connectors to
performance parameters to specific customer integrated circuits with power ON can
requirements. To enter Configure Mode, you result in premature failure of those or
must enter the Password or Superword. other components. Always disconnect
NOTE: Some items in Configure Mode appear the battery before making or breaking
only if Superword is entered and/or the any connections.
option has been enabled.

For detailed description, see “Using Configure

Mode”
Mod e” on page
page 3-2
3-266.
During Maintenance Output Te Tests,
sts,
Learn always jack the drive tire off the floor
and open the Emergency Lowering
Use Learn Mode to calibrate the lift truck for  Valve.
correct operation. You can select the following
fol lowing
sub-categories for calibration: Use extreme care when the truck is
jacked up for any reason. Never block
• Contro
Controls
ls (travel
(travel,, tra
traver
verse,
se, li
lift/
ft/low
lower
er,, rota
rotate)
te) the lift truck between the carriage and
• Lo
Load
ad Hand
Handle
lerr (Ld
(Ld Hndl
Hndlr)
r) the floor. Keepthe
hands and feet clear
• Weight    while jacking lift truck. After the lift
truck is jacked, place solid blocks or jack
• Guidance stands beneath it to support it. Do not  
rely on the jack alone. See “Jacking
 To enter Learn Mode, you must enter the Safety” on page 2-10
2-10..
Superword.
Follow all instructions contained in this
For detailed description, see “Using Learn manual for each test. If you are unsure
Mode”
Mod e” on page
page 3-3
3-333. how to conduct a test while in
Maintenance Mode, do not proceed with
Maint the test.

Maintenance Mode allows service technicians to

check/test individual circuits within the
 Active Maintenance
Maintenance Mode
system. Maintenance Mode is accessed through  Active Maintenance Mode (ActMaint), when
Program Mode after the Superword is entered.
enabled in Config, permits testing of various
Refer to “Using Maintenance Mode” on
systems on the truck. In Active Maintenance,
page
page 3-
3-37
37 to
 to access Maintenance Mode.
all Analog and Digital inputs can be selected
NOTE: If the input/test does not appear in the  with the results displayed while operating the
Maintenance Mode menu for an option truck in Run Mode. Refer to “Using Active
 when you think it should, either that Maintenanc
Maint enancee Mode (ActMaint)” on page 3-39
3-39..
option is not enabled (via FlashWare) or
the truck does not have the latest
software.
Passwords
NOTE: If you need to enter Maint several times Electronic Operator Key 
to resolve a problem, it may save time if
Superword is temporarily changed to a Electronic Operator Key is a feature that allows
single digit Superword
the correct code. Remember
when to re-enter
you are the customer to assign up to 20 operator
electronic keys (passwords). With Operator Key
done.

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Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Modes of Operation
enabled, the operator is prompted to enter • A tract
traction
ion system
system shutdo
shutdown wn - trave
travell is not
his/her electronic key when the key switch is allowed. Lift, lower, steering, and horn
turned ON. Truck operation is not allowed functions operate normally.
unless the correct electronic key or Superword   • A shutd
shutdown
own in the lif
lift/lo
t/lower
wer system
system - lift
lift
is entered. and lower are not allowed. Travel, horn,
and steering functions operate normally.
Password • Lo
Load
ad Hand
Handle
lerr shut
shutdo
down
wn

Password permits access to Configure Mode Tone 4. A continuous tone with deadman pedal
only. It is intended for customer use in setting pressed and Auto/Manual switch in Manual
performance parameters within those features indicates the truck is over the guide wire.
purchased with the lift truck.
Tone 5. Tone ramps up then repeats, indicating
Superword the truck is seeking and aligning over the guide
 wire. The tone continues until the truck is
Superword permits access to all Program locked on the guide wire or the Auto/Manual
Modes. Superword is intended to limit service switch is changed to Manual.
access to qualified and trained service
technicians. Tone 6. Descending tone (bomb drop) that
indicates an incorrect Password or Electronic
 We strongly  recommend
 recommend that, during Passkey was entered.
installation, you change the Superword from
the factory default to a code known only to the  The tones described do not repeat continuously.
dealer and/or owner so that access to  A fault code and associated message scroll
Diagnostic Mode is limited to qualified across the Operator's Display. The message
personnel. Make sure to record the new repeats continuously until the key switch is
Superword in a safe place. If this code is lost or turned OFF.
forgotten, a technician must reset the lift truck
to factory default settings. This makes it
necessary to reconfigure all variable settings.

Run Mode Tones

Tone 1. A single tone that indicates:

• A key
key on the
the Ope
Opera
rato
torr Key
Keypa
pad
d
(Up/Down/Left/Right/Enter) is depressed
• Maxi
Maximu
mum
m st
steer
eer req
reques
uestt is reach
reached
ed

Tone 2. Two tones (high/low) that indicate the

 TPC and LPC contactors are disabled
disabled (opened).
 Travel, steering, and lift/lower are disabled and
the brake is applied until the problem is
corrected.

Tone 3. Three tones (high/medium/low) that

indicate:
• A trav
travel
el performa
performance
nce limitat
limitation
ion - trav
travel
el
speed is limited to 1 mph (1.6 km/h). Lift,
lower, steering, and horn functions
operate normally.

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3-24 Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Modes of Operation

Using Program Mode appears. Initially, the left-most character

position is flashing, showing it is the
currently selected position.
he left/right buttons to select a
2. Use tth
different character position.
By entering Program Mode, safety
3. Once the chara
character
cter position
position is selected,
selected,
circuits
are associated
disabled. with
Follow all the
instructions in  
 ACR System  use the up/down buttons to select the
this manual for each test. If you are desired number, letter, or space. The
unsure how to conduct a test while in character set wraps between “z” and “_”
Program Mode, STOP: do not proceed   (space). To go quickly from the letter “z” to
 with the test. Contact an authorized the number “0,” press the down button
Raymond dealer.
dealer. twice.

 To enter Program Mode, use the the right button to _0123456789ABCDEFGHIJKLMNOPQR
obtain the cursor prompt. Using the up/down  STUVWXYZ
 buttons to scroll to the desired number and the 4. Repeat steps 2 and
and 3 for the remaining
remaining
left/right buttons to move to a different Electronic Operator Key, Password, or
character position, enter the Password or Superword characters.
Superword, then press Enter. 5. When
When all charac
character
ters
s in the Ele
Electro
ctronic
nic
Operator Key, Password, or Superword are
Figure 3-34. Operator Display
1092022-button.cgm
Display Control Buttons entered, press the Enter button once.
6. If an
an invalid
invalid Electronic
Electronic Opera
Operator
tor Key,
Key,
Password, or Superword is entered, a tone
sounds and Invalid Password is displayed
 before returning to the password prompt
screen.
7. If a mistake
mistake is made entering
entering a chara
character
cter,,
repeat steps 2 thru 5.
Up  When a correct Electronic Operator Key  is
 is
Left entered, the truck completes SelfTest and
Enter Right
enters Run Mode.
 When the correct Password or Superword  
is entered, one of the following is displayed
for 3 seconds:
Down a. If Password
Password is entered
entered,, the fol
followin
lowing
g is
displayed:
• Quit  
Entering Electronic Operator Key, • Serial #
Password, or Superword • Version
• Hr Meter  
 An Electronic Operator Key, Password, or
Superword can be one to eight characters in • Config
length, having any combination of letters,
numbers, and/or spaces (indicated by an
underscore). A password of all spaces is not
 permitted.

1. When the password

password prompt
prompt displays,
displays, an
an
eight character field of underscores

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Publication: 1089040, Re-issued: 15 Jun 2010 3-25
 

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Modes of Operation
 b. If Superword is entered, the following is  To reinstate factory default settings:
displayed: 1. Select Defaults from the main menu and
• Quit   press Enter. Select Re
Rese
set?
t? Y.
• Serial # 2. Select Quit Cfg.
• Version
• Hr Meter   Changing Password or Superwrd
• Config Both Password and Superwrd can be changed
• Lear n to any combination of letters and/or numbers.
Blank spaces are not allowed [spaces are
• Maint  
represented by a down bar ( _ )].
 To exit Program Mode, select Quit and press
Enter.
If Program Mode is entered with a password,
only Password can be changed. If Program
Mode is entered with a superword, both
Using Configure Mode Password and Superwrd be changed.

Configure Mode can be accessed with  The minimum number of characters is one, the
Superword or Password, however some items in maximum is eight.
Config will only appear if Superword is entered.
 To change Password or Superwrd:
 Table 3-2
3-2 outlines
 outlines all menus and submenus 1. Enter Config using the current password
available in Config. or superword.
Quit Cfg is first displayed when Config is 2. Select Password or Superwrd (as
selected. Use the Up/Down buttons until the applicable) from the Config menu and
desired selection is displayed. Press Enter. This press Enter.
 will take you into the submenu for that item. 3. Enter
Enter the
the new
new co
code using the Up/Down 
de using
and Enter buttons.
Current values of configurable items or the
4. When
When the new
new code
code is displa
displayed
yed,, press
press
ability to enable/disable an option appear in
Enter. The display returns to the main
the submenu. To change the value, press the
menu.
Up/Down button. When the desired value
appears, press Enter.

 All possible truck configurations and options

are listed in these instructions. Only the
options associated with that particular truck
are displayed on the OD.

 To save changes, select Quit Cfg from the

Config menu and press Enter. Select Savave
e ? Y 
to save the changes made and exit Config.

 To disregard changes made in Config, select

Save? N. Config exits without saving changes.

Default Settings

NOTE: Once defaults

previous reset (R
arecannot
settings (Res
eset?
be et? Y), the
recalled.

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3-26 Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Modes of Operation
Tab
able
le 3-
3-2.
2. Conf
Config
igur
uree M
Mod
odee Men
Menuu

CONFIGURE MODE MENU

Can be entered with Password unless Superword is specified

Menu Item Selection Description

Quit Cfg Save? Y  Exits

SaveConfigure Mode
changes and leave Configure Mode
Save? N  Abandon changes and leave
leave Configure Mode

Defaults Restore Factory Defaults - see “Default Settings”

on pag
pagee 3-2
3-26
6.
Reset? Y  Restore Factory Defaults
Reset? N (default ) Do not restore Factory Defaults
CAUTION: The previous settings cannot be
recalled once defaults are reset (Reset? Y).

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Publication: 1089040, Re-issued: 15 Jun 2010 3-27
 

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Modes of Operation

CONFIGURE MODE MENU

Can be entered with Password unless Superword is specified

Menu Item Selection Description

Speed Set Max Travel Speed

Max Speed (default ) 0.0 or 1.0 to 6.0 mph (0.1 mph increments)

 T Accel Set Travel Acceleration

Hard
Medium (default )
Soft 

Coast  Set Coast 

Long
Medium (default )
Short 

Spd/Hgt-1 Set Max Travel Speed above a given height 

Height1 Height 1 (1 in. increments)
Speed1 Speed 1 (0.1 mph increments)

Spd/Hgt-2 Set Max Travel Speed above a given height 

Height2 Height 2 (1 in. increments)
Speed2 Speed 2 (0.1 mph increments)
OOA Spd Out-of-Aisle Speed: Set Max Travel Speed when
(Superword only ) truck is not located in a rail or wire guided aisle
 Travel - enabled with FlashWare.
Max Speed (default ) 0.0 or 1.0 to 6.0 mph (0.1 mph increments)

UnNestSp Set Max Travel Speed when Load Handler is

(Superword only ) Unnested - enabled with FlashW
FlashWare.
are.
1 mph (default ) 0 to 1.0 mph (0.5 mph increments)

 AlarmT  Set Alarm for Traction - enabled with

(Superword only ) FlashWare.
FlashW are. Choose one of following:
None Off 
Both (default ) On in both directions
Fork Ld On when forks leading
Fork Trl On when forks trailing

EOASpeed Set End-of-Aisle Speed - enabled with

FlashWare.
1.0 mph (default ) 0.0 or 1.0 to 6.0 mph (0.1 mph increments)

 AuxSpd/Ht  Set Max Travel Speed when mini-mast is above

(Superword only ) a given height - enabled with FlashWare.
Max Speed Speed (0.1 mph increments)
Max Height  Height (1 in. increments)
Note: “Travel Speed Limited due to Aux Mast
Ht” must be enabled in FlashWare.

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3-28 Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Modes of Operation

CONFIGURE MODE MENU

Can be entered with Password unless Superword is specified

Menu Item Selection Description

LftAccel Set Lift/Lower Start/Stop Acceleration

Hard
Medium (default )
Soft 

LwrDecel 2 (default ) Set Lower Deceleration Rate: 0-5

0 = quickest, 5 = slowest 
Note:  This setting affects the height that decel
 begins.

LftLimit  Enter a height between 0 and maximum

(Superword only ) elevated height. If option is enabled with
FlashWare,
FlashW are, lift is disabled above the configured
height.
Enable Enable
Height 
Disable

Lft Byps Disable Set Lift Bypass height - enabled with

Lift  (Superword only ) Enable (default ) FlashWare.
Height1 - lowest  Note: Up to 4 different bypass heights can be
Height2 programmed. The default is the maximum
Height3 height programmed using FlashWare.
FlashWare.
Height4

 AlarmL  Set Alarm for Lift/lower - enabled with

(Superword only ) FlashWare.
None Off 
BOTH (default ) ON in both directions
Lift  ON when lifting
Lower  ON when lowering

Lwr Byps Set Lower Bypass Height - enabled with

(Superword only ) FlashWare.
Disable
Enable
10 inches 0.0 to 48 in. (1 in. increments)
Note: Setting the height to 0.0 is the same as
not having a Lower Bypass

LH Accel Set Load Handler Acceleration for Traverse and

Rotate
Hard
Medium (defaul tt))
Ld Hndlr  Soft 

 Trvse Sp Set Traverse Speed

(Superword only ) Slow (default )
Medium
Fast 

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Publication: 1089040, Re-issued: 15 Jun 2010 3-29
 

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Modes of Operation

CONFIGURE MODE MENU

Can be entered with Password unless Superword is specified

Menu Item Selection Description

Reset  Battery State-of-Charge Reset 

BSOC 75 (default )  Variable
 Variable from 55 to 100 in increments of 1
(Superword
only ) Cut Out  Select Battery Cutout Volta
Voltage
ge
20 (default )  Variable
 Variable from 0 to 50 in increments of 1

Units English (default ) Select English or Metric units of measure.

Metric

 Type Wire Select between Wire, Rail Guidance, or None

Rail (only appears if the option is installed on the
None truck and enabled in FlashWare).

Set Heading Angle and Distance From Wire

HA SLOW 1.6 deg (default ) 0.6 to 2.0° in 0.2° increments

HA STOP 3.0 deg (default ) 2.0 to 4.0° in 0.2° increments

DFW SLOW 1.6 in. (default ) 0.6 to 1.6 in. in 0.2 in. increments

DFW STOP 3.0 in (default ) 1.6 to 3.0 in. in 0.2 in. increments

 AcquirSpd Set Acquire Speed (tractor-first only)

Guidance
1.0 mph (default) 1.0 to full speed in 0.1 mph increments
increments
Note:  Forks-first acquire speed is fixed at
1.0
1.0 mp
mph.h.

FreeSpeed Set top speed of truck when not in wire

guidance mode (Auto/Manual switch in
Manual) and the wire is not sensed.
Max Speed (default ) 1.0 to max speed (0.1 mph increments
increments))

SensCreep Enable (1.0 mph max) Set Sense Creep Speed. When enabled,
Disable  Auto/Manual switch in Manual,
Manual, and wire is
sensed, truck soft plugs to 1 mph and remains
remains
speed limited until wire is no longer sensed or
 Auto/Manual switch is set
set to Auto.

Language English (default ) Set language for Error Messages - enabled with
Spanish FlashWare
French

Password Enter New Password

1_______ Display Current Password
 (factory setting 
 factory setting )

Superwrd Enter New Superword

(Superword only ) 2_______ Display Current Superword
PassWord
(factory setting 
  factory setting )

Elec Key  Enter New Electronic Keys (up to 20) - enabled

 with FlashWare
FlashWare
3_ _ _ _ _ _ _ Display Current Elec Key 
( factory setting 
 factory setting )

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3-30 Publication: 1089040, Re-issued: 15 Jun 2010
 

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Modes of Operation

CONFIGURE MODE MENU

Can be entered with Password unless Superword is specified

Menu Item Selection Description

Mnt Mind Set parameters for Maintenance Minder 

Enab\Dis Disable  Turn Maintenance Minder  ON/OFF 
 ON/OFF 
Enable
Reset  Reset #hours (deadman) until next reminder 

Setup 300 Hrs (default ) Set #hours between reminders

Msg Only (default ) Choose between Lift CutOut or Message Only 
For more information, refer to “Maintenance
Minder™
Mind er™ Tool” on
on page
page 4-3
4-3))

Clock  Set Time/Date

 Time HH:MM:SS Set time of day (AM or PM)
 –AM
 –PM
Date MM/DD/YY  Set date
24-Hour  Disable  Turn 24 hour clock ON/OFF 
Enable

 Auto Off Disable

10 Min (default ) Set idle
turns offtime
afterfor automatic
the shut-off.
programmed Truck
setting with no
5 Min activity while off the deadman.
4 Min
3 Min
2 Min
1 Min

 ActMaint  Set Active Maintenance

(Superword Enable (default )
only ) Disable

Brighten Up Set brightness of Operator Display 

Down
Default 

CustInt1 Customer Interlock Input 1 - Platform: enabled

(Superword CI Speed  with FlashWare
FlashWare
only ) 0.0 mph (default ) 0.1 mph increments
CI Lift 
Enable
Disable (default )  This option can disable lift and load handler
handler
CI LH functions, and also limit the truck's speed
Enable  based on the state of the input to the CM.
Disable (default )

CustInt2 Customer Interlock Input 2 - Platform: enabled

Customer
(Superword CI Speed  with FlashWare
FlashWare
only ) 0.0 mph (default ) 0.1 mph increments
CI Lift 
Enable  This option can disable lift and load handler
handler
Disable (default ) functions, and also limit the truck's speed
CI LH  based on the state of the input to the CM.
CM.
Enable
Disable (default )

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Publication: 1089040, Re-issued: 15 Jun 2010 3-31
 Publication: 1089040, Re issued: 15 Jun 2010 3 31

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Modes of Operation

CONFIGURE MODE MENU

Can be entered with Password unless Superword is specified

Menu Item Selection Description

CustInt3 Customer Interlock Input 3 - Tractor: enabled

(Superword CI Speed  with FlashWare
FlashWare
only ) 0.0 mph (default ) 0.1 mph increments
CI Lift 
Enable  This option can disable lift and load handler
handler
Disable (default ) functions, and also limit the truck's speed
CI LH  based on the state of the input to the TM.
Enable
Disable (default )

CustInt4 Customer Interlock Input 4 - Tractor: enabled

(Superword CI Speed  with FlashWare
FlashWare
only ) 0.0 mph (default ) 0.1 mph increments
CI Lift 
Enable  This option can disable lift and load handler
handler
Disable (default ) functions, and also limit the truck's speed
CI LH  based on the state of the input to the TM.
Enable
Disable (default )
Init Spd Set max travel speed after key switched ON and
 before the 3rd party unit sends a speed request.
0.1 mph increments
iPort  MAX SPEED (default )

Err Spd Set max travel speed after communication is

lost with the 3rd party unit.
MAX SPEED (default ) 0.1 mph increments

 TF MAX SPD 6.0 mph Max TF travel speed se

setting
tting

FF MAX SPD 6.0 mph Max FF travel speed setting

iP Lim Mast Vel DN 100% Percentage of max lower speed setting

(View only ) Mast Vel UP 100% Percentage of max lift speed setting

 T Accel Medium Travel acceleration profile setting

L Accel Hard Lift acceleration profile setting

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 3 32 Publication: 1089040, Re issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Modes of Operation

Using Learn Mode

 To place the lift truck in Learn Mode: Make sure there is sufficient room for
1. Ente
Enterr Supe
Superw
rwor
ord.
d. the Load Handler to traverse and rotate
2. From
From the Pro
Progra
gram
m Mode Super
Superwor
word
d Level
completely in both directions.

menu, up/down buttons to select

Learn, use
thenthe
press the Enter button. The  The fork carriage can be in any position at the
start of Learn. However, for best results, start
selected menu item is indicated by an
from the Load Handler nested right position.
arrow to the left of the selection.
3. The Learn
Learn Mode
Mode menu
menu is
is displa
displayed
yed::  With LD Hndlr selected at the Learn Mode
• Controls menu, press Enter.
• Ld Hnd
Hndlr
lr (Lo
(Load
ad Han
Handl
dler
er))
 The Load Handler traverses and rotates with no
• Weight   control inputs once Learn is selected and both
• Wire Gu
Guidance Deadman pedals are depressed.
• Rail Gu
Guidance
 The Load Handler first rotates clockwise to the
Use the up/down and/or left/right  stop, then counterclockwise to the stop. The
 buttons to select the category desired. Load Handler hits the stops harder than when

Learn Controls in Runclockwise

rotate Mode. The Load
and Handler shouldagain,
counterclockwise then
slowing down just before reaching the stops.
 With Controls selected at the Learn Mode
menu, press Enter.  The Load Handler then traverses left to the
stop, pause, then traverse right to the stop. The
During Learn Controls, the Carriage Manager Load Handler hits the stops harder than when
control circuits are calibrated to the output in Run Mode. The Load Handler should then
 voltage of the Rotate (VR3)
(VR3) and Traverse/Reach traverse left and right again, slowing down just
jus t
(VR4) pots.  before reaching the stops.

 The Carriage Manager also

also communicates the Learn Weight
status of the Travel (VR1) and Lift (VR2) pots to
the Tractor Manager for calibration. Learn Weight is used to calibrate the weight
displayed. The Main Lift Pressure transducer is
 This determines the neutral position for the used with the main lift cylinders and the Mini
command pots. The maximum and minimum Lift Pressure transducer is used with the
positions are calculated during Run Mode and mini-mast lift cylinder.
adjusted as necessary to compensate for
component wear.
wear.

Learn Ld Hndlr (Load Handler) Make sure there is sufficient lifting

height to elevate both the main and
Use Learn Load Handler to determine the
mini-masts.
extreme positions of the Rotate Position
1. With Weight selected at the Learn Mode
Feedback (VR6) and Traverse Position Feedback
menu, press Enter. The following message
(VR5) pots, and opening points for the
should be displayed.
proportional valves (SOL7 and SOL8) by the
Carriage Manager.
Lift main mast at least 4 inches with the
forks empty, then press Enter

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 Publication: 1089040, Re issued: 15 Jun 2010 3 33

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Modes of Operation
NOTE: If mast will not lift the required 4 in.,  With Wire Guidance selected at the Learn Mode
check Lift Bypass (Lft Byps) setting in menu, press Enter.
Configure mode (refer to Table
Table 3-2 on
page
page 3-
3-27
27)). Step 1 - Initial Learn Frequency and Signal
Strength
2. Elevate
Elevate the
the truck
truck as
as instru
instructed
cted..

LEARNING Step 1 learns the frequency and field strength of

the floor signal. The guidance system actually
PASSED
“searches” for the frequency generated by the
should display. floor signal as well as the field strength.
3. Lift mini mast at least 4 inches with the
forks empty, then press Enter Center on wire. LLL

should display. Press ENTER. @LLL

4. Elevate
Elevate the
the truck
truck as
as instru
instructed
cted.. LL=58 LN=103 LR=64
TL=71 TN=98 TR=65

LEARNING
PASSED  When the Enter button is pressed, the numbers
should display. on the display change, indicating the system is
switching between multiple frequencies and
strengths. The Guidance Manager determines
Learn Wire Guidance  what frequency and field strength the floor
signal is generating.
 The following information is for a correctly
functioning wire guidance system. If problems Busy learning wire..
are encountered while trying to perform these
procedures, refer to “Bad Coil Values” on
page
page 5-
5-21
21.. LL= 58 LN=103 LR= 64
TL= 71 TN= 98 TR= 65
Learn Guidance is a six step process:
1. Initia
Initiall Learn Frequ
Frequenc
ency
y and Signa
Signall  The numbers cycle from 1 to 199 until the
Strength system is able to calibrate itself to the floor
2. Initia
Initiall Learn Offset
Offset Betwee
Between
n Anten
Antennas
nas signal. If the message Learn wire failed, Press
3. Initia
Initiall Learn
Learn Steer
Steer Zero
Zero Posit
Position
ion Enter to retry is displayed, refer to “Bad Coil
 Values”
 Values” on page 5-21
5-21..
4. Final
Final Learn
Learn Freque
Frequency
ncy a
and
nd Signa
Signall
Strength Step 2 - Initial Learn Offset Between
5. Final
Final Offset
Offset Betwee
Between
n An
Anten
tennas
nas  Antennas
6. Final
Final Learn
Learn Ste
Steer
er Zero
Zero P
Posit
osition
ion
Step 2 learns the Offsets for the antennas.
Before performing the following procedures: Following the screen message, Must lock onto
wire, press the Auto/Manual switch to AUTO,
• Veri
erify
fy the
the line
line driver
driver is a
adju
djusted
sted to the
the
correct frequency and amplitude. Must lock onto wire..
• Center
Center the truc
truck
k ov
over
er tthe
he guid
guide
e wire
wire with
within
in
0.5 in. (13 mm).
NOTE: It is easier to center the load antenna
first, then center the tractor antenna.
• Place
Place the truck
truck in an area
area that
that all
allows
ows Guide Tractor First. is displayed. The display
tractor-first travel for upcoming steps. also shows Trac Ant = +x.xx’’ which is the
distance from the wire as calculated by the

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 3 34 Publication: 1089040, Re issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Modes of Operation
 Tractor Antenna. The display also shows Step 4 - Final Learn Frequency and Signal
+x
+x.x
.x mph
mph. Drive tractor-first at 1.5 to 2 mph Strength
(2.4 to 3.2 km/h) for a distance of approx. 20 ft.
(6m). Re-enter Wire Guidance Learn.

Guide tractor first. Step 4 learns the frequency and field strength
s trength of
the floor signal.
Trac Ant = +0.09”
  + x.x mph Center on wire. LLL

Press ENTER. @LLL

Gently coast to a stop, and hit ENTER is LL=58 LN=103 LR=64
displayed. Return the throttle to neutral and TL=71 TN=98 TR=65
allow the truck to coast to a stop. After the
truck has come to a complete stop, press Enter. the Enter button is pressed, the numbers
 When the
 The Trac Ant value should be 0.00 ±0.40. on the display change, indicating the system is
switching between multiple frequencies and
Gently coast to a stop,
and hit ENTER. strengths. The Guidance Manager determines
 what frequency and field strength the floor
Trac Ant = x.xx” signal is generating.
  +x.x mph

Busy learning wire..

Step 3 - Initial Learn Steer Zero Position
LL= 58 LN=103 LR= 64
Step 3 learns the Steer Zero Position. Guide TL= 71 TN= 98 TR= 65
both ways to minimize, hit ENTER.  is
displayed. The display also shows Wire Dist:
+x.xx”  and +x.x mph.  The numbers cycle from 1 to 199 until the
system is able to calibrate itself to the floor
Guide both ways to signal.
minimize, hit ENTER.
 Wire Dist: +0.09”
Step 5 - Final Learn Offset Between
+1.2 mph Done=None
 Antennas

NOTE:  While performing this portion of Learn, Step 5 learns the Offsets for the antennas.
the truck must travel at least 1.5 mph Following
wire , pressthe
thescreen Must lock
message switch
Auto/Manual onto
to AUTO,
(2.4 km/h) and not be aggressively
accelerating. A rotating spinner in the
upper right corner of the display Must lock onto wire..
indicates a valid Learn is in process.

 Travel in both directions a minimum of 100 ft.

(30.5m) (shorter aisles require multiple runs)
until the numbers for Wire Dist are
consistently within ±0.25 in. in both directions. Guide Tractor First. is displayed. The display
Press Enter. Learn Wire Guidance exits and the also shows Trac Ant = +x.xx’’ which is the
Learn Mode menu is displayed. distance from the wire as calculated by the
 Tractor Antenna. The display also shows
NOTE: If, after several attempts, the truck does +x
+x.x
.x mph
mph. Drive tractor-first at 1.5 to 2 mph
not consistently track within ±0.25 in., (2.4 to 3.2 km/h) for a distance of approx. 20 ft.
press Entersteps
and repeat  to exit. Re-enter
1 thru 3. Guidance (6m).

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 Publication: 1089040, Re-issued: 15 Jun 2010 3-35

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Modes of Operation
1. Place the truck
truck in an area
area where
where there
there is a
Guide tractor first. straight line at least 20 ft. (6m) in length
that can be used as a reference (such as
Trac Ant = +0.09”  wire guidance groove, yellow aisle marker,
marker,
  + x.x mph or rail).
2. Select Manual  (ON)
 (ON) on the Auto/Manual
Gently coast to a stop, and hit ENTER is switch. The truck is now in “seeking
“see king mode”
displayed. Return the throttle to neutral and and can be driven with manual steering.
allow the truck to coast to a stop. After the 3. Position the truck
truck so that
that it drives parallel
parallel
st op, press Enter.
truck has come to a complete stop, to the reference line. Make small
 The Trac Ant value should be 0.00 ±0.10. corrections with the steer tiller until the
truck tracks 10 ft. (3m) without deviating
Gently coast to a stop,
and hit ENTER. more than 1/2
1/2 in. (13 mm)
mm) from the
straight line.
Trac Ant = x.xx”
  +x.x mph 4. Manually
Manually activate
activate and
and secure the rail
switch to simulate the truck is in a rail
guided aisle.
Step 6 - Final Learn Steer Zero Position
5. With Rail Guidance selected at the Learn
Mode menu, press Enter. The display
Step 6 learns the final Steer Zero Position.
Guide both ways to minimize, hit ENTER. is shows
number “Rail Offset:
between +/–X.X
–5.0 where
and +5.0. X.Xisisthe
This a
displayed. The display also shows Wire Dist:
steer proximity offset from dead center in
+x.xx”  and +x.x mph.
degrees. Rail Detect and Auto/Manual
Guide both ways to switch status is also displayed.
minimize, hit ENTER.
 Wire Dist: +0.09” Rail Offsets +X.X 
+1.2 mph Done=None Rail Detect Sw: ON/OFF
 Auto/Manual Sw: ON/OFF

NOTE:  While performing this portion of Learn,

the truck must travel at least 1.5 mph 6. Select Auto  on
 on the Auto/Manual switch
(2.4 km/h) and not be aggressively (OFF). The steer unit centers and manual
accelerating. A rotating spinner in the steer is disabled.
upper right corner of the display 7. Drive
Drive forwar
forward
d 10 ft
ft.. (3m).
(3m). Measu
Measure
re
indicates a valid Learn is in process.
deviation
Deviation from thebe
should reference line.mm). If
<1 in. (25.4
 Travel in both directions a minimum of 100 ft. deviation
deviation is >1 in. (25.4
(25.4 mm), proceed to
(30.5m) (shorter aisles require multiple runs). the next step.
step. If devi
deviation
ation is <1 in.
 The display indicates when it has successfully (25.4 mm), proceed
proceed to step
step 11.
learned each direction by displaying Fork, Trac 
or Both (when both directions are learned). 8. Drive
Drive the
the truc
truck
k back
back to the
the origina
originall
position.
Continue to drive the truck in both directions 9. Use tthhe up/down buttons to adjust the
until Done=Both is displayed.  value on the display. More negative
numbers cause the truck to drive to the
Learn Rail Guidance right when driven tractor-first. Changing
the value by 0.1 corresponds to a deviation
Perform Learn Rail Guidance to adjust the of approx. 0.25 in. (6 mm) over 10 ft. (3m).
center position of the drive unit so that the 10. Repeat steps 7 thru
thru 9 until a deviation
deviation of
truck tracks straight while in the aisle. 1 in. (25.4
(25.4 mm) or less
less over 10 ft. (3m)
(3m) is
achieved.

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 3-36 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Modes of Operation
11. To save
save the
the value,
value, press the Enter button.
press the number and its status. To return to the Input
Select Save? Y and press Enter. menu, press the left or right button.
12. Learn
Learn Rail
Rail Guidan
Guidance
ce is comp
complete
lete..
Refer to “Digi
“Digital
tal Inputs”
Inputs” on page
page 6-35
6-35..

Using Maintenance Mode Output Tests

 To place the lift truck in Maintenance Mode:
 When Output is selected, Output Tests are
1. Ente
Enterr Supe
Superw
rwor
ord.
d. displayed in numerical sequence. Use the
2. From
From the Pro
Progra
gramm Mode Super
Superwor
word
d Level up/down and left/right buttons to scroll to the
menu, use the up/down buttons to select desired test.
Maint, then press the Enter button. The
selected menu item is indicated by an
arrow to the left of the selection.
3. The Maintenanc
Maintenance
e Mode
Mode menu
menu is displayed:
displayed:  When performing an output test, elevate
the drive tire off the floor. See “Jacking
• Analog
Safety” on page 2-10
2-10.. Open the
• Input   Emergency Lowering Valve. See “Main
• Output   Manifold”
Manif old” on
on page
page 7-70.
• Wire Gu
Guidance
• EvtLog  To “run” a selected test, press the Enter button.
 The Operator Display prompts you to jack thethe
• Quit Mnt   drive wheel off the floor and to open the
Emergency Lowering Valve. The Operator
Use the up/down buttons to select the
Display shows the test number and its results.
category desired, then press the Enter 
 To return to the Output menu, press the left or
 button.
right button.

 Analog (Inputs)
(Inputs) “Output
Refer to “Output Tests” on page 6-36
6-36..

 When Analog is selected, Analog inputs are

displayed in numerical sequence. Use the
 Wire Guidance
Guidance
up/down and left/right buttons to scroll to the
 Wire Guidance Maintenance Mode can be used
desired input.
to examine system tracking ( Tracking Values),
 To display the selected input, press the Enter   view
Valuesindividual antenna
), and clear coil inputs
the EEPROM (Coil
on the
 button. The Operator Display shows the input
Guidance Manager card ( Clear WG EEPROM).
number and its status. To return to the Analog
 The system can function at several different
menu, press the left or right button.
frequencies and strengths. The Wire Guidance
floor signal strength must be consistent
“Analog
Refer to “Analog Inputs”
Inputs” on page 6-35
6-35..
throughout the warehouse. Refer to Publication
PDSS-0051 for floor adjustment,
Input (Digital) troubleshooting, and additional information.

 When Input is selected, Digital inputs are Tracking Values

displayed in numerical sequence. Use the
up/down buttons to scroll to the desired input. Use Tracking Values to monitor the Wire
Guidance calculated position and record
 To display the selected input, press the Enter   Tractor First (TF) and Forks First (FF) position
 button. The Operator Display shows the input  values. When centered over the wire, near-wire
coil signal strength is typically about 100%.

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 Publication: 1089040, Re-issued: 15 Jun 2010 3-37

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Modes of Operation
 When the Auto/Manual switch transitions from  wire, minimum and maximum tracking values
Manual to Auto, the stored values are cleared. are automatically recorded. The following table
 When the Auto/Manual switch transitions from lists acceptable values.
 Auto to Manual after tracking the wire,
wire, the
following values are displayed (see Figur
Figuree 3-
3-35
35):
): DFW” NW%

• Truck speed (X.X ) in upper left corner  MaxT and MaxF 0.00 to +1.00 90 to 130%
• Di
Dist
stan
ance
ce From
From th
the
e Wire (DFW”) in inches
Wire MinT and MinF 0.00 to –1.00 70 to 110%
• Heading Angle (HA ) in degrees
ing
• Near
Near Wire
Wire s
sig
igna
nall as a perc
percen
entage (NW% )
tage If the values displayed are not within these
limits, re-Learn the Wire Guidance system and
Figure 3-35. Wire Guidance Tracking
Tracking Values
Values check again. See “Learn Wire Guidance” on
_SYR0095.jpg

page
pa ge 3-
3-34
34..

Coil Values

Use Coil Values to monitor what the Guidance

Manager is sensing from the individual antenna
coils for multiple frequencies. The readings can
 be used to aid in troubleshooting the system.
 The Now , Min , and Max  coil strengths can be
selected for display. When the truck is centered
centere d
over the wire, the inner (near wire) coil signal
strength is typically about 100%. Outer (left
and right) coil signal strength is approx. 60% to
 Term Meaning
70%. These values are affected by truck
Now
Now Pr
Pres
esen
entt cal
calcu
cula
late
ted
d rea
readi
ding
ng of coil
coils
s position relative to the wire and wire depth in
the floor. For more information, refer to “Wire
MaxT
MaxT Max.
Max. calcu
calculat
lated
ed rread
eading
ing of tr
trac
actor
tor c
coil
oil pai
pair 
r 
Guidance
Guida nce Troubleshooting”
Troubleshooting” on page
page 5-21
5-21..
MinT
MinT Min.
Min. calc
calcula
ulated
ted rea
readin
ding
g of
of trac
tractor
tor coil
coil p
pair 
air 
Clear WG EEPROM
MaxF
MaxF Max.
Max. c
calc
alcula
ulated
ted rea
readin
ding
g of
of fork
fork coil
coil pa
pair 
ir 

MinF
MinF Min.
Min. c
cal
alcu
cula
late
ted
d rea
readi
ding
ng o
off fork
fork coil
coil pa
pair 
ir   This is used to clear the EEPROM on the
Guidance Manager card. When this occurs,
NOTE: Coil NW% can range from 0 to 199%. learn Wire Guidance must be performed. See
“Learn W
Wire
ire Guidance”
Guidance” on page 3-34
3-34..
 When traveling TF, thethe NW% coil readings are 1. Select Clear WG EEPROM from Wire
from the tractor end antenna coils. When Guidance sub-menu.
traveling FF, the NW% coil readings are from 2. Reset? N is displayed. Press the right 
the load end antenna coils. The display  button.
alternates automatically, depending on
direction of travel. Use the Up/Down buttons to 3. Reset? Y is displayed. Press Enter. The
obtain differences between the TF and FF  wire guidance EEPROM is cleared.
tracking information when the truck is not over
the guide wire and tracking. Evt Log
Procedure: Enter Wire Guidance/Maintenance  When Event Log is selected, the last twenty
Mode/Tracking Values. Lock the truck onto the error codes recorded are displayed. Each entry
 wire (if presently locked onto the wire, cycle the shows the code and the date and time of
 Auto/Man switch to clear existing values) and occurrence.
travel in both directions. Drive the truck the full
length of the aisle. As the truck travels on the

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 3-38 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 3. Systems Overview
Modes of Operation
• Use the up/down buttons to switch 6. The Operato
Operatorr Display
Display then shows
shows in la
large
rge
 between pages 1 and 2 of the log. letters:
• Use the left/right buttons
 buttons to exit the log Configuration Download in Progress
 back to the Maintenance Mode menu. 7. Wait for
for the
the download
download to complete
complete (approx.
(approx.
• If the
the log
log d
disp
isplay
lays
s the
the messag
message
e “Erro
“Errorr Log
Log 45 seconds to 1 minute). When the

is empty”,
since nowas
the log error codes
last were recorded
cleared. download has completed, the Operator
Display shows:
• To clea
clearr and
and rreset
eset the Event
Event Log,
Log, select
select Configuration Download Complete
Clear and press Enter. On the Clear 8. Step
Step off both
both deadm
deadman
an pedal
pedals.
s. Turn
Turn the
menu, select Yes with the down button, key switch OFF.
then press the Enter button. The log is
cleared and the display returns to the 9. Turn the
the key
key switch
switch ON.
ON. The lift
lift truck
truck
Maintenance Mode menu. should go through normal SelfTest.

Using Active Maintenance Mode

(ActMaint)
 Active Maintenance Mode allows inputs to be
displayed while the truck is in Run mode.

 ActMaint is enabled in Configure Mode. Refer to

“Usin
“Using
g Configure
Configure Mode” on page 3-26
3-26..
1. While
While in Run
Run Mode
Mode (while
(while time
time and d
date
ate
are displayed), use the up/down buttons
to scroll to either Analog or Input and
press Enter.
he up/down buttons to scroll to the
2. Use tth
desired item. Refer to “Analog Inputs” and
Inputs” and
“Digit
“Digital
al Inputs”
Inputs” on page 6-35
6-35..

Graphics Database Download

Perform a graphics database download:

• if the Operat
Operator
or Display
Display shows
shows Code
Code 5
57
7 and
and
the truck is operational
• the
the Displ
Display
ay Int
Interf
erfac
ace
e Ca
Card
rd is
is repla
replace
ced
d
• anyt
anytim
ime
e the ttru
ruck
ck soft
softwa
ware
re is upd
updat
ated
ed

 To do this:
1. Turn the key switch
switch OFF.
OFF.
2. Press and hold the lift select button.
button.
3. Step
Step on and
and hold
hold both
both deadma
deadman
n pedals
pedals..
4. Tu
Turn
rn th
the
e key
key swit
switch
ch O
ON.
N.
5. Press and release the lift select button

three times.

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 Publication: 1089040, Re-issued: 15 Jun 2010 3-39

Section 3. Systems Over view Model 9600/9700 Swing-Reach ® Maintenance Manual

Modes of Operation

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 3-40 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 4. Scheduled Maintenance

Sect
Sectio
ion
n 4. Sc
Sche
hedu
dule
led
d Mai
Maint
nten
enan
ance
ce

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 Publication: 1089040, Re-issued: 15 Jun 2010 4-1

Section 4
4.. Scheduled M
Ma
aintenance 9600/9700 Swing-Reach ® Maintenance Manual
Model 96
Scheduled Maintenance Guidelines

Scheduled Maintenance Perform all of the scheduled checks and

maintenance during the suggested intervals.
Guidelines  The time intervals given in this guide are based
on Deadman Hours (HD) under normal
operating conditions.
Following a regularly scheduled maintenance

program:  When operating under Severe or Extreme

• pr
prom
omot
otes
es max
maxim
imum
um ttru
ruck
ck perf
perform
orman
ance
ce conditions, perform these services more often
• prol
prolon
ongs
gs tr
truc
uck
k lif
life
e as indicated in the following table.
• re
redu
duce
ces
s cos
costl
tly
y dow
down
n ttim
ime
e
• avoi
avoids
ds un
unne
nece
cessa
ssary
ry repa
repair
irs
s

Scheduled maintenance includes:

• Lubrication
• Cleaning
• Inspection
• Service

Operating  W
 Working
orking Environment
Environment Service Frequency
Frequency
Conditions
Light to  An eight hour shift of basic material handling
handling 180 days or 500 hours,
Moderate  whichever comes first 
Severe • Extended heavy duty operation 250 hours
• Fr
Free
eeze
zerr oper
operat
atio
ion
n
• Sudden te
tempera
mperature
ture cha
changes
nges s
such
uch as goin
going
g from freez
freezer
er to
room temperature
Extreme • All UL Type EE rated lift trucks 100 hours
• Dusty or sa
sandy
ndy cond
conditions
itions such
such as in cement
cement plan
plants,
ts, lumb
lumber
er
or flour mills, coal dust or stone-crushing areas
• High tem
temperat
perature
ure area
areas
s such as in st
steel
eel mills,
mills, found
foundries,
ries,
enclosed
enclosed (Type EE) applica
applications
tions
• Corros
Corrosive
ive atmosphe
atmosphere
re such as iin
n chlorine
chlorine or salt-sea
salt-sea air
environments

Hour Meters • TM : Total distance traveled (miles or

kilometers, depending on Units specified
 To display the lift truck hour meters, turn the in Config)
key switch OFF. Press and hold the horn button • HT : Total hours spent traveling
 while turning the key switch ON. The Operator • HA : Total hours on Load Handler 
Display lists the accumulated totals in the
following lift truck hour meters:  To exit, press and release both
both deadman pedals.
• KH : Total hours the key switch has been
turned ON
• HD : Total hours on deadman
• HL : Total hours spent lifting and lowering

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 4-2 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 4. Scheduled Maintenance
Maintenance Minder™
Minder ™ Too
Tooll

Maintenance Minder ™  Setting or Changing Time

Interval and Action Option
Tool
 With Configuration Mode selected, use the
Maintenance Minder  Tool
 Tool is a feature that down button to display the “Mnt Mind” item.
Press the right button. Use the down button to
permits
truck is prompting of a customer
due for scheduled when the lift
maintenance. select “Setup.” Press the right button.

Maintenance Minder , when configured and  The first time the Setup menu is entered, the
enabled, monitors the Hours on Deadman (HD) Factory default setting is displayed. Afterward,
meter. When the time interval is exceeded, the  when the Setup menu is eneterd, the setting
operator is informed in the following ways: last used is displayed. Values
Values from 50 to 500
deadman pedal hours are available. Use the
• One
One of two
two messa
message
gess appe
appear
ars
s on the
the
up/down buttons to scroll to the desired time
Operator Display following the “Daily
interval. With the selected value displayed,
Checklist” message.
press the Enter button.
• “S
“Sch
ched
edul
uled
ed Mai
Maint
nten
enan
ance
ce D
Due
ue””
• “Lift
“Lift Cuto
Cutout,
ut, Schedu
Scheduled
led Mainte
Maintenan
nance
ce Next, select one of the following options:
Due” • “Msg
“Msg Only”
Only” causes
causes the Operat
Operator
or Displa
Display
y tto
o
• Th
Thee audi
audibl
ble
e alarm
alarm soun
sounds
ds a hig
high
h pitc
pitch
h show “Scheduled Maintenance Due” when
tone every 5 seconds. the scheduled maintenance time interval
is exceeded.
Lift Cutout, when active, does not disable the • “L Cut Out”
Out” causes
causes the Operat
Operator
or Disp
Display
lay
lift function until power to the control circuits is to show “Lift Cut Out, Scheduled
cycled (key switch OFF or battery Maintenance Due” when the scheduled
disconnected). When control circuit power is maintenance time interval is exceeded. Lift
cycled, lift is disabled until Maintenance Minder   is disabled the next time the power circuits
is reset or disabled, or the lift cutout option is are cycled.
turned OFF.
Use the up/down  buttons to select the option
Enabling  you want, then press the Enter button. Exit
Program Mode.
Once installed, Maintenance Minder  appears
 appears in
the Configure Mode menu. The initial factory Resetting Maintenance Minder 
setting is “Disable.” To enable the feature, enter
Configure Mode. If you want to reset the reminder prompt when
NOTE: For instructions on selecting Modes of Maintenance Minder  is
 is active and you have done
Operation, see “Overview of Modes” on scheduled maintenance, enter Configure Mode.
page
page 3-
3-22
22..
 With Configuration Mode selected, use the
 With Configuration Mode selected, use the down button to display the “Mnt Mind” item.
down button to display the “Mnt Mind” item. Press the right button. Use the down button to
Press the right button. With “Enab/Dis” select “Reset”. Press the Enter button. Exit
highlighted, press the right button. Use the Program Mode.
down button to select “Enable.” Press the Enter 
 button. Maintenance Minder  is
 is enabled with the Disabling
last stored time interval and action option.
 When Maintenance Minder  is is active and you
Exit Program Mode.  want to disable it, enter Configure
Configure Mode.

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 Publication: 1089040, Re-issued: 15 Jun 2010 4-3

Section 4
4.. Scheduled M
Ma
aintenance 9600/9700 Swing-Reach ® Maintenance Manual
Model 96
Maintenance Minder™
Minder ™ TTool
ool
 With Configuration Mode
Mode selected, use the
down button to display the “Mnt Mind” item.
Press the right button. With “Enab/Dis”
highlighted, press the right button. Use the up  
 button to select “Disable.” Press the Enter 
 button. Exit Program Mode.

Exiting Program Mode

1. Use the left button to back out of the
menus.
2. The Operat
Operator
or Displ
Display
ay show
shows:
s:
Restore
Save
3. Use the down button to select Save. Press
the Enter button. Your new values are
saved.
NOTE:  You cannot exit to the main menu until
have selected either Restore or Save 
 you have
and pressed the Enter button.
he up/down buttons to select Quit.
4. Use tth
Press the Enter button. The truck goes
through reset, then enters Run Mode.

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 4-4 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 4. Scheduled Maintenance
Initial 90 Day/250 Deadman Hour (HD) Maintenance

Initial 90 Day/250
Deadman Hour (HD)
Maintenance
Perform the following maintenance tasks 90 days or 250 HD after the truck was put into service,
 whichever comes first
first..

Component Task

Dri
riv
ve U
Uni
nitt Bre
rea
ak m
mou
ount
ntin
ing
g bol
bolts
ts fre
free a
and
nd rea
reapply
pply thre
threa
ad-
d-llocki
ocking
ng com
ompo
poun
undd (P/
(P/N
N9990
90--54
544)
4)..
Re-torque mounting bolts to 350 ft. lb. (475 Nm). Ch
Change
ange fluid.

Hydraulic T
Ta
ank Change fflluid a
an
nd fi
filter.

Powe
Powerr A
Amp
mpli
lifi
fier
ers
s Torq
Torque
ue po
powe
werr c
cab
able
le te
term
rmin
inal
al nuts
nuts to 11 ft.
ft. lb
lb.. ((15
15 Nm).
Nm).

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 Publication: 1089040, Re-issued: 15 Jun 2010 4-5

Section 4
4.. Scheduled M
Ma
aintenance 9600/9700 Swing-Reach ® Maintenance Manual
Model 96
Every 180 days or 500 Deadman Hours (HD)

Every 180 days or 500

Deadman Hours (HD)
Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first.

Component Task

Battery Check the weight stamped on th the

e batte
terry in the lift truck against the minimum and
maximum allowable weights on the spec tag for the lift truck. Report any lift trucks
that are running with batteries under the minimum or over the maximum allowable
 weight. Inspect all battery connectors
connectors and leads for damage and cuts cuts in protective
coatings. Make sure the battery gates are in place and not damaged. Make sure the
 battery has no more than 0.5 in. (13 mm) free play in any any direction.

Brakes In an open area, measure stopping distance. Tr Tra

aveling to 2 to 3 mph (3.2 to
4.8 km/h) empty, push the EPO switch; the empty lift truck should s stop
top within 2 to 4
feet (0.6 to 1.2 m). During normal
nor mal operation, with a rated load and traveling at top
speed, the lift truck should stop within approximately
appr oximately one and one-half truck lengths.
Stopping distance depends on the load, floor, and tire condition. Examine for signs of
oil on the pads or rotor. If oil is present, disassemble brake, clean rotor, and replace
pads.
Measure for correct air gap
gap between armature and armature plate: 0.040 0.040 in. (1.0 mm)
max. See Fig
Figure
ure 7-4
7-43
3 on pag
page e 7-3
7-36
6.

Conta
ontac
cto
torr In
Ins
spe
pect
ct co
con
ntac
tactor
tor tip
tips
s for
for bu
burn
rntt o
orr p
pit
itte
ted
dssur
urfa
face
ces.
s. Failu
ailure
re to repl
replac
ace
e the
the tips
tips ma
may
y
prevent the contactor from opening or closing causing unscheduled downtime. With
the key switch OFF and the battery disconnected, check the plunger for smooth
operation with no binding. If binding occurs, the lift truck may malfunction or exhibit
intermittent fault codes.

Control  Verify:
 Verify:
Handle(s) • lift/lower
lift/lower functi
function
on is s
smooth
mooth and
and con
controllab
trollable
le
• travel
travel function
function is smooth a
and
nd responsive
responsive th
through
rough full ra
range
nge of motion
motion
• rotate functi
function
on is smoot
smooth
h and control
controllable
lable
• traverse
traverse function
function is smooth
smooth and responsiv
responsive
e through fu
full
ll range of m
motion
otion
Check for play in the center position of all pots; repair/replace
r epair/replace control handle if
necessary. Verify
Verify function of all switches.
Deadm
Deadman
an P
Peda
edals
ls Che
Check
ck for
for smoo
smooth
th opera
operation
tion with
with no bin
bindin
ding
g throug
through
h full
full rang
range
e of pedal
pedal strok
stroke.
e. T
Test
est
correct operation of the deadman switch by the pedal.

Dr
Drai
ain
nHHol
oles
es Be
Bene
neat
ath
h dea
deadm
dman
an peda
pedall a
and
nd in batt
batter
ery
y com
compa
part
rtme
ment
nt - m
mak
ake
e sur
sure
e the
the dr
drai
ain
nhhol
oles
es ar
are
e
not blocked by any debris.

Dri
rive
ve Uni
nitt Che
heck
ck fl
flui
uid
d lle
eve
vel.
l. Ins
nspe
pec
ct for
for le
lea
aks.
ks. M
Ma
ake su
sure
re O-ring
ring is p
pre
rese
sent
nt on tthe
he di
dips
psti
tick
ck..
Check drive axle for play. Examine for drive unit radial ring wear.
wear.  See “Radial Ring
Inspection”
Inspection” on page
page 7-32
7-32..

Electr
Electrica
icall Cable
Cables
s Ins
Inspec
pectt al
alll power
power c
cabl
ables
es ffor
or ni
nicks
cks or cu
cuts.
ts. G
Give
ive spe
specia
ciall at
atten
tentio
tion
n to tthos
hose
e ca
cable
bles
s that
that
are not stationary, for example, cables to the drive motor. Replace any cable that is
damaged or shows signs of excessive heat. Failure to do so causes intermittent
system shutdowns and/or electronic failures. Check the tension of the over -the-mast
cables. Set tension so the cables just stay on the pulleys. Higher tension causes
premature failure. Maximum spring tension is 5 to 7 lb. (2.2 to 3.2 kg).
Fans Check for correct operation. Run Test O23 – Fans (page 6-133)
6-133)..

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 4-6 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 4. Scheduled Maintenance
Every 180 days or 500 Deadman Hours (HD)

Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first.

Component Task

Forks Check fork mounting surfarfaces for wear. Make sure fork positioning lock is working
correctly. Examine for excessive wear, bends, cracks, welding arcs, excessive heat, or
unauthorized modifications. Replace if found. Measure fork thickness (Tool
P/N 922-369).
922-369). See “Fork Inspect
Inspection”
ion” on page 4-15
4-15..

Frame and Baseleg General visual inspection of structural members for cracks, including but not limited
Checks to baselegs, main frame, and tractor.

Hardw
ardwa
are Che
hec
ck b
boolt to
torq
rque
ue of major
ajor co
com
mpo
pone
nennts (moto
motors
rs,, p
pum
umps
ps,, b
bra
rake
ke,, d
dri
riv
ve u
uni
nit,
t, man
aniifo
follds,
ds,
mast-to-tractor mounting bolts). Tighten any loose hardware. Replace any broken or
missing hardware. See “Component S Specific
pecific Service/Torque
Service/Torque Chart” on page A-4 A-4..

Horn Check that horn sounds when activated. Check mounting bracket insulators.

Hydrau
Hydraulic
lic Hoses
Hoses Ins
Inspec
pectt al
alll hydra
hydrauli
ulic
c hose
hoses
s for
for leaks
leaks,, ni
nicks
cks,, c
cut,
ut, chafin
chafing, g, a
and
nd bulg
bulges.
es. Rep
Replac
lace
e
damaged hoses as soon as possible. Inspect all fittings
fit tings for leaks. Repair any leaks
immediately. Inspect over-the-mast hoses for correct tension.t ension. Make sure
over-the-mast pulleys spin freely and show no signs of wear.

Hydraulic Tank Check fluid level.

Lift Chains Check adjustment. See “Chain Maintenance” on page 4-14

4-14.. Inspect for excessive
Lubricate. See “Lubrication Specification
stretch or wear (tool P/N 950-350/CG). Lubricate.
Chart”
Char t” on page A-2.

Lower Solenoid Run Test O62 – Lower Sol [Lower Solenoid (SOL1)] (page 6-153)
6-153)..

Lubrication Lubricate all grease points. See “Lubricati

“Lubrication
on Points” on page 4-11
4-11..

Mast Examine mast bearings. Inspect mast an and carriage stops for ti
tightness and wear.
Inspect the outside of the main frame for wear
wear.. Inspect rails for abnor
abnormal
mal wear, metal
flakes, or shavings. Repair any grooves worn in the mast deeper than 1/8 in. (3 mm).
9600 Only  -
 - Wipe old grease off mast uprights and apply new grease.

Min
inii-M
-Ma
ast Tr
Trav
aver
ers
se - Ins
nspe
pec
ct tthe
he trav
traver
erse
se rack
rack and
and g
gea
ears
rs fo
forr w
wea
earr. C
Che
hec
ck w
we
ear pa
pad
d adj
adjus
ustm
tmen
ent.
t.
Check traverse stop mounting bolt torque. Make sure traverse roller bearings are not
 binding or damaged.
damaged. Make sure hose and cable guards are not damaged. RemoveRemove and
clean Load Handler manifold filter. See “Load Handler
Handler Manifold” on page 7-717-71.. Apply
a thin coat of grease where the pucks contact the Mini-Mast lift cylinder
cylinder..

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 Publication: 1089040, Re-issued: 15 Jun 2010 4-7

Section 4
4.. Scheduled M
Ma
aintenance 9600/9700 Swing-Reach ® Maintenance Manual
Model 96
Every 180 days or 500 Deadman Hours (HD)

Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first.

Component Task

Motors AC  - Check the cable lugs to make sure they are tight to the terminal studs. Verify the
inside and outside nut are torqued to the values listed. Replace any cable that shows
signs of excessive heat. Check sensor wires for sound connection and condition. Blow
out the inside of the motor with compressed air.

DC  - Visually inspect brushes for excessive heat (discoloration of the pigtails). If

excessive heat is evident, inspect the armature circuit for loose connections. Check
condition of commutator per photos on pa page
ge 5-
5-6
6. Find the shortest brush in the
holder. Remove the brush and check overall dimension. See Tab Table
le 7-6 on page
page 7-5
7-54
4.
Inspect the brush for even wear over the full surface of the brush. If the brush is not
contacting the complete surface, replace the brushes. Inspect the brush rigging for
damage or loose brush holders. Make sure the connections on the brush leads are
tight. Check brush spring tension. Blow out the inside of the motor with compressed
air. Check
Check the cable lugs to make sure they are tight
t ight to the terminal studs. Verify both
the inside and outside nut are torqued to the values listed. Replace any cable that
shows signs of excessive heat. Check sensor wires for sound connection and
condition.

Over
Overhea
head
d Guar
Guard
d Inspec
Inspectt gu
guard
ard for phy
physic
sical
al damage
damage.. If str
struct
uctura
urally
lly dam
damage
aged,
d, rrepl
eplac
ace
e ca
carri
rriage
age..

Po
Powe
werr Ampl
Amplif
ifie
iers
rs Chec
Check
k to
torq
rque
ue on powe
powerr a
amp
mpli
lifi
fier
er conn
connec
ecti
tion
ons.
s.

Pu
Pump
mp Coupl
Couplin
ing
g Sepa
Separa
rate
te li
lift
ft pum
pump
paand
nd moto
motorr. App
Apply
ly Mo
Moly
lybd
bden
enum
um An
Anti
ti-S
-Sei
eize
ze Comp
Compou
ound
nd
(P/N 990-638)
990-638) to the splines. See “Pump Maintenance” on page 7-68.
splines.

Safety Belt or Check for signs of wear

wear,, fraying, or damage. Check anchor points on overhead guard
Harness and Tether  for damage.

Shor
Shorts
ts to Fram
Frame
e Chec
Check
k fo
forr ele
elect
ctri
rica
call sh
shor
orts
ts to fram
frame.
e. See “Shorts to Frame Test” on page 5-3.
5-3. Wipe
 Wipe
compartments clean.

Side Gates and Check for correct operation and/or damage.

Barrier 

St
Stab
abil
ilit
ity
yPPad
ads
s Chec
Check
kssta
tabi
bili
lity
ty pa
pad
dccle
lear
aran
ance
ce to flo
floor
or.. Rep
Repla
lace
ce if clea
cleara
ranc
nce
e is
is >
>0.
0.75
75 in
in.. ((19
19.0
.05
5 mm)
mm)..

Stat
Static
ic Stra
Straps
ps Make
Make sure
sure st
stat
atic
ic st
stra
raps
ps ar
are
ennot
ot worn
worn o
orr bro
broke
ken.
n. Cl
Clea
ean
nddeb
ebri
ris
s fro
from
m str
strap
aps.
s. Ch
Chec
eck
k
resistance of resistor in standoff. EE Labeled lift trucks require
r equire a phosphor bronze
static strap; do not use steel braided cable on EE labeled lift trucks.

Stee
teering Check tth
hat st
steering sy
system ffu
unction iis
s sm
smooth aan
nd re
responsive. IIn
nspect th
the te
teeth o
on
n
the steering gear and drive unit for wear.
Check gap on Home Steering Proximity Sensor.
Sensor.

Switches Check all switches for correct operation and adjust as needed.

 Travel Alarm(s) If epuipped, check for correct operation.

 V
 Ventilation
entilation Slots Make sure ventilation slots in the tractor
tractor frame/cover are clear of obstructions and
debris.

 Warning
 Warning Decals Replace any illegible or dam
damaged
aged decals.

 Warning
 Warning Lights Check for correct operation.

 Wheels and Tires Examine for bond failure, chunking, and exces
excessive
sive or uneven wear.
wear. Inspect load
 wheel bearings for binding or excessive
excessive play.

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 4-8 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 4. Scheduled Maintenance
Every 180 days or 500 Deadman Hours (HD)

Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first.

Component Task

 Wire Guidance Check sensor

sensor assemblie
assemblies
s for dama
damage
ge and mounting hardware for tightness. Ve Verify
rify the
lift truck acquires and tracks the guide wire correctly. Verify
Verify the brake is applied
 when truck loses wire signal.

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 Publication: 1089040, Re-issued: 15 Jun 2010 4-9

Section 4
4.. Scheduled M
Ma
aintenance 9600/9700 Swing-Reach ® Maintenance Manual
Model 96
Every 360 Days

Every 360 Days

Perform the following maintenance tasks every 360 days.

Component Task

Drive Unit Change fluid.

Hyd
ydra
raul
ulic
ic Ta
Tank
nk Cha
hang
nge
e hy
hydr
dra
aulic
ulic fl
flui
uid
d and fi
fillte
terr.

Pu
Pump
mp C
Cou
oupl
plin
ing
g Sepa
Separa
rate
te lloa
oad
d ha
hand
ndle
lerr pu
pump
mp a and
nd moto
motorr. Ap
Appl
ply
y Moly
Molybd
bden
enum
um A
Ant
nti-
i-Se
Seiz
ize
e Co
Comp
mpou
ound
nd
(P/N 990-638)
990-638) to the spli
splines.
nes.

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 4-10 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 4. Scheduled Maintenance
Lubrication Points

Lubrication Points
Fluids
See “Lubrication Specification Chart” on
page
page A-
A-2.
2.

Hydraulic Fluid
Reservoir capacity is 15 gal. (57 l),
l ), not including  
fluid in cylinders and hoses.

Drive Unit
Drive unit
unit capacity is 7.12
7.12 qt. (6.75
(6.75 l).

Lubrication Point Locator Photos

Fig
Figure
ure 4-1
4-1.. Lubric
Lubricati
ation
on Poin
Points,
ts, For
Forkk Carri
Carriag
agee Fi
Fitti
ttings
ngs Fig
Figure
ure 4
4-2.
-2. Lubric
Lubricati
ation
on Poin
Points,
ts, Fork
Fork C
Carr
arriag
iagee Beari
Bearings
ngs
7i15008s.tif  8a07022s.tif 

Reach Carriage
Reach Roller Bearing Channels

Rotate Carriage
Lower Bearing
Reach Scissors
Half-Shaft
Grease Fitting

Reach Piston End Grease Fitting

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 Publication: 1089040, Re-issued: 15 Jun 2010 4-11

Section 4
4.. Scheduled M
Ma
aintenance 9600/9700 Swing-Reach ® Maintenance Manual
Model 96
Lubrication Points
Fi
Figu
gure
re 4-
4-3.
3. Mi
Mini
ni Mast
Mast and
and Loa
Load
d Han
Handl
dler 
er 
8c11036h.tif 

Fig
Figure
ure 4-5.
4-5. Lower
Lower Tr
Trave
averse
rse Gears
Gears and Bearin
Bearings
gs
7k24188s.tif 

Traverse Gear (lower)

Inner
Telescopic
Channels
(9600 only)

Mini-Mast
Pucks and
Cylinder

Mini-Mast Lift
Chain
Fork Pins

Traverse Follower
Bearings Grease Fittings

Fig
Figure
ure 4-6.
4-6.
7k24186s.tif 
Upper
Upper Trav
ravers
ersee Gear
Gearss and
and Bearin
Bearings
gs
Traverse Shaft
Fig
Figure
ure 4
4-4
-4.. Trav
raver
ersse RRa
ack  Gear (to
7k24068s.tif 

traverse
motor)

Traverse Rack (lower)

Traverse Follower
Traverse Gear
Bearing Grease
(upper)
Fittings

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 4-12 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 4. Scheduled Maintenance
Lubrication Points
Fi
Figu
gure
re 4
4-7
-7.. Lu
Lubr
bric
icat
atio
ionn Poin
Points
ts,, Driv
Drivee Un
Unit 
it 
7k24010s.tif 

Grease Fittings
(3 places)

Spur Gear

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 Publication: 1089040, Re-issued: 15 Jun 2010 4-13

Section 4
4.. Scheduled M
Ma
aintenance 9600/9700 Swing-Reach ® Maintenance Manual
Model 96
Chain Maintenance

Chain Maintenance Figur

iguree 4-8.
4-8.
MA0634.EPS
Chai
hain Gaug
Gauge 
e 
Chain Replace
Chain
Inspection
      A       A

Make sure chains are not damaged. Check the

chain for wear using a Chain Gauge
Chain
(P/N 950-350/C
950-350/CG). Figure
G). See Figure 4-
4-8
8. Gauge

      A       A
M A 06 34 .ill

Problem Cause Maintenance Procedure

Chain Elongation Wear Use a chain gauge or lay the chain on a flat sur face and
push it together. Measure and mark a 12 in. (305 mm)
Lack of oil length that has operated over the
t he pulley sheave. Stretch
the chain; if more than 5/16 in. (8 mm) play is detected,
replace the chain.

Ru
Rust
st and
and C
Cor
orros
rosio
ion
n Stea
Steam
m cl
clea
eani
ning
ng o
orr Oil chain frequently. Refer to Scheduled Maintenance.
Maintenance.
degreasing new truck
chains.

Cracked Plates Infrequent Oiling Replace the chain.

Rust 

Corrosion

Chain Fatigue

 Tight Joints Bent pins or plates Replace the chain.

Rusty joints or peened Replace the chain.

plate edges

Chain Si
Side W
We
ear Chain m
miisalignment Realign tth
he c
ch
hain o
on
n tth
he p
pu
ulleys.

Chain Adjustment
See “Main Lift
Lift Chains (9600)”
(9600)” on page 7-92
7-92,,
“Main Lift
Lift Chains (9700)”
(9700)” on page
page 7-94
7-94,, and
“Fork Height and Lift Chain Adjustment” on
page
page 7-
7-11
115
5.

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 4-14 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 4. Scheduled Maintenance
Fork Inspection

Fork Inspection 2. Multiply

Multiply these numbers
numbers by
by 0.5%.
0.5%. The
smallest number is your maximum
deviation.
 The following tools are required to perform fork
• Length of blade  _____
 _____ x 0.5% = ______
inspection:
• Height of shank  _____
 _____ x 0.5% = ______
• Fo
Fork
rk Wea
Wearr Cali
Calipe
perr (P/N
(P/N 922
922-3
-369
69))
• Tap
Tape Mea
Measu
sure
re or Ru
Rule
ler 
r  3. Place a 24 in.
in. framing
framing square on the
the blad
bladee
of the fork, 2 in. away from the heel of the
• 24 in.
in. Fram
Framin
ing
g Sq
Squa
uare
re fork. See Figur
Figure e 4-1
4-10.
0.
• 4 ft. Level 4. At 21
21 in.,
in., measure
measure the distance
distance between
the face of the shank and the framing
Do the following when performing Scheduled square. See Figur
Figure
e 4-1
4-10.
0.
Maintenance.
Figure
Figure 4-10.
4-10. Fork Meas
Measureme
urement
nt wi
with
th Framing
Framing Square 
Square 
4forkstraight.svg

Surface Inspection   

Remove the forks from the carriage. Visually

inspect all fork surfaces for signs of damage,
including, but not limited to:
• cracks
• exces
ess
sive
ive wear 
• excessive he
heat 
• defor mation 
• unau
unauth
thor
orize
ized
d mod
modif
ifica
icati
tion
ons
s

Pay special attention to the heel and welds

attaching mounting components. If any damage
is found, remove the fork from service.


Straightness of Blade and
Shank  5. Compar
Compare e this measu
measureme
rement,
nt, mi
minus
nus 2 in.,
in.,
to the smallest maximum deviation
OTE
N :  This
forksmeasurement
on or removedcan be the
from done w
with
ith the
carriage. number determined in step 2.
6. If the
the maximum
maximum devia
deviatio
tion
n number
number is
is
1. Measure
Measure the length of the
the bla
blade
de and
and ththe
e exceeded, remove the fork from service.
Figu
height of the shank. See Figure
re 4-9
4-9..
Fi
Figu
gure
re 4
4-9
-9.. Me
Meas
asur
urin
ing
g Fork
Fork Bla
Blade
de and
and S
Sha
hank 
nk 
4forkFacts1.svg
Fork Angle
NOTE:  This measurement can be done w
with
ith the
forks on or removed from the carriage.
1. Place the fork
fork caliper
caliper on the
the blad
blade.
e. Make
Make
sure that the two extruded points are
Shank  touching the blade of the fork. See
Figure
Figure 4-1
4-11.
1.
Blade 2. Now open and move the
the caliper
caliper so
so the two

extruded
See epoints
Figure
Figur 1.are touching the shank.
4-11.
4-1

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 Publication: 1089040, Re-issued: 15 Jun 2010 4-15

Section 4
4.. Scheduled M
Ma
aintenance 9600/9700 Swing-Reach ® Maintenance Manual
Model 96
Fork Inspection
Fi
Figu
gure
re 4-
4-11
11.. Fo
Fork
rk An
Angl
gle 
e  4. Raise
Raise one end
end of the
the level
level to ma
make
ke it level
level..
4ForkArmWearCaliperGuide_2.svg
Figure
See Figure 4-1
4-12.
2.
5. Measure
Measure the distance
distance from
from the tip of
of the
Shank  fork. See Figure
Figure 4-1
4-12.
2.
Figur
Figuree 4-12.
4-12. Measur
Measuring
ing Fork
Fork TTip
ip Heig
Height 
ht 
4Fork Inspection.jpg

Forks

Indicator
Lines
Distance
Blade from tip
Level of fork 

3. When
When all four
four extr
extrude
udedd points
points are
are in
contact with the fork, gently remove the Tips
caliper and note the reading on the
indicator line, located right above the 6. Compar
Compare
e this
this measur
measuremen
ementt to the
the
hinge pin. See Figur
Figure
e 4-1
4-11.
1. maximum deviation.
4. If the
the deviation
deviation is greater
greater than 3° of the 7. If the
the maximum
maximum devia
deviatio
tion
n number
number is
is
original angle, remove the fork from exceeded, remove the fork from service.
service.
NOTE: Most forks are manufactured with a 90°  Wear
 Wear
angle; therefore, a reading greater than
93° or less than 87° is unacceptable. Fork Blade and Shank 
However, there are some forks that are
purposely manufactured to angles 1. Remove
Remove the fork
forks
s fro
from
m the carri
carriage
age..
greater than or less than 90°.
2. front
Approx.
Approx . half
half
teeth of way
wa
they jaws
up the shank,
shank,
of the set on
caliper the
thethe
Fork Tip Height shank. Make sure the caliper is held
square across the shank to get an
1. With forks on the
the carriage,
carriage, measure the accurate reading. The caliper is now set to
length of the blade. See Figu
Figure
re 4-9
4-9.. measure fork blade wear. Carefully remove
• For forks
forks 4
42
2 in.
in. (106.
(106.77 cm) or less,
less, max
max.. the caliper from the shank. See
deviation
deviation is 0.25 in.
in. (6.3 mm). Figure
Figure 4-1
4-13.
3.
• If leng
length
th of
of fo
fork
rk is
is >42 in. (106.7
(106.7 cm),
multiply length of blade by 3%.
Blade length  _____in.
 _____in. x 3% = _____in.
 This is the maximum deviation.
2. Elevate
Elevate forks
forks approx.
approx. 4 ft. (1.2 m) off the
floor.
3. Place a 4 ft. level
level a
across
cross the
the tips
tips of the
Figur
forks. See Fi guree 4-1
4-12.
2.
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 4-16 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Ma
aintenance Manual Section 4. Scheduled Maintenance
Fork Inspection
Fig
Figure
ure 4-1
4-13.
3. Measu
Measurin
ring
g Fork
Fork Sha
Shank 
nk 
4Fork Inspection.jpg

If there is greater than 10% wear of the

fork arm, the fork has at least a 20%
reduction in capacity.

NOTE:  The caliper is designed to measure forks

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

Fork Hooks
3. Measure
Measure 2 in. (50
(50 mm)
mm) out from the
the heel
heel of
the fork. 1. Remove
Remove the
the forks
forks from
from the carri
carriage
age..
2. Determi
Determine
ne the ffork
ork moun
mountin
ting
g cla
class.
ss.
4. arm
Placeblade
the caliper
ca
atliper
thisover
2 in.the
the
(50fl
flanks
anks of the
the fork
mm) point. See a. Measure
Measure the height
height of the carriage
carriage or
Figure
Figure 4-1
4-14.
4. the distance between the hooks. See
Fig
Figure
ure 4-14.
4-14. Measu
Measurin
ring
g Fork
Fork Blade
Blade Wea
Wear 
r  Figure
Figure 4-1
4-15.
5.
4Fork Inspection.jpg
Figure
Figure 4-15. Determi
Determining
ning Fork Mount
Mounting
ing Class
4Fork Inspection.jpg

Distance between hooks

Carriage Height

 b. Compare this

this measurement to the table
 below.

Fork Distance Carriage

Mounting Between Hooks Height
Class in. (mm) in. (mm)

5. If the
the inside
inside teeth
teeth of the caliper
caliper hit the
the 1 12.05 (306) 13 (331)
fork, there is <10% wear. If the inside teeth
2 15.04 (382) 16 (407)
pass freely over the fork arm, there is
>10% wear and the fork must be removed 3 18.78 (477) 20 (508)
from service.

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 Publication: 1089040, Re-issued: 15 Jun 2010 4-17

Section 4
4.. Scheduled M
Ma
aintenance 9600/9700 Swing-Reach ® Maintenance Manual
Model 96
Fork Inspection
3. Locate
Locate the corre
correct
ct extrude
extruded
d edge on the
the
caliper for the fork mounting class. See
Figure
Figure 4-1
4-16.
6.
4. Slide the extrude
extruded
d edge
edge up into the hook
hook
pocket. See Figure
Figure 4-1
4-16.
6.

5. If the
the calipe
caliper’s
r’s extr
extrude
uded
d edge
edge completely
slides up into the fork pocket , remove the
fork from service. See Fi
Figur
gure
e 4-1
4-16.
6.
Fig
Figure
ure 4-1
4-16.
6. For
Forkk Hook
Hook Insp
Inspect
ectio
ionn
4Fork Inspection.jpg

Fork Pocket

Fork Mounting Class

Designation

Markings
Make sure the fork’s marking (individual load
rating) is legible (typically located on side of
fork). If fork marking is not legible, remove the
fork from service.

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 4-18 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Sect
Sectio
ion
n 5. Trou
oubl
bles
esho
hoot
oting
ing

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 Publication: 1089040, Re-issued: 15 Jun 2010 5-1

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Electrical Troublesho
Troubleshooting
oting

Electrical • Printe
Printed
d cir
circuit
cuit boards
boards are conform
conformal
al
coated. Make sure meter leads make a
Troubleshooting good electrical connection with test points.
• When
When m mea
easu
suri
ring
ng v
volt
oltag
age,
e, conn
connec
ectt the
positive meter lead to the connector or
General probe point marked (+) in the test.
Connect the negative meter lead to the
connector or probe point marked (–).
• Whenev
Whenever er measuri
measuring
ng resista
resistance
nce,, tturn
urn the
Block the lift truck so that the drive tires key switch OFF and disconnect the battery
are off the floor whenever a connector. Battery current can damage an
troubleshooting procedure requires ohmmeter. Isolate the component from the
turning the key switch ON. This prevents circuit.
accidents caused by unexpected lift
truck travel. Shorts to Frame
Use extreme care when the truck is Shorts to frame is an industry term for
jacked up for any reason. Never block unintentional current leakage paths between
the lift truck between the carriage and normally isolated electrical circuits and their
the floor.
floor. Keep hands and feet clear
 while jacking the lift truck. After the lift metal enclosures.
truck is jacked, place solid blocks
bl ocks or jack Shorts to frame may be metallic connections,
stands beneath it to support it. Do not   such as a wire conductor contacting metal
rely on the jack alone. See “Jacking through worn insulation. More often, shorts to
Safety”
Safety ” on page 2-10
2-10.. frame are resistive “leakage” paths caused by
contamination and/or moisture.
Unless otherwise directed, disconnect
the battery connector when you check  These leakage paths can result in unwanted
electrical circuits or components with an electrical noise on the metallic lift truck
ohmmeter.. Electrical current can damage
ohmmeter structure and can cause incorrect operation.
an ohmmeter.
Shorts to frame are caused by:
Before removing a power amplifier,
• Accu
Accumu
mula
lati
tion
on of di
dirrt 
discharge the amplifier’s
amplifier’s internal
capacitor • Batte
Battery
ry elect
electro
roly
lyte
te leak
leakag
age
e
terminals by jumpering
with the25W
a 100 ohm + and –
resistor. • Motor br
brush
ush ddu
ust 
• Motor
Motor bru
brush
sh lea
leads
ds touchi
touching
ng the housin
housing
g
• Many
Many ppro
robl
blems
ems can
can b
be
e cause
causedd by a dirt
dirty
y
 battery. Make sure the battery is clean. • Br
Brea
eakd
kdow
own
n iin
n iins
nsul
ulat
atio
ion
n
• Save
Save time
time and
and tro
troub
uble
le b
by
y looki
looking
ng ffor
or • Bare wires
simple causes first. • Pi
Pinc
nche
hed
dwwir
irin
ing
g har
harne
ness
ss
• Use a Digi
Digital
tal MultiM
MultiMeter
eter (DMM)
(DMM) such as a • In
Inco
corr
rrec
ectt mo
moun
unti
ting
ng of
of circ
circui
uitt card
cards
s
Fluke meter for all measurements. Analog
meters can give inaccurate readings and Shorts to frame can occur at numerous
load down sensitive electronic circuits locations on a lift truck, including:
enough to cause failure. Make sure meter
• Batteries
cables are connected to the correct meter
 jacks and that the correct function and
and • Motors
scale are selected. • Cabl
Cables,
es, wi
wiri
ring
ng,, a
and
nd harne
harness
sses
es
• Heatsinks
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 5-2 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Electrical Troubleshoo
Troubleshooting
ting
• Bus bars the truck frame during the remaining
• Solenoids tests.
• Contactors 4. With the battery
battery disconne
disconnected
cted (or removed
removed
and disconnected) from the truck, use a
• Ter
ermi
min
nal strips DMM to measure the resistance from lift
• Switches truck frame to truck B+, to truck B– (not
• Po
Powe
werr pan
panel
el insu
insula
lati
tion
on  battery B+ and B–), and
and to all fuses and
motors. A reading of <1000 ohms indicates
• Circu
ircuit
it ca
card
rd moun
mounts
ts a serious short. Do not continue until this
condition is corrected. The meter may be
Shorts to Frame Test damaged if you proceed before correcting
this condition.
1. Turn the
the key swit
switch
ch OFF a
and
nd discon
disconnec
nectt
the battery connector.
c onnector. a. To identify
identify the
the cause
cause of the
the short
short to
frame, disconnect circuit components
2. To test the battery
battery for short
shorts
s to case,
until the low resistance condition
connect a 12V test light to the battery case
disappears. Do not reconnect
from battery B+, and then to the battery
components one at a time, but leave
case from battery B–. If the light
them disconnected until the low
illuminates at all, even momentarily, there
resistance reading disappears. Prevent
is a serious problem with the battery, disconnected terminals or connectors
either external contamination or internal from touching the lift truck frame or
damage. Do not continue until this
other conductive surfaces.
condition is corrected. The meter may be
damaged if you proceed before correcting  b. The most likely areas to check are:
this condition. • Motors

Install another battery in the truck and • Heatsinks

repeat this procedure from Step 1. • Power cables
• Po
Powe
werr circ
circuit
uit compo
compone
nent
nts
s
If the test light does not illuminate,
continue to the next step. • Cont
Contro
roll c
cir
ircu
cuit
it comp
compon
onen
ents
ts
c. Repair
Repair or replace
replace the
the com
componen
ponentt
3. Use a DMM
DMM set on the
the amper
amperee functio
function
n to
measure the current leakage from the causing the low resistance condition.
 battery case to battery B+ and from the Repeat Step 4.
 battery case to battery B–. Begin
Begin d. Reconnect
Reconnect a all
ll other
other components
components
measuring at the highest ampere scale previously disconnected, one at a time,
and work toward the lowest. A reading
r eading of measuring resistance between steps. If
more than 0.001A (1mA) indicates a a reading is <1000 ohms when
serious short. Do not continue until this reconnecting a component, that
condition is corrected. The meter may be component or its wiring is faulty; repair
damaged if you proceed before correcting or replace as appropriate.
this condition. e. When, after all components
components are
reconnected, you get readings
Install another battery in the lift truck and >1000 ohms, continue
continue with the
the next
repeat this procedure from Step 1. step.
If the current is <0.0002A (0.2mA), go to 5. Reconnect
Reconnect th
the
e battery
battery connector
connector and turn
Step 4. If the current is >0.0002A (0.2mA) the key switch ON. If the battery was
and <0.001A (1mA), remove the battery previously removed, make sure the battery
from the truck, then continue with Step 4. case does not touch the lift truck frame.
Make sure the battery case does not touch
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 Publication: 1089040, Re-issued: 15 Jun 2010 5-3

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Electrical Troublesho
Troubleshooting
oting
NOTE:  The functions being checked must be • Cont
Contro
roll c
cir
ircu
cuit
it compo
compone
nent
nts
s
energized. Example: to check for shorts c. Repair or replace
replace the compone
component(s)
nt(s)
to frame in the travel circuit, travel must causing the leakage current.
 be requested. Repe
Repeat
at Step
Step 6.
6. Use a DVM set
set to the current
current function
function to d. Reconnect
Reconnect a
all
ll other
other compon
components
ents
measure
frame from current leakage
B+, B–, and alltofuses
the truck
and previously disconnected, measuring
current between steps. If a reading is
motor terminals. Begin measuring at the more than 0.001A (1mA) when
highest ampere scale and work toward the reconnecting a component, that
lowest. If the current is <0.001A (1mA), go component or its wiring is bad. Repair
to step 7. If the current is more than or replace as appropriate.
0.001A (1mA), continue with the following
follo wing
steps. 7. When,
When, after
after all
all compo
componen
nents
ts ar
are
e
reconnected, you get a reading <0.001A
a. To identify
identify the
the cause
cause of the
the short to (1mA) there is no short to frame condition
frame, disconnect circuit components  with the truck or the battery.
battery. If you
until the leakage current reads <0.001A previously removed the battery from the
(1mA). Do not reconnect components truck, re-install the battery.
one at a time, but leave them
disconnected until the leakage current
reads <0.001A (1mA). Prevent Fuses
disconnected terminals or connectors
from touching the lift truck frame or Test/Inspection
other conductive surfaces.
 b. The most likely areas to check are: Examine the fuse for signs of overheating,
discoloration, cracking, or other physical
• Motors damage. Replace as necessary.
• Heatsinks
• Power c
ca
ables  To test a fuse, remove it from the lift truck. The
resistance should be <1 ohm.
• Po
Powe
werr ci
circ
rcui
uitt compo
compone
nent
nts
s

Table 5-1. Fuse Chart 

Fuse Amps Location Function
FU1 100 Contactor/Fuse Panel Power fuse for steering
FU2 500 Contactor/Fuse Panel Power fuse for traction
FU3 675 Contactor/Fuse Panel Power fuse for lift  
FU4 200 Contactor/Fuse Panel Power fuse for Load Handler Motor  
FU5 15 Fuse/Relay Card B+ Control fuse for Key switch and EPO
FU6 15 Fuse/Relay Card B– Control fuse for Tractor and Carriage Manager  
FU7 15/5 Fuse/Relay Card B+ Control fuse for options
FU8 15/5 Fuse/Relay Card B– Control fuse for options
FU11 70 Contactor/Fuse Panel Power fuse for Aux option
F101 2
F102 2
Light/Fan Package Fans/Lights
F103 2
F104 2
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 5-4 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Electrical Troubleshoo
Troubleshooting
ting

DC Motors the segments. This can lead to a short circuit in

the armature.
Types of DC Motors Good commutation is indicated by a dark
 brown polished commutator and an evenly
 There are two primary types of DC Motors:
polished brush wearing surface. See Table
Table 5-2
5-2,,
• A seri
series
es-w
-wou
ound
nd moto
motorr ha
has
s only
only two
two “Commutator Surfaces.”
external connections because the
armature and field windings are connected If the commutator appears rough, pitted, or has
internally. signs of burning or heavy arcing between the
Fi
Figu
gure
re 5-1
5-1.. Seri
Series
es-W
-Wou
ound
nd M
Mot
otor
or Cir
Circu
cuit 
it  commutator bars, remove the motor for service.
  5motor-series.eps

Service
S/D

If the commutator requires service, you must

remove the armature from the motor.

Do not  use
 use a stone to even out high and low
spots on the commutator.
co mmutator.
MP

Servicing
surface a motor and
condition for an
highabnormal
mica orcommutator
mica
A
undercutting requires special equipment at a
• A perm
perman
anen
entt magn
magnet
et motor
motor has
has two
two motor rebuilding facility.
external connections. The field is produced
 by an internal magnet.
Fi
Figu
gure
re 5-2.
5-2. Pe
Perm
rman
anen
entt Magnet  Motor Circuit 
Magnet 
motor-pmagnet.eps

MS+
A2

MS

A1
MS–

NOTE: Field connections may be labeled A or S.

Series wound motor field connections
may be labeled D.

Inspection
Inspect commutator for surface condition and
high mica. Most armatures have the mica
undercut. If the armature on your motor does
not, do not attempt to cut it.

 The commutator must be smooth and clean to

provide maximum brush wear. When
commutators arecollect
carbon dust can not correctly maintained,
in the grooves between
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 Publication: 1089040, Re-issued: 15 Jun 2010 5-5

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Electrical Troublesho
Troubleshooting
oting
Tab
able
le 5-2
5-2.. Comm
Commut
utat
ator
or Sur
Surfa
face
cess
Condition Probable Cause Commutator Surface

Uniform coloring indicates satisfactory operation

of machine and brushes. Film color is largely an
Good Condition-Light Film
effect of thickness; therefore, provided the film is
uniform, it is perfectly acceptable.

 This is not a good condition, however,

however, machines
having this pattern have operated with
satisfactory results for long periods of time. This
Satisfactory Condition- condition can appear in alternating bars as
Light and Dark Pattern shown or every 3rd or 4th bar. This is related to
the winding design of the armature or difficulty
dif ficulty
caused from split windings crossing in the same
slot.

Frequently due to under-loaded operation,

Unsatisfactory Condition- machine grossly over-brushed, or brush grade
Streaky Film with No incorrect for particular machine application.
Commutator Wear   Atmosphere and environmental
environmental conditions can
contribute.

Patchy colors of varying densities and shape. Due

Unsatisfactory Condition-
to unclean operating conditions or incorrect
Uneven Film
physical condition of commutator.
commutator.

 These areas can be isolated

isolated or regular.
Commutator out-of-round. This can be caused by
Unsatisfactory Condition-
 vibration or mechanical
mechanical deficiencies in
Film with Dark Areas
equipment operation, bearings, couplings, and so
forth.

Unsatisfactory Condition- Bars are low on entry and leaving edges giving
Example of Poor rise to the brushes riding on the middle of the
Commutator Machining  bars.

Bars are low in the middle giving rise to the

Unsatisfactory Condition-
 brushes riding on entry and leaving
leaving bar edges.
Example of Poor
 This and the previous illustration indicate
indicate the
Commutator Machining
need for better maintenance.

 This is a further development of the third

Unsatisfactory Condition-
example. Brush grade, machine applications,
Streaky Film with
and working environment are all suspect. Earlier
Commutator Wear 
corrective action should have been taken.

Darkening of commutator in sequences two pole

Unsatisfactory Condition-
Double Pole Pitch pitches apart is due to armature fault, bad coil,
riser bars, or equalizer connections.

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 5-6 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Electrical Troubleshoo
Troubleshooting
ting

Condition Probable Cause Commutator Surface

Storage of machines, for lengthy periods, with

Unsatisfactory Condition-  brushes in position. This can also result from
Brush Contact Mark  operation of machine in prolonged stall
conditions.

Unsatisfactory Condition- Illustration shows high mica in every slot. Same

Bar Edge Burning-Cause effect can occur on one bar only. Similar
High Mica  conditions can be caused by a high or low bar.

Related to overloaded machines and low brush

Unsatisfactory Condition- pressure. Due to sparking under brush, that
Small Bright Spots gives rise to spots being of a random distribution.
If not corrected, results
r esults in scored commutator.

Open Circuit Motor Test 4. If the

the meter
meter indicate
indicates
s high
high rresistan
esistance
ce in
the armature, check the condition of the
 An open circuit is an electrical circuit within the  brushes before replacing the motor.
motor.
motor that is broken. This can be caused by: 5. If you
you find
find an open
open circu
circuit
it in a
• ba
bad
d bru
brush
shes
es or br
brus
ush
h spr
sprin
ings
gs series-wound motor, the motor must be
disassembled by a motor rebuilding facility
• a brok
broken
en wir
wire
e in the
the fiel
field
d or a
arma
rmatur
ture
e
to isolate the problem to the field or
 winding
armature circuit.
• lo
loos
ose
e or
or bad
bad co
conn
nnec
ecti
tion
ons
s

Refer to Figures 5-1 and

5-1 and 5-2
5-2 while
 while performing
Grounded Motor Test
the following procedure:
In a grounded motor, an electrical circuit exists
1. Isolate
Isolate the motor from the
the lift
lift truc
truck
k circuit
circuit  between the current-carrying conductors and
 by removing the power cables. Use two the motor housing. This can be caused either by
 wrenches to avoid twisting the terminal direct contact or through conductive foreign
stud. material.
2. With
With the motor
motor at room
room temper
temperatu
ature,
re,
connect the leads of a digital ohmmeter  The ground may be caused by:
 between the individual circuits in the • insu
insula
lati
tion
on brea
breakd
kdow
own
n
motor.
• br
brus
ush
h leads
leads touc
touchi
hing
ng tthe
he moto
motorr ho
hous
usin
ing
g
3. Observ
Observe
e the foll
followi
owing
ng mea
measure
suremen
ments:
ts:
• build-
build-up
up o
off carbo
carbon
n du
dust
st or
or ot
other
her mat
materi
erials
als
DC
Probe Points Resistance Isolate the motor from the lift truck circuit by
Motor
removing the power cables. Use two wrenches
LHM-A1 to
to L
LH
HM-S1 <1 o
oh
hm
Load to avoid twisting the terminal studs.
Handler  LHM-A1 or LHM-S1
>100,000 ohms
to Frame
 Attach one lead of a megohm meter or a digital
MSA1 to MSA2 <1 ohm ohmmeter to a motor terminal and the other
Steer  MSA1 or MSA2 to lead to an unpainted surface of the motor
>100,000 ohms
Frame housing. Set the ohmmeter to the highest scale.

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 Publication: 1089040, Re-issued: 15 Jun 2010 5-7

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Electrical Troublesho
Troubleshooting
oting
If the ohmmeter reads resistance of
<100,000
<100, 000 ohms, the motor is grounded.
grounded. Clean
Clean,,
repair, or replace the motor as necessary.

Short Circuited Armature or Field

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

 A shorted motor may be indicated by:

• Sl
Slow
ow o
orr slug
sluggi
gish
sh ope
opera
rati
tion
on
• Runnin
Running g fast
faster
er than
than u
usua
suall (sug
(sugges
gests
ts a
short in the field)
• Overheating
• Bl
Blow
owin
ing
g a pow
ower
er fu
fuse
se
• Burn
Burnin
ing
g of brus
brush
h wir
wires
es
• Seve
Severe
re b
burn
urnin
ingg or disc
discolo
olora
ratio
tion
n on
armature coil
• Severe
Severe burning
burning or discolo
discolorat
ration
ion on one or
two commutator segments every 90° of
rotation.

 These symptoms can be caused by problems

other than the motor itself, such as binding in a
related pump, hose, or solenoid valve.

 Testing a motor for short circuited windings

requires special equipment at a motor
rebuilding facility.

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 5-8 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Electrical Troubleshoo
Troubleshooting
ting

 AC Motors
 AC motors used on this
this lift truck are brushless,
3-phase, internally delta-connected, variable
speed motors.

 The AC motor has a rotor (in place of the DC

armature) and a stator (in place of the DC field).
 There is no electrical connection to the rotor;
current is induced in the rotor. The stator has
three windings staggered 120° apart, and three
external connections labeled
l abeled U, V, and W. See
Figu
Figure
re 5-
5-3.
3.
Fi
Figu
gure
re 5-
5-3.
3. Tract
ractio
ionn M
Mot
otor
or Circ
Circui
uits
ts
5motor_AC3phaseA.eps

AC
3φ

V W

Open Winding
If the AC motor fails with an open winding, the
motor moves erratically, as if hunting, and
there is a ticking sound. Rotation is much
slower than usual.

Using a clamping ammeter, measure current in in

each of the motor power cables. The open phase
reads significantly lower than the other two
phases.

Shorted Winding
If the AC motor fails with a shorted winding, the
motor moves erratically, as if hunting, and
there is a high-pitched sound.

Using a clamping ammeter, measure current in in

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

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 Publication: 1089040, Re-issued: 15 Jun 2010 5-9

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Electrical Troublesho
Troubleshooting
oting

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

 below 95% charge will not change the
Battery State-of-Charge (BSOC) is a feature that Operator Display. Older batteries or
monitors and remembers the charge level of the applications providing inadequate
 battery connected to the lift truck and helps to charging time could require a lower
prevent excessive discharging of the battery. configured value for BSOC since older
Operating a lift truck using a discharged  batteries might be unable to reach a
 battery can damage both the battery and the higher percent charge. Therefore, some
electrical components of the lift truck.  batteries could require BSOC configured
as low as 55% before lift cutout resets and
 At power-up, BSOC tests the battery voltage to the Operator Display shows the charge of
determine if it is the same as it was at power- the replacement battery.
down. If the voltage is the same, BSOC assumes
it is the same battery and continues to monitor Setting Battery State-of-Charge
the battery for discharge and updates the Cutout
Operator Display as required.
1. Fill, charge,
charge, and
and install
install a battery
battery that
that is
If a different battery voltage is detected, BSOC typical of the batteries normally used in
assumes a different battery is installed and this application.
tests to determine the state-of-charge of the 2. Have
Have a custome
customerr operat
operator
or use the
the lift
lift
replacement battery. The replacement battery truck in normal application until cutout
must meet one of the following criteria before occurs.
the display resets and lift is restored.
3. Allow the batter
battery
y to cool
cool and
and stabilize
stabilize for
• Th
The
e repl
replac
aceme
ement nt bat
batter
tery
y must
must hav
haveea at least two hours.
charge level at least 50% different from the
4. Before filling
filling the
the battery,
battery, either take
previously installed battery,
specific gravity readings or measure open
• Th
The
e char
charge
ge v
val
alue
ue of
of th
the
e repl
replac
aceme
ement
nt circuit voltage of the battery cells.
 battery must be greater than the
5. Compar
Compare e the measu
measureme
rements
nts w
with
ith the
the
configured BSOC setting.
 battery manufacturer’s recommendations
for maximum discharge.
 The criteria are determined in this way:
6. Adjust
Adjust the
the cutout
cutout val
value
ue as needed
needed and
and
• BSOC
BSOC compa
compares
res the charg
charge
e of the batter
battery
y
repeat the previous steps until battery
that was connected to the lift truck with
cutout occurs at the desired discharge
the replacement battery’s charge. A charge
difference of at least 50% between the two level.
 batteries resets BSOC to show the state-
of-charge of the replacement battery, that
is, the measured state-of-charge of the
replacement battery minus the
remembered state-of-charge of the old
 battery must equal or exceed 50%. This
reset can be higher or lower than the old
 battery.
• BSOC
BSOC look
looks
s at the config
configure
ured
d re
reset
set point.
point.
BSOC reset is programmable from 55% to
100% of total battery charge and can be
changed by entering the Configure Mode
using the Superword. The replacement
 battery must be greater than the
configured percent of charge before BSOC
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changes. Example - BSOC configured at
 5-10 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Electrical Connector Locator Chart

Electrical Connector single ridge at pin number 1. The long side has
1, 2, and 3 raised ridges at pin numbers 1, 2,
Locator Chart Figu
and 3. See Fi gure
re 5-
5-4
4.
Figu
Figure
re 5-4
5-4.. Mole
Molexx Ja
Jack
ck and
and Pin
Pin Con
Conne
nect
ctor 
or 
8c04013s.tif 

Terminology 
Pin Identifier Lines (color added for clarity)
 The term “connector JPx” means a mated
connector consisting of two connector halves.
One half contains male connectors, or pins (P);
the other half contains female connectors, or
 jacks (J).

 When you disconnect a mated JP connector,

connector,
 you will have two connector halves. The  Jacks Pins
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. Use Table 5-3
Use Table 5-3 (or
 (or the graphics beginning on
page
page 5-5-15
15)) to locate electrical connectors on the
t he
lift truck.
Molex connectors have ridges on the sides to
help locate pin number 1. The short side has a

Table
able 5
5-3.
-3. Ele
Electr
ctrica
icall Conn
Connect
ector
or Locato
Locatorr Chart 
Chart 
Connector Location Function/Destination

 J1 Near Tractor Manager Lift/Lower pendant 

 JP1L Under Platform Wire guidance load sensor

sensor antenna 

 JP1T Behind Front Bumper Wire guidance tractor sensor

sensor antenna 

 JP2 Load Handler Mini-mast height prox 

 JP3 Near Reach Scis

Scissors
sors Reach prox 

 JP4 Near Rotate Pot Rotate pot 

 JP5 Turret - underside Mini power supply 

 JP10 Top Tractor Cover Warning/strobe

Warning/strobe light 

 JP12 Mast Crosstie Travel light 

 JP18 Under Seat 

OTM cable
 JP19 Under seat - left side

 JP20 Right side of Seat 

Load handler solenoid intermediate connector 
 JP21 Top of Mini-Mast 

 JP27 Left Control Handle Left-hand deadman

 JP46 Main Manifold Mini-Mast lift pressure transducer 

transducer 

 JPA1 Supplemental Display Supplemental Operator Display 

Display 
 JPA7 Drive Unit - right side Home steer prox 
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 Publication: 1089040, Re-issued: 15 Jun 2010 5-11

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Electrical Connector Locator Chart

Connector Location Function/Destination

 JPB–  B– cable
Battery 
 JPB+ B+ cable

 JPBR Top of Traction Motor Brake coil

 JPBSEN1 Above Main Manifold Battery gate prox 1

 JPBSEN2 Underneath Horn Battery gate prox 2

 JPC4

 JPC6

 JPC10

 JPC12
Carriage Manager Refer to “Sch
“Schemat
ematics”
ics” on page A-19
A-19..
 JPC14

 JPC18

 JPC22

 JPC24

 JPD1 Display screen

 JPD2 Menu switches

 JPD3 Display Interface Card CAN Bus+ power 

 JPD4 Horn (sounder)

 JPD5 CAN baud rate

 JPE1
Unde
Underr L
Lef
eftt C
Con
ontro
troll Han
Handl
dle
e Stee
Steerr E
Enc
ncod
oder 
er 
 JPE2

 JPE4 Steer Motor Steer motor feedback encoder 

 JPE5 Tractor Bulkhead Panel Main lift height encoder intermediate connector 
connector 

 JPE5A Top of Mast Main lift height encoder 

 JPF1

 JPF2
Fuse/Relay Card Refer to “Sch
“Schemat
ematics”
ics” on page A-19
A-19..
 JPF3

 JPF4

 JPK2 Top of Mini-Mast Traverse Feedback Pot 

 JPKP Right Control Handle Operator display control switches

 JPL1 Left Control Handle Left control handle inputs to CM

 JPL2 Inside Left Control Handle 5V supply to VR3 and VR4

 JPL19 Right side of Seat Light/Fan harness intermediate connector 
connector 
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 5-12 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Electrical Connector Locator Chart

Connector Location Function/Destination

 JPLA1 Lift Power Amp LPA connector 

 JPLA2 Lift motor encoder 

Near Lift Motor 
 JPLA3 Lift motor temperature sensor 

 JPOM1 Top of Mini-Mast 

 JPOM2 Turret - underside

Over the mini-mast cable
 JPOM3 Top of Mini-Mast 

 JPOM4 Turret - underside

 JPFAN1 Near Load Handler pum

pump
p Load handler cooling fan

 JPFAN2
 Top cover Top cover cooling fan (optional)
 JPFAN3

 JPR1 Right Control Handle Right control handle

Inside Right Control

 JPR2 Handle 5V supply to VR1 and VR2
 JPRDP Supplier Wireless Mod
Module
ule iWarehouse 

 JPLHA1 Left control handle - intermediate connector 

Below Left Control Handle
 JPLHA2 Left control handle heater option - intermediate connector 
connector 

Right controls (handle, EPO, key switch) - intermediate

 JPRHA1 Below Right Control connector 
Handle
 JPRHA2 Display, lights, and fan switches
switches - intermediate connector 

 JPRHA3 Near Carriage M

Manager
anager Right control handle heater option - intermediate connector 
connector 

 JPS1
Contactor Panel Contactor panel interface
 JPS2

 JPS3 Tractor Bulkhead Panel Slack Chain Switch 1

 JPS4 Guidance Mana

Manager
ger Guidance Manag
Manager 
er 

 JPS5 Tractor Bulkhead Panel Slack Chain Switch 2

 JPS6 Guidance Mana

Manager
ger Guidance Manag
Manager 
er 

 JPS7 Behind Fuse/Rela

Fuse/Relay
y Card Top cover cooling fan (optional)

 JPS8 Lift reference prox switch

 JPS25  Tractor Bulkhead Panel

OTM cable
 JPS26

 JPS27 Right side of Seat Over the mini-mast

mini-mast cable

 JPS44  Travel light - intermediate connector 

Near Guidance Manager 
 JPS45 https://www.forkliftpdfmanuals.com/
Travel alarm - intermediate connector 
 Publication: 1089040, Re-issued: 15 Jun 2010 5-13

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Electrical Connector Locator Chart

Connector Location Function/Destination

 JPS50 Main Manifold Main lift pressure transducer 

 JPS54 Behind Fuse/Rela

Fuse/Relay
y Card Aisle detect sensors - intermediate connector 
connector 

 JPS55 Near Steer Motor Rail guidance switch

 JPT2

 JPT4

 JPT6

 JPT9

 JPT10

 JPT12  Tractor Manager Refer to “Sch

“Schemat
ematics”
ics” on page A-19
A-19..

 JPT14

 JPT18

 JPT20

 JPT22

 JPT24

 JPTA1 Traction Power Amplifier TPA connector 

 JPTA2  Traction motor encoder 

 Traction Motor 
 JPTA3 Traction motor temperature sensor 

Harness above Traction

 JPTA4  Traction motor encoder/temp sensor intermediate connector 
connector 
Motor 

 JPW1 Load sensor antenna connector 

Filter Card
 JPW2 Tractor sensor antenna connector 

 JPW7 Right Control Handle Control handle heater,

heater, right side - optional
 JPW8 Left Control Handle Control handle heater,
heater, left side - optional

 JPZ Near Load Handler Fa

Fan
n Load Handler Motor temperature se
sensor 
nsor 

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 5-14 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Circuit Card Connectors

Circuit Card Connectors

Refer to the following figures for circuit card
connector and pin locations.

Tractor and Carriage Manager

Fig
Figure
ure 5-5
5-5.. Trac
ractor
tor/Ca
/Carri
rriage
age Ma
Manag
nager
er Con
Connec
nector
torss
R1019283_B.cgm

22 12 10 6 6 4 24 13

11 1 5 1 3 1 12 1
P22 P10 P6 P24 J9 P3
1 7 1 9 1 10 1 6 1 2

8 14 10 18 11 20 7 12 3 4

P14 P18 P2 0 P12 P4

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 Publication: 1089040, Re-issued: 15 Jun 2010 5-15

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Circuit Card Connectors

Fuse/Relay Card
Fi
Figu
gure
re 5-
5-6.
6. Fu
Fuse
se/R
/Rel
elay
ay Card
Card Conn
Connec
ecto
tors
rs
1079010_C.tif 

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 5-16 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Circuit Card Connectors

Guidance Manager
Fi
Figu
gure
re 5
5-7
-7.. Gu
Guid
idan
ance
ce Man
Manag
ager
er Con
Conne
nect
ctor
orss
1003823_J-1.jpg

C B  A

 JS1

16

1 11 1 12 1 4 1 3 1 2

12 22 13 24 5 8 5 6 3 4

P1 P2 P3 P4 P5

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 Publication: 1089040, Re-issued: 15 Jun 2010 5-17

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Circuit Card Connectors

 Wire Guidance Filter Card

Card
Fig
Figure
ure 5-8.
5-8. Wi
Wire
re Guid
Guidanc
ancee FFilt
ilter
er Card
Card con
connec
nector
torss
114-018-762_B-1.jpg

C B  A     2
    W
    J
1

 JP1

 A
16

    1
    W
    J

 A

1 8

9 15

 VIEW A-A
(JW1 and JW2)

Display Interface Card

Fig
Figure
ure 5-9.
5-9. Di
Displ
splay
ay Int
Interfa
erface
ce Card
Card Con
Connec
nector
torss
8c04068s.tif 

P3 P2 P4 P5 P1

Pins 2 and 4 jumpered

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 5-18 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Troubleshooting
Troubleshooting Communication Error Codes (5x Series)

Troubleshooting
Communication Error
Codes (5x Series)
Troubleshooting Intermittent
Communication Error Codes
If a Code 50, 51, 55, 56, 57, 59, 5A, 5E, 5G, or
5J is intermittently displayed, determine if
there is a particular pattern that repeats itself.
 The following table lists possible causes and
actions to perform.

Scenario Action

Check static straps. Refer to “Component Specific Service/

Code is displayed while traveling
 Torque Chart” on page A-4
A-4..

Code is displayed while lifting Check over -the-mast cable.

Refer to Shorts to Fr
Frame
ame Test
Test (page 5-3)
5-3).. Check static straps.
Refer to “Component Specific Service/Torque Chart” on
Codes are randomly displayed page
page A-
A-4
4. Check wiring harness for loose connections in CAN
Bus splices. Unplug and inspect associated CAN Bus jacks and
pins.

Check cables and wiring to the Traction Motor. Cable ties

Code is displayed while steering should not be too tight. Make sure cable and wire insulation is
not damaged.

If the above checks are performed and the code

is still displayed, replace the Tractor Manager.

Troubleshooting Code 51
If Code 51 is displayed during SelfTest:
1. Check for correct jumper installation
installation at
the Carriage Manager between JPC22-22
J PC22-22
and JPC24-4.
2. Check
Check connec
connectio
tions
ns at JPC14
JPC14-4
-4 and
and
 JPC14-11.
3. Connect
Connect FlashW
FlashWare
are di
directly
rectly to the Carri
Carriage
age
Manager to verify manager is able to
communicate. Refer to “Install Cleared
(New) Manager
Manager”” on page 3-19
3-19..

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 Publication: 1089040, Re-issued: 15 Jun 2010 5-19

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Troubleshooting
Troubleshooting Communication Error Codes (5x Series)

Troubleshooting Code 57
Code 57 is displayed when the Display Interface
Card is unable to communicate with the T ractor
Manager.. The appearance of this code (much
Manager

larger scale
displayed numbers)
code. Inputsdiffers from any
and Output testsother
are not
accessible when this code is displayed and a 5Q
is registered in the error log.
NOTE:  This code is displayed if the
the K2 relay tips
are welded when the key switch is
turned OFF.

Diagnosis and Repair

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

1  JPT14-1 Perf
rfo
orm step 4 Perf
rfor
orm
m st
step 2
Key ON/
 JPT14-12
2 DCV   TP4  Approx. 48V  Perform step 3  T/S OTM cable, key switch,
fuse circuit, and wiring

3 DCV TP1 JPT14-1 Per form step 1 T/S fuse circuit and wiring

4 Unplug all connectors from

CM except JC14 and check
Key ON/  voltage again. If 12V is
 JPC14-5 JPC14-2 Approx. 12V Perform step 5
DCV  present, T/S the circuit that is
pulling it down. If not OK,
replace the CM.

5  Attempt to load a valid

 T/S Bus1 wiring
software version into the TM.
from the TM to
Connect FlashWare
FlashWare to the truck and check TM If unable to load software,
the Display
software version. If a valid software version replace TM. If S/W load was
Interface Card.
appears, the test is a success. successful, check for shorts to
Check jumper at
 JPD5. frame, static straps, and
repair as necessary.

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 5-20 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Wire Guidance Troubleshoo
Troubleshooting
ting

 Wire Guidance
Troubleshooting If it is necessary to interrupt the floor
signal, notify all personnel that may be
using the guidepath.

Intermittent
Problems Codes or Learn 2. Positi
Position
on the truck
truck over
over the guid
guidewi
ewirere to
 within 0.5 in.
in. (13 mm) of center (it is easier
If Wire Guidance related codes are displayed to center the load antenna first).
intermittently or problems running Learn Wire 3. Enter Maint/Wir
Maint/Wire e Guidance
Guidance/Coil
/Coil Values.
Guidance occur, check for the following: Values”
Refer to “Coil Values” on page
page 3-38
3-38..
• bad ra
radial rriings
NOTE: If truck is locked on the wire when Coil
• dirt
irty ante
ten
nnas  Values is entered, cycle the Auto/Man
• worn
worn load
load whe
wheel
els
s or
or dr
driv
ive
e tir
tire
e switch.
• bad
bad s
spu
purr ((st
stee
eeri
ring
ng)) g
gea
ear 
r  4. Usin
sing the right button, cycle to the
the
• bad st
ste
eer moto
otor  frequency of the line driver determined in
step1.
• damaged ca
cab
bles
5. Observ
Observe
e coil rread
eading
ings.
s. Se
See
e Figures
Figures 5-10 
5-10 
• bad lin
ine
e drive
ver 
r 
5-11.. If all are low (less than 10%),
and 5-11
• short
orts to frame refer to Diagnosis and Repair. Figure 5-10
5-10  
shows a good Load Antenna and a bad
Refer to Publication PDSS-0051 for floor related  Tractor Antenna.
issues.
Figure
Figure 5-10.
5-10. Coil Readings
Readings - Bad
Bad Tracto
Tractorr Antenna
Antenna

Bad Coil Values

If a Code 93, 94, 9J, or 9K is displayed or
problems performing Step 1 of the Learn Wire
Guidance process are encountered, perform the
following procedure.
1. Verify line driver freque
frequency/ou
ncy/output.
tput.
OTE
N Most line
: decal drivers
on the are
inside ofequipped with
the access a
door
that identifies the frequency.
NOTE:  Antenna signal strength can be
influenced by several factors that are
floor related and not truck related. If the
 value displayed varies at the same
location (such as an expansion joint)
every time, this may indicate a problem
in the floor. For more information, refer
to Publication PDSS-0051.

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 Publication: 1089040, Re-issued: 15 Jun 2010 5-21

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Wire Guidance Troubleshoo
Troubleshooting
ting
Fi
Figu
gure
re 5-
5-11
11.. Coil
Coil Loca
Locatition
onss 6. If one
one or more coil
coil readings
readings are low,
low, turn
the key switch OFF, disconnect the
9600_steerCoils.svg

Tractor NearWire Coils  battery, and swap the JPW1

JPW1 (Load) and
Tractor Right Coil Tractor Left Coil  JPW2 (Trac) connectors at the Filter Card.
• If the
the prob
problem
lem fol
follow
lows
s th
the
e anten
antenna
na and
and
cable, troubleshoot the cable and
antenna.
• If the
the read
reading
ings
s do not change
change,, refer
refer to
Diagnosis and Repair.
Repair.

Load Right Load Left

Coil Coil

Load NearWire Coils

Diagnosis and Repair

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

1 Disconnect Ante
ten
nna  JW1-15 JW1-14 Perform step 2 Perform step 3
Cables at JPW1 and
2  JPW2/DCV   JW2-15 JW2-14 Replace Filter Card Perform step 3

3 10.5 to 13V  Replace Filter Card.

 JPS6-24 Recheck coil values.
Remove Filter Card/
 JA1-B1 (Back probe If correct results are Replace the GM
DCV 
connection) still not obtained,
replace GM

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 5-22 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Troubleshooting
Troubleshooting Steering Fault Codes (G Series)

Troubleshoo
roubleshooting
ting Steering
Fault Codes (G Series)
If Code G2, G3, or G4 is displayed before  the
 the
truck is operated, refer to “Code Displayed After
Deadman Pedal Is Depressed”. If code is
displayed during  operation,
 operation, refer to
“Intermittent Steering Related Error Codes”.

Code Displayed After Deadman

Pedal Is Depressed
If a code is displayed after the deadman pedal is
depressed, observe the reaction in the steering
system and refer to the following table:

Scenario Action
Refer to Inp
Inputut I25 – Str Encdr
Encdr [Stee
[Steerr Motor
Motor Encoder
Encoder]]
 Truck steers and does not contact (page
(page 6-8
6-84)
4) and
 and Input
Input I39 – Ne
Neut
ut Pulse
Pulse [Neut
[Neutral
ral Pulse
Pulses]
s]
mechanical stops. (page
(page 6-9
6-91)
1).. Run Test
Run Test O44 – Steer Mtr [Steer Motor]
(page
(page 6-1
6-140)
40)..
Check home steer prox sensor adjustment. Refer to Inpnput
ut I2I24
4 – 
 Truck steers in one direction only and Str Home [Home Steer Proximity Sensor] (page
(page 6-83)
6-83) and
 and
contacts mechanical stop. Input
Input I25 – Str Encdr
Encdr [Stee
[Steerr Motor
Motor Encode
Encoder]
r] (page
(page 6-8
6-84)
4).. Run
 Test O44 – Steer Mtr [Steer Motor] (page 6-140)
6-140)..
No movement in steering. Mechanical issue,
Run Test O44 – Steer Mtr [Steer Motor] (page 6-140)
Run Test 6-140)..
 worn radial ring.

Intermittent Steering Related

Error Codes
If the truck has intermittent error codes,
determine if there is a particular pattern that
repeats itself. The following table lists possible
causes and actions to perform.

Possible Cause Action

Refer to Shorts to Frame

Frame Test
Test (page 5-3)
5-3).. Check static straps.
Noise, shorts to frame Refer to “Component Specific Service/Torque Chart” on
page
page A-
A-44.

Check adjustment of home steer prox. Check home steer prox

Calculated position of the drive unit bad
sensor sense rail for damage.

Steer Motor Encoder, Steer Amplifier (SA), or TM may be bad.

Large correction to steering prior to braking
Check home steer prox adjustment.

Refer to Input A37 - Str Curr

Curr [Steer
[Steer Motor Curre
Current]
nt] (page
(page 6-58)
6-58)  
Mechanical issue, worn radial ring to determine if excessive current is required by the steer motor.
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Repair or replace as necessary.
 Publication: 1089040, Re-issued: 15 Jun 2010 5-23

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Hydraulic Troubleshooting Guidelines

Hydraulic
Troubleshooting
Guidelines

 After elevating or reaching the carriage

for troubleshooting, use blocks to secure
the carriage. Never remove a block
 when it is supporting the mast.

Lower the carriage fully and retract the reach

mechanism fully.

 When you check voltage at solenoids, make

sure hydraulic lines and components are fully
installed.

 Whenever possible, keep the key switch OFF,

OFF,
the battery connector disconnected, and the
Emergency Lowering Valve open.

Cap open hydraulic lines to prevent

contamination.

https://www.forkliftpdfmanuals.com/
 5-24 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Symptom Tables: Hydraulic System

Symptom Tables:
Section 5. Troubleshooting
ng

Hydraulic System

Load Handler Functions

Traverse - Erratic Operation
Possible Cause Action

Bad Traverse Position Feedback Pot Refer to Input A86 – Trv Posn
Posn [Traver
[Traverse
se Positi
Position
on Feed
Feedback
back
or wiring Pot (VR5)]
(VR5)] (page
(page 6-64)
6-64)..

Inspect mesh screen in Load Handler manifold, Traverse

Contamination in hydraulic system Solenoids 9A/B and CV4 for contamination. If found, flush
and refill system.

Run Test O56 – Sol9A DirA [Traverse DIR A (SOL9A)]

Run Test
(page
(page 6-1
6-147)
47) and
 and
Bad Traverse Directional Solenoid
 Test O57 – Sol9B DirB [Traverse DIR B (SOL9B)]
(page
(page 6-1
6-148)
48)..

Check REL-3 pressure setting. Refer to “Traverse Pressure

 Traverse Relief Valve
Valve
 Adjustment” on page 7-78
7-78..

Run Test O58 – Traverse PWM [Traverse PWM (SOL7)]

Run Test
Bad Traverse PWM Solenoid
(page
(page 6-1
6-149)
49)..

Mechanical binding in Rack

Refer to “Shimming the Mini-Mast” on page 7-105
7-105..
assembly 

Binding or excessive play in Traverse

Replace Traverse Motor.
Motor 

Traverse - Intermittent Operation

Possible Cause Action

Refer to Input A86 – Trv Posn

Posn [Traver
[Traverse
se Positi
Position
on Feed
Feedback
back
Bad Traverse Feedback Pot 
Pot (VR5)]
(VR5)] (page
(page 6-64)
6-64)..

Inspect mesh screen in Load Handler manifold, Traverse

Contamination in hydraulic system Solenoids 9A/B and CV4 for contamination. If found, flush
and refill system.

Run Test O56 – Sol9A DirA [Traverse DIR A (SOL9A)]

Run Test
(page
(page 6-1
6-147)
47) and
 and
Bad Traverse Directional Solenoid
 Test O57 – Sol9B DirB [Traverse DIR B (SOL9B)]
(page
(page 6-1
6-148)
48)..

Run Test O58 – Traverse PWM [Traverse PWM (SOL7)]

Run Test
Bad Traverse PWM Solenoid
(page
(page 6-1
6-149)
49)..

Check REL-3 pressure setting. Refer to “Traverse Pressure

 Traverse Relief Valve
Valve  Adjustment” on page 7-78
7-78..
Bi
Bind
ndin
ing
goorr d
def
efor
orme
med
d Trhttps://www.forkliftpdfmanuals.com/
Trav
aver
erse
se Rack
Rack Re
Refe to “Shimming the Mini-Mast”
ferr to Mini-Mast” on page 7-105
7-105..
 Publication: 1089040, Re-issued: 15 Jun 2010 5-25

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Symptom Tables: Hydraulic System

Possible Cause Action

Binding T raverse Motor Replace T raverse Motor.

Traverse - Noisy 
Possible Cause Action

Misaligned, damaged, or worn Rack

Refer to “Shimming the Mini-Mast”
Mini-Mast” on page 7-105
7-105..
assembly 

 Worn Traverse Shaft Gear 

Gear  See “Traverse Gear Shaft”
Shaft” on page 7-110.

 Worn Traverse Follower Bearings

Bearings Replace bearings. See “Traverse Gear Shaft” on page 7-110.

Traverse - Slow Operation

Possible Cause Action

Inspect Traverse Solenoids 9A/B for contamination. If

Contamination in hydraulic system
found, flush and refill system.

Incorrect Load Handler pressure  Adjust pressure. See “Load Handler Pressure Adjustment”
relief setting on page
page 7-7
7-77.
7.

Check pressure. See “Load Handler Pressure Adjustment”

Bad Load Handler Pump
on page
page 7-7
7-77.
7.

Replace or swap valves and see if symptoms change. If so,

Bad Traverse Directional Solenoid original solenoid valve is bad. See “Load Handler Manifold”
on page
page 7-7
7-71.
1.

Refer to Input
Input A85 – Trv Pot [Trave
[Traverse
rse/Re
/Reach
ach Pot
Pot (VR4)]
(VR4)]
Bad Traverse Pot 
(page
(page 6-6
6-63)
3)..

Mechanical binding in Traverse Rack

Refer to “Shimming the Mini-Mast”
Mini-Mast” on page 7-105
7-105..
or Motor 

 Traverse Relief Valve

Valve Check REL-3on
 Adjustment” pressure setting.
page 7-78
7-78.. Refer to “Traverse Pressure

Traverse - One Direction Only 

Possible Cause Action

Run Test O56 – Sol9A DirA [Traverse DIR A (SOL9A)]

Run Test
(page
(page 6-1
6-147)
47) and
 and
Bad Traverse Directional Solenoid
 Test O57 – Sol9B DirB [Traverse DIR B (SOL9B)]
(page
(page 6-1
6-148)
48)..

Rotate - Erratic Operation

Possible Cause Action

Bad Rotate Position Feedback Pot or Refer to Input A88 – Rot Posn [Rota
[Rotate
te Positi
Position
on Feedb
Feedback
ack Pot
 wiring https://www.forkliftpdfmanuals.com/
(VR6)]] (page
(VR6) (page 6-66)
6-66)..
 5-26 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Symptom Tables: Hydraulic System

Possible Cause Action

Inspect Rotate Direction Solenoids 10A/B for

Contamination in hydraulic system
contamination. If found, flush and refill system.

Refer to Input I04 – Bypa

Bypass
ss S7 [Lift/L
[Lift/Lower
ower Inhib
Inhibit
it Bypass
Bypass
Bad Reach Prox or wiring Switch (S7)] (page
Switch (page 6-76)
6-76).. Tap lightly on the sensor to see if
condition changes.

Run Test O53 – Sol10A DrA [Reach/Rotate

Run Test [Reach/Rotate DIR
DIR A (SOL10A)]
Bad Fork Control Solenoids (page
(page 6-1
6-144)
44) and
 and Test
 Test O54 – Sol10B DrB [Reach/Rotate
[Reach/Rotate
DIR B (SOL10
(SOL10B)]
B)] (page
(page 6-1
6-145)
45)..

Run Test
Run  Test O58 – Traverse PWM [Traverse PWM (SOL7)]
Bad Traverse PWM Solenoid
(page 6-1
(page 6-149)
49)..

Run Test O55 – Rch/Rot PWM [Reach/Rotate

Run Test [Reach/Rotate PWM (SOL8)]
Bad Reach/Rotate PWM Solenoid
(page
(page 6-1
6-146)
46)..

Mechanical binding in Rotate

Check the Rotate Actuator and replace if necessary.
 Actuator 

Incorrect or missing orifices in

Examine. Replace as necessary.
Rotate Actuator elbow fittings

Rotate - Intermittent Operation

Possible Cause Action

Run Test
Run  Test O53 – Sol10A DrA [Reach/Rotate
[Reach/Rotate DIRDIR A (SOL10A)]
(page 6-1
(page 6-144)
44) and
 and Test
 Test O54 – Sol10B DrB [Reach/Rotate
[Reach/Rotate
Bad Fork Control Solenoids
DIR B (SOL10
(SOL10B)]
B)] (page
(page 6-1
6-145)
45).. Monitor current flow while
tapping on coil body.

Refer to Input I04 – Bypa

Bypassss S7 [Lift/L
[Lift/Lower
ower Inhib
Inhibit
it Bypass
Bypass
Bad Reach Prox or wiring Switch
Switch (S7)] (page
(page 6-76)
6-76).. Tap lightly on the sensor to see if
condition changes.

Mechanical binding in Rotate

Replace Rotate Actuator.
 Actuator 

Rotate - Slow Operation

Possible Cause Action

Check pressure. See “Load Handler Pressure Adjustment”

Bad Load Handler Pump
on page
page 7-7
7-77.
7.

Inspect Fork Control Solenoids 10A/B for contamination. If

Contamination in hydraulic system
found, flush and refill system.

Replace or swap valves and see if symptoms change. If so,

Bad Fork Control Solenoid Valves original solenoid valve is bad. See “Load Handler Manifold”
on page
page 7-7
7-71.
1.

Bad Traverse PWM Solenoid Run

Run Test
 Test O58 – Traverse PWM [Traverse PWM (SOL7)]
(page
(page 6-1
6-149)
49)..
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 Publication: 1089040, Re-issued: 15 Jun 2010 5-27

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Symptom Tables: Hydraulic System

Possible Cause Action

Incorrect Load Handler pressure

relief setting.
 Adjust pressure. See “Load Handler Pressure Adjustment”
Note:  Incorrect pressure relief would
on page
page 7-7
7-77.
7.
likely also affect reach and traverse
functions.
Mecha
Mechanic
nical
al bi
bindi
nding
ng in Load
Load H
Hand
andler
ler Rep
Replac
lace
e parts
parts a
as
s necess
necessary
ary..

Rotate - Noisy Operation

Possible Cause Action

 Worn, damaged, or misaligned

misaligned
Replace bearing.
Rotate Carriage Lower Bearing

Bad Rotate Actuator Replace Rotate Actuator.

Rotate - One Direction Only 

Possible Cause Action

Run Test
Run  Test O53 – Sol10A DrA [Reach/Rotate DIR
DIR A (SOL10A)]
Bad Fork Control Solenoids (page 6-1
(page 6-144)
44) and
 and Test
 Test O54 – Sol10B DrB [Reach/Rotate
[Reach/Rotate
DIR
DIR B (SOL10B
(SOL10B)])] (page
(page 6-1
6-145)
45)..

Mechanical binding or bad Rotate

Replace Rotate Actuator.
 Actuator 

Reach - Erratic Operation

Possible Cause  Action

Bad Rotate Position Feedback Pot or Refer to Input A88 – Rot Posn [Rota
[Rotate
te Positi
Position
on Feedb
Feedback
ack Pot
 wiring (VR6)] (page
(VR6)] (page 6-66)
6-66)..

Dama
Damage
ged
d or
or w
worn
orn Re
Reac
ach
hCCyl
ylin
inde
derr Re
Repl
plac
ace
e Rea
Reach
ch Cy
Cyli
lind
nder
er..

 Worn Scissors Bearings

Bearings or deformed
Replace bearings or repair/replace scissors assembly.
Scissors Assembly 

Run Test
Run  Test O58 – Traverse PWM [Traverse PWM (SOL7)]
Bad Traverse PWM Solenoid
(page 6-1
(page 6-149)
49)..

Run Test
Run  Test O55 – Rch/Rot PWM [Reach/Rotate
[Reach/Rotate PWM (SOL8)]
Bad Reach/Rotate PWM Solenoid
(page 6-1
(page 6-146)
46)..

Run Test O06 – Sol11Rch [Reach Select Solenoid

Run Test Solenoid (SOL11)]
Bad Reach Solenoid
(page
(page 6-1
6-128)
28)..

Run Test O53 – Sol10A DrA [Reach/Rotate DIR

Run Test DIR A (SOL10A)]
Bad Fork Control Solenoids (page
(page 6-1
6-144)
44) and
 and Test
 Test O54 – Sol10B DrB [Reach/Rotate
[Reach/Rotate
DIR
DIR B (SOL10B
(SOL10B)])] (page
(page 6-1
6-145)
45)..

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 5-28 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Symptom Tables: Hydraulic System
Reach - Intermittent Operation
Possible Cause Action

Bad Rotate Position Feedback Pot or Refer to Input A88 – Rot Posn [Rota
[Rotate
te Positi
Position
on Feedb
Feedback
ack Pot
 wiring (VR6)] (page
(VR6)] (page 6-66)

Run Test O06 – Sol11Rch [Reach Select

Run Test Select Solenoid (SOL11)]
Bad Reach Solenoid
(page
(page 6-1
6-128)
28)..

Run Test
Run  Test O58 – Traverse PWM [Traverse PWM (SOL7)]
Bad Traverse PWM Solenoid
(page 6-1
(page 6-149)
49)..

Run Test O53 – Sol10A DrA [Reach/Rotate

Run Test [Reach/Rotate DIR
DIR A (SOL10A)]
Bad Fork Control Solenoids (page
(page 6-1
6-144)
44) and
 and Test
 Test O54 – Sol10B DrB [Reach/Rotate
[Reach/Rotate
DIR B (SOL10
(SOL10B)]
B)] (page
(page 6-1
6-145)
45)..

Run Test
Run  Test O55 – Rch/Rot PWM [Reach/Rotate
[Reach/Rotate PWM (SOL8)]
Bad Reach/Rotate PWM Solenoid
(page 6-1
(page 6-146)
46)..

Excessive play in the Reach

Mechanism, due to mechanical Repair/replace components as necessary.
 wear/deformation

Contamination in hydraulic system Inspect Reach Solenoid SOL11 for contamination. If found,
flush and refill system.

Reach - Noisy or Slow Operation

Possible Cause Action

 Worn
 Worn Scissors Bearings or deformed
Replace bearings or repair/replace
r epair/replace scissors assembly.
Scissors Assembly 

Inspect Reach Solenoid (SOL11) for contamination. If found,

Contamination in hydraulic system
flush and refill system.

Dama
Damage
ged
d or
or w
wor
orn
nRRea
each
ch Cy
Cyli
lind
nder
er Re
Repl
plac
ace
e Rea
Reach
ch Cy
Cyli
lind
nder
er..

Run Test O55 – Rch/Rot PWM [Reach/Rotate

Run Test [Reach/Rotate PWM (SOL8)]
Bad Reach/Rotate PWM Solenoid (page
(page 6-1
6-146)
46)..
Run Test
Run  Test O58 – Traverse PWM [Traverse PWM (SOL7)]
Bad Traverse PWM Solenoid
(page 6-1
(page 6-149)
49)..

Run Test O53 – Sol10A DrA [Reach/Rotate

Run Test [Reach/Rotate DIR
DIR A (SOL10A)]
Bad Fork Control Solenoids (page
(page 6-1
6-144)
44) and
 and Test
 Test O54 – Sol10B DrB [Reach/Rotate
[Reach/Rotate
DIR B (SOL10
(SOL10B)]
B)] (page
(page 6-1
6-145)
45)..

Run Test
Run  Test O06 – Sol11Rch [Reach Select
Select Solenoid (SOL11)]
Bad Reach Solenoid Valve
(page 6-1
(page 6-128)
28)..

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 Publication: 1089040, Re-issued: 15 Jun 2010 5-29

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Symptom Tables: Hydraulic System
 Auto Traverse
Traverse and Rotate and
and/or
/or Auto C
Center
enter Nest Does Not Function
Possible Cause Action

 V
 Verify
erify proper operation of the traverse and rotate. V
Verify
erify the
 Traverse and rotate do not function
display shows the load handler in the nested position when
correctly independently.
it should.
Function being activated with rotate
or traverse outside the allowable
start positions. Allowable start Place the load handler in the nested position and retry.
positions may very slightly between
trucks and platform widths.

Switch S5 not functioning correctly.

Rotate will operate but no traverse.
Refer to Input I110 – Attach S5 [Attachment (S5)].
 Traverse will only operate with the
traverse command pot.

Lift/Lower System

Slow Lift
Possible Cause Action

Bad Lift Motor Encoder Refer to Input

Input I20 – Lif
Liftt RPM
RPM [Lift
[Lift Mot
Motor
or RPM]
RPM] (pa
(page
ge 6-8
6-80)
0)..

Check and adjust lift pressure setting. See “Lift Pressure

Incorrect lift pressure adjustment 
 Adjustment” on page 7-76.

Check pressure. See “Lift Pressure Adjustment” on

Bad Lift Pump
page
page 7-7
7-76.
6.

Bad Lift Motor Run Test O28 – Lift RPM [Ramp Lift Motor] (page 6-134)
6-134)..

Battery problems Replace battery with fully-charged good battery.

Bad Flow Limiters “Flow

Replace the Flow Limiters. See “Flow Limiters” on page 7-84.

Contamination in hydraulic system Inspect valves for contamination. If found, flush and refill
system.

Run Test O11 – Sol1 Lwr [Lower Solenoid (SOL1)]

Run Test
Bad Lower Solenoid
(page
(page 6-1
6-129)
29)..

LPA overtemperature Refer to Input

Input A19 - LA Temp
Temp [LPA
[LPA Temp]
Temp] (pag
(page
e 6-5
6-52)
2)..

Intermittent Lift
Possible Cause Action

If problem occurs only with Main Run Test O52 – Sol4 ManSl [Main Lift Select
Run Test Select (SOL4)]
Mast, Main Lift Select Solenoid may (page
(page 6-1
6-143)
43).. Flex harness while running test to check for
 be intermittent. intermittent wires.

If problem occurs only with Run Test

Run  Test O50 – Sol6 MinSl [Mini Lift Select (SOL6)]
(SOL6)]
Mini-Mast, Mini Lift Select Solenoid (page
(page 6-1
6-141)
41).. Flex harness while running test to check for
https://www.forkliftpdfmanuals.com/
may be intermittent. intermittent wires.
 5-30 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Symptom Tables: Hydraulic System
Slow Lower
Possible Cause Action

Bad Lift Motor Encoder Refer to Input

Input I20 – Lif
Liftt RPM [Li
[Lift
ft Moto
Motorr RPM]
RPM] (pag
(page
e 6-8
6-80)
0)..

Lower Solenoid may be

intermittent/bad Run  Test
Run Test
(page
(page O62
6-153)
6-1 . – Lower Sol [Lower Solenoid (SOL1)]
53).

If problem occurs only with Run Test

Run  Test O43 – Sol5 MinLH [Mini Load Hold
Hold (SOL5)]
Mini-Mast, Mini Load Hold Solenoid (page 6-1
(page 6-139)
39).. Flex harness while running test to check for
may be intermittent. intermittent wires.

If problem occurs only with Main Run Test O51 – Sol3 ManLH [Main Load
Run Test Load Hold (SOL3)]
Mast, Main Load Hold Solenoid may (page
(page 6-1
6-142)
42).. Flex harness while running test to check for
 be intermittent. intermittent wires.

Mechanical binding in Bearings or

 Adjust or replace bearings.
 Telescopic

Replace the Flow Control valves. See “Flow Limiters” on

Bad Flow Limiter 
page
page 7-
7-84
84..

Intermittent Lower
Possible Cause Action

If problem occurs only with Main Run Test O51 – Sol3 ManLH [Main Load
Run Test Load Hold (SOL3)]
Mast, Main Load Hold Solenoid may (page
(page 6-1
6-142)
42).. Flex harness while running test to check for
 be intermittent. intermittent wires.

Mechanical binding in bearings or

 Adjust or replace bearings.
telescopic

If problem occurs only with Run Test O43 – Sol5 MinLH [Mini Load Hold
Run Test Hold (SOL5)]
Mini-Mast, Mini Load Hold Solenoid (page
(page 6-1
6-139)
39).. Flex harness while running test to check for
may be intermittent. intermittent wires.

Load Drifting/Settling
Drifting/Settling
Possible Cause Action

Leaking or contaminated Emergency Make sure the handle is not bottoming out before the valve
Lower Valve is seated. Inspect, clean, flush, or replace as needed.

Lower Solenoid may be Run Test

Run  Test O62 – Lower Sol [Lower Solenoid (SOL1)]
intermittent/bad (page 6-1
(page 6-153)
53)..

Bouncing Lower
Possible Cause Action

Bleed cylinders. See “Bleeding the Hydraulic System” on

 Air in lift cylinders
page
page 7-
7-74
74..

Lubricate/adjust pucks as necessary. See “Main Mast

https://www.forkliftpdfmanuals.com/
Main Mast bearing pucks binding
Lateral Bearing
Bearing Adjustment (9600)”
(9600)” on page 7-99.
 Publication: 1089040, Re-issued: 15 Jun 2010 5-31

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Symptom Tables: Travel Problems

Symptom Tables: Travel

Problems

Slow or Sluggish Acceleration or Travel

Possible Cause Action

In Config Mode, set Travel Accel to Medium or Hard. Refer to

Configuration set to soft acceleration “Usi
“Using
ng Configure
Configure Mode” on page 3-26
3-26 and
 and Table
 Table 3-2,
“Configure Mode
Mode Menu,” on page 3-273-27..

In Config Mode, set Coast to Long. Drive and coast to a stop.

Note:  Determine if problem is
Compare coasting distance with a normally operating
op erating lift
configuration settings, mechanical,
truck, if possible. If coasting distance is short, problem is
or electrical:
mechanical.

Mechanical

Input
Check amp draw. Refer to Inp ut A11 - Dr Curr
Curr [Trac
[Tractio
tion
n
Binding Drive Unit 
Motor Current]
Current] (page
(page 6-45)
6-45)..

 Worn Load Wheel Bearings

Bearings Replace load wheel bea
bearings.
rings.

Dragging brake “Brake” on page

See “Brake” page 7-36.

  lectrical

Low battery Install a fully charged battery.

Bad Traction Motor 

Run Test
Run  Test O29 – Traction RPM [Ramp Traction Motor]
(might test OK with no load, but fail
(page 6-1
(page 6-135)
35)..
under load)

Speed is limited due to Traction Refer to Input A08 - Dr Mr

Mr Tmp [Tracti
[Traction
on Motor
Motor Temp]
Temp]
Motor or TPA overtemperature or bad (page
(page 6-4
6-42)
2) and
 and
 Temperature Sensor  Input A10
Input A10 - TA Temp
Temp [TPA
[TPA Temp
Temp]] (page
(page 6-4
6-44)
4)..

Refer to Input
Input I19 – Trac RPM
RPM [Tracti
[Traction
on Motor
Motor RPM]
RPM]
Bad Traction Motor Encoder (TME)
(page 6-7
(page 6-79)
9)..
Refer to Input
Input A04 – Thrt
Thrtll Pot [Thr
[Throttl
ottlee Pot (VR1
(VR1)]
)]
 Throttle Pot problem (page
(page 6-4
6-40)
0) and
 and
Input A22 – Thr
Input Thrtl
tl % [Tra
[Travel
vel Req
Reques
uest]
t] (pag
(pagee 6-5
6-54)
4)..

https://www.forkliftpdfmanuals.com/
 5-32 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Symptom Tables: Travel Problems

Uneven Travel Speed

Possible Cause Action

In Config Mode, set

set Coast to Long. Drive to 4 mph
Note:  First determine if the problem (6.5 km/h) and coas
coastt to a stop. If the lift truck deceleration
is mechanical or electrical. is not smooth or lift truck drags as it coasts, the problem is
mechanical.

Mechanical

Binding Drive Unit Replace Drive Unit.

  lectrical

Run Test O29 – Traction RPM [Ramp Traction Motor]

Run Test
Bad Traction Motor 
(page
(page 6-1
6-135)
35)..

Input
Refer to Inp ut A04 – Thr
Thrtl
tl Pot [Thr
[Throttl
ottle
e Pot (VR1
(VR1)]
)]
Bad Throttle Pot 
(page
(page 6-4
6-40)
0)..

Refer to Input
Input I19 – Trac RPM
RPM [Tract
[Traction
ion Moto
Motorr RPM]
RPM]
Bad Traction Motor Encoder (TME)
(page
(page 6-7
6-79)
9)..

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 Publication: 1089040, Re-issued: 15 Jun 2010 5-33

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Symptom Tables:
Tables: Electrical Problems

Symptom Tables:
Electrical Problems

Motor Overheating
Possible Cause Action

Fans Run Test O23 – Fans (page 6-133)

6-133)..

 Wrong motor for lift truck Verify correct motor for lift truck.

 Application exceeds designed

designed
 workload -- short runs with
Refer to service manager for evaluation.
plugging/acceleration or heavy-duty
lifting cycles

Check voltage, both open circuit and under load. Replace if

Bad Battery 
necessary with fully-charged, good battery.

Corroded or damaged Battery Inspect battery connector.

connector. See “Battery Connector/Cables”
Connector Tips on page
page 7-4
7-40.
0.

Check battery specific gravity at cutout, after battery has

stabilized. Compare to battery manufacturer specifications
Incorrect BSOC Cutout value
for discharged battery. Adjust BSOC Cutout as needed.
to Table 3-2, “Configure Mode Menu,” on page 3-27
Refer to Table 3-27..

Heat stressed cables: Look for

discolored terminals, drawn
Replace power cables.
insulation, and hard spots and
 bulges.

Refer to Input A11

A11 - Dr Curr
Curr [Traction
[Traction Motor
Motor Current]
Current]
Drive Motor Current problem
(page
(page 6-4
6-45)
5)..

Check gearbox or pump for binding. Clean, repair, or

Binding Gearbox or Pump
replace as necessary.

Dragging Brake Check gap. See “Brake”

“Brake” on page
page 7-36.
Incorrectly adjusted steer centering
Run “Learn Rail Guidance” on page 3-36
3-36..
on a rail guided lift truck 

Motor Arcing (Load Handler Motor)

Possible Cause Action

Replace brushes and/or brush springs. See “Motor

 Worn Brushes or incorrect
incorrect Brush
Brushes”
Brushes” on page
page 7-52
7-52 and
 and “Motor Brush Spring Tension”
 Tension
on page
page 7-5
7-53
3.

Rough
Rough or
or pit
pitted
ted M
Moto
otorr Co
Commu
mmutat
tator
or Ref
Refer
er to mot
motor
or rebui
rebuild
ld facil
facility
ity.. Re
Repla
place
ce m
moto
otorr.

https://www.forkliftpdfmanuals.com/
 5-34 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Maintenance Manual Section 5. Troubleshooting

Symptom Tables: Electrical Problems

BSOC Reset or Cutout Does Not Occur

Possible Cause Action

Check battery specific gravity at cutout, after battery has

stabilized. Compare to battery manufacturer specifications
Incorrect BSOC Cutout value
for discharged battery. Adjust BSOC Cutout as needed. See
“Setting Battery State-of-Charge Cutout” on page
page 5-10.

Scrambled or Intermittent Display 

Possible Cause Action

Loose
Loose Harn
Harness
ess or Ca
Card
rd Con
Connec
nectors
tors Res
Reseat
eat car
cards
ds and harn
harness
ess con
connec
nectio
tions.
ns.

Intermittent wires or connectors in  Test for continuity while flexing harness. If discontinuity is
harness found, replace wiring harness.

Bad Display Module Run Test O39 – Display Test [Cycle Display]

Display] (page 6-138)
6-138)..

Operator Display Dark or Inoperative,

Possible Cause Action
Truck Runs
Travel Speed Not Limited - Bad
Operator Display Module or Display Check JPD1 connection. If OK, replace Display Module.
Interface Card

Travel Speed Limited - Bad Display

Check wiring. If OK, replace Display Interface
Inter face Card.
Interface Card or wiring

Display is Dark; Lift Truck is not  Operational

 Operational
 Action/
Step (+) Lead (–) Lead Expected Results Step Passed Step Failed
Meter Scale

1  JPC14-1 Pe
Perf
rfor
orm
m ste
step
p4 Pe
Perf
rfor
orm
m ste
step
p2
Key switch
 JPC14-12  T/S battery, OTM
ON/DCV 
2 TP4  Approx. 48V  Per form step 3 cable, key switch, fuse
circuit, and wiring

 T/S OTM cable, fuse

3 DCV TP1 JPC14-1 Per form step 1
circuit, and wiring

Extract JC14-2 and

unplug all connectors
except JC14. Check
4  JPC14-5 JPC14-2 Perform step 5 again. If 12V is present,
Key switch  T/S the circuit that is
 Approx. 12V 
ON/DCV  pulling it down. If not
OK, replace CM.

5 JPD3-3 https://www.forkliftpdfmanuals.com/
JPD3-4
Replace Display
 T/S wiring
Interface Card
 Publication: 1089040, Re-issued: 15 Jun 2010 5-35

Section 5. Troubleshooting Model 9600/9700 Swing-Reach ® Maintenance Manual

Symptom Tables:
Tables: Electrical Problems

https://www.forkliftpdfmanuals.com/
 5-36 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Mai
aint
nten
enan
ance
ce Manu
Manual
al Se
Sect
ctio
ionn 6. Me
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Code
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and Tes
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Sectio
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n 6. Mes
Messag
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Codes,
es, a
and
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estss

https://www.forkliftpdfmanuals.com/
 Publication: 1089040, Re-issued: 15 Jun 2010 6-1

Se
Secction
tion 6. Me
Messsa
sage
ges,
s, Co
Code
dess, a
and
nd Test
ests Mo
Mode
dell 960
9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes Summary List

Messages and Codes Summary List

Messages
Battery Low, No Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Check Battery Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Deadman? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
EPO Depressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Learn Timed Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Lift Cut-Out Pending ... Low Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Lift Cut-Out, Scheduled Maintenance Due . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Lift Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Lift Speed Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Load Handler Overheated, Allow Time To Cool . . . . . . . . . . . . . . . . . . . . . . . 6-7
Load Handler Stalled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Lower Disabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Lower Sidegates To Resume Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Mismatched Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Overheated, Allow Time To Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Press Bypass Switch To Continue
Continue Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Press Bypass Switch To Continue Lowering Lowering . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Reach Not Nested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Release Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Release Bypass Switch to Continue Lifting Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Release Lift Select Button to Resume Operation...Main Lower is Enabled . . . 6-9
Release Lift To Resume Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Release Rotate To Resume Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Release Traction Handle To Resume Operation . . . . . . . . . . . . . . . . . . . . . . 6-10
Release Traverse Handle To Resume Operation . . . . . . . . . . . . . . . . . . . . . . 6-10
Retract Reach for Full Speed Travel Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Rotate Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Rotate and Traverse Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Scheduled Maintenance Due . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Speed Limited Due To Load Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Speed Limited Due To Unknown Main Height . . . . . . . . . . . . . . . . . . . . . . . 6-12
Speed Limited Due To Unknown Mini Mini Height . . . . . . . . . . . . . . . . . . . . . . . 6-12
Stalled, Release Control Handle To Resume Operation . . . . . . . . . . . . . . . . 6-12
Step on Deadman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
 Travel Cut-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
 Traverse Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
 Waiting For Download Command
Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Codes
Code 1H: TPA Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 1K: Platform Hung Lift Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 2A: Traction Motor Approaching Overtemp . . . . . . . . . . . . . . . . . . . . . 6-13
Code 2E: Traction Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . . 6-14
Code 2G: Failure
Code 2H: Phase Open on Traction
DetectedTraction Motor
in Traction Motor . . .Speed
. . . . .Sensor
. . . . . .. .. .. .. .. .. .. .. .. .. .. .. .. 6-14
6-14
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Code 2M: TPA Pre-Charge
Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
 6-2 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Mai
aint
nten
enan
ance
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Manual
al Se
Sect
ctio
ionn 6. Me
Mess
ssag
ages
es,, Co
Code
des,
s, and
and Tes
ests
ts
Messages and Codes Summary List
Code Current Calibration Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
2T: TPA Current
Code 2U: TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 2V: TPA High DC BUS Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 2W: TPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 2X: TPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Code
Code 42:
43: LPC
LPC Detected
Detected ClosedWWhen
Open When CommandedClosed
hen Commanded Open .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-15
6-15
Code 49: Load Handler Contactor Detected Closed When Commanded Open 6-16
Code 4A: Load Handler Contactor Detected Open When Commanded Closed 6-16
Code 4B: Steer Contactor Detected Closed At Start-Up . . . . . . . . . . . . . . . . 6-16
Code 4C: FU1 Sense Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 4F: TPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . 6-16
Code 4G: TPC Detected Open After Power-Up . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 4H: TPA, TPC Contactor Coil or Coil Driver
Driver Open or Shorted . . . . . . . 6-17
Code 4K: LPA, LPC Contactor
Contactor Coil or Coil Driver Open or Shorted Shorted . . . . . . . . 6-17
Code 50: No TM
TM Communications Received by CM . . . . . . . . . . . . . . . . . . . 6-17
Code 51: No CM
CM Communications Received by TM . . . . . . . . . . . . . . . . . . . 6-17
Code 55: CAN Bus 1Transmission
1Transmission Buffer Error . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 56: CAN Bus 1 Error Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 57: No Communications Received by Display Interface Interface Card . . . . . . . . 6-18
Code 59: CAN Bus 0 Transmission Buffer Error . . . . . . . . . . . . . . . . . . . . . 6-18
Code 5A: CAN Bus 0 Error Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 5E: No Guidance
Guidance Manager CAN Communications
Communications Received by TM . . . 6-18
Code 5G: No Communications Received by TM from TPA . . . . . . . . . . . . . . . 6-19
Code 5J: No communications Received by TM from LPA . . . . . . . . . . . . . . . 6-19
Code 5M: TPA Start Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 5P: LPA Start Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 5Q: Display Interface
Interface Card Not Responding . . . . . . . . . . . . . . . . . . . . 6-20
Code 64: Main Mast Height
Height System Error . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 65: Mini-Mast Height
Height System Error . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 67: Main Mast
Mast Count Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 6D: Main Lift Pressure Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . 6-20
Code 6E: Mini Lift Pressure Sensor
Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . 6-21
Code 6F: Lift Motor Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 78: Lower Continues After Request is Removed . . . . . . . . . . . . . . . . . 6-21
Code 79: Regen Lower Fault
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 7E: Lift Motor Temperature Sensor
Sensor Out-of-Range . . . . . . . . . . . . . . . . 6-21
Code 7F: LPA Temp Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 7G: LPA Motor Phase Open
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 7H: Lift Motor Speed Sensor Failure Detected . . . . . . . . . . . . . . . . . . . 6-22
Code 7M: LPA Failed to Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 7T: LPA Current
Current Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 7U: LPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 7V: LPA High Voltage on DC BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 7W: LPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 7X: LPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 80: Throttle
Throttle Pot Voltage Out-of-Range
Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 81: Lift/Lower Pot Voltage Out-of-Range
Out-of-Range . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 83: Throttle Pot Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code
Code 84:
88: Brake Inoperable
+5V Power Supply- Out-of-Range
Not Applied e. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-24
Out-of-Rang 6-24
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Code 8A: Rotate Pot Voltage Out-of-Range
Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
 Publication: 1089040, Re-issued: 15 Jun 2010 6-3

Se
Secction
tion 6. Me
Messsa
sage
ges,
s, Co
Code
dess, a
and
nd Test
ests Mo
Mode
dell 960
9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes Summary List
Code 8B: Traverse Pot Voltage Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code 8C: Deadman Pedal Switch Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code 8F: Lift/Lower Pot Out-of-Neutral
Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code 8L: Brake Feedback Current Out-of-Range . . . . . . . . . . . . . . . . . . . . . 6-25
Code 8M: Mini Power Supply
Supply Voltage Out-of-Range . . . . . . . . . . . . . . . . . . 6-25

Code
Code 8V: Traverse
8X: Rotate Pot Out-of-Neutr
Out-of-Neutral
Pot al . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-25
Out-of-Neutral 6-25
Code 91: Drive Unit Turned >10° While On Wire . . . . . . . . . . . . . . . . . . . . . 6-26
Code 92: Tracking Limits Exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 93: Not Near Wire - Tractor Coil Pair . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 94: Not Near Wire - Load Coil Pair . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 9A: Bad WG Learn Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 9B: Incorrect Firmware in Guidance Manager . . . . . . . . . . . . . . . . . . 6-26
Code 9E: Track and Hold Signal Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 9F: Filter Card Not Connected
Connected to Guidance Manager . . . . . . . . . . . . . 6-27
Code 9G: No Signal - Load Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code 9H: No Signal - Tractor Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code 9J: Load Antenna Input
Input Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code 9K: Tractor Antenna Input Too High . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code A0: Incorrect Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code A2: Software
Software Compatibility Issue with TM and TPA . . . . . . . . . . . . . . 6-27
Code A4: Software
Software Compatibility Issue with TM and LPA . . . . . . . . . . . . . . 6-28
Code AP: TPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code AT: LPA Software
Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code AV: Primary Memory Mismatch
Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code B0: Rotate Position Feedback Pot Out-of-Range
Out-of-Range . . . . . . . . . . . . . . . . . 6-28
Code B1: Traverse Position Feedback Pot Out-of-Range . . . . . . . . . . . . . . . 6-28
Code FE: Internal TM Circuit for BSOC Not Calibrated . . . . . . . . . . . . . . . . 6-28
Code FG: TM Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code FH: Battery Voltage Out-of-Range
Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code FK: CM Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code FN: Relays Did Not Open at Power Off . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code FP: TM In-Circuit Hardware Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code FT: TM Internal Software
Software Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code FX: CM In-Circuit Hardware
Hardware Failure . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code FY: CM Internal Software Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code G0: Steer Tiller Encoder 1 Bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code G2: Auto Steer Center Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code G3: Home Prox Switch Not Functioning Correctly . . . . . . . . . . . . . . . . 6-30
Code G4: Open Detected in Steer
Steer Control Circuit . . . . . . . . . . . . . . . . . . . . 6-30
Code G5: Short Detected In Steer Power
Power Circuit . . . . . . . . . . . . . . . . . . . . . 6-31
Code G7: Steer Tiller Encoder 2 Bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Code GD: No Steer Motor Encoder Pulses Seen . . . . . . . . . . . . . . . . . . . . . . 6-31
Code GE: Both Steer Tiller Encoders Bad . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Code GF: Wire Guidance Position Out-of-Range . . . . . . . . . . . . . . . . . . . . . 6-31
Code J2: Aisle Exit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Code J4: End-of-Aisle Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Code T4: Traverse
Traverse Proportional Valve Solenoid Open . . . . . . . . . . . . . . . . . 6-32
Code T5: Rotate/Reach Proportional Valve Solenoid Open . . . . . . . . . . . . . 6-32
Code TE: Load
Code TF: Load Handler
Handler Motor
Handler Motor Overtemp
Temp Sensor . . .Out-of-Range
. . . . . . . . . . . .. .. .. .. .. .. .. .. .. .. .. .. .. 6-33
6-32
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Code X6: EPO Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
 6-4 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

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and Tes
ests
ts
Messages and Codes

Messages and Codes

Section 6. Messages, Codes, and Tests

Message: Battery low,

low, no lift
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Battery Low, No Lift If charging or changing Charge/change battery.

Lift interrupt has occurred due to the battery does not
the battery state-of-charge. clear the message, refer
to "I
"Inp
nput
ut A1
A155 – Ba
Batt
ttV
Vol
oltt
[Battery Voltage]"
(page
(pa ge 6-4
6-49)
9)

Message: Check battery gates

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Check Battery Gates "Inp

"Input
ut I8
I87
7 – BG Lt S57
S57 Check battery gates for correct
[Left Battery Gate Switch installation. Cycle key switch to clear.
(S57)]"
(S57) ]" (page
(page 6-101)
6-101),,
"I
"Inp
nput
ut I8
I88
8 – BG Rt S58
S58
[Right Battery Gate
Switch (S58)]"
(page
(page 6-1
6-102)
02)

Message: Deadman?
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Deadman? "I
"Inp
nput
ut I0I00
0 – Dm
Dman an S2
S23
3 Message displayed during SelfTest   --
Deadman switch(es) activated [Carriage Deadman release deadman(s), resume operation. If
 while truck is attempting to Switch (S23)]" message does not clear,
clear, refer to the inputs
perform SelfTest or control handle (page
(page 6-7
6-74)
4),, listed.
inputs detected and deadman "Inp
"Input
ut I3I32
2 – Dm
Dman an S2
S2
pedal(s) not depressed. [Brake Deadman Switch Message displayed after SelfTest  -
 - depress
(S2)]"" (page
(S2)] (page 6-86)
6-86),, deadman pedal(s). If message does not go
"Inp
"Input
ut I0I02
2 – Li
Lift
ft S11
S11 [Li
[Lift
ft away, refer to Inputs listed.
Reference Prox (S11)]"
(page
(page 6-7
6-75)
5)

Message: EPO depressed

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

EPO Depressed "Inp

"Input
ut A41
A41 - CM EPO
EPO Lift EPO Button and cycle key switch to
EPO depressed. CM senses the [CM EPO Sense]" clear.
EPO switch is open (IN). (page
(page 6-6
6-60)
0)

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-5

Se
Secction
tion 6. Me
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ges,
s, Co
Code
dess, a
and
nd Test
ests Mo
Mode
dell 960
9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes
Message: Learn timed out
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Learn Timed Out "I

"Inp
nput
ut I0
I00
0 – Dm
Dman
an S23
S23 Restart Learn and step on both deadman
One or all deadman switches were [Carriage Deadman pedals.
open longer than 2.8 consecutive Switch (S23)]"
minutes during Learn Load (page
(page 6-7
6-74)
4),,
Handler process. "Inp
"Input
ut I3
I32
2 – Dm
Dman
an S2
S2
[Brake Deadman Switch
(S2)]" (page 6-86)
6-86),,
"Inp
"Input
ut I1
I102
02 – Ld
LdDm
Dm S9S9
[Load Handler Deadman
(S9)]" (page 6-105)

Message: Lift cut-out pending ... low battery 

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Lift Cut-Out Pending ... Low None Message is displayed for five minutes,
Battery then lift is disabled.
d isabled. Change Battery.
Battery low.

Message: Lift cut-out, scheduled maintenance due

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Lift Cut-Out, Scheduled None Reset or disable Mnt Mind in Configure

Maintenance Due Mode menu.
Displayed when Mnt Mind is
enabled in Configure Mode menu.

Message: Lift limited

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Lift Limited None If truck is equipped with the Out-of-Aisle

 An option that inhibits lift in Lift Inhibit option, enter aisle to allow lift.
certain situations has been If truck is equipped with the Lift Limit
activated.  w/o Bypass option, lower the carriage
 below the height set in Config Mode to
allow lift.

Message: Lift speed limited

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Lift Speed Limited "I

"Inp
nput
ut I2
I20
0 – Li
Lift
ft RPM
RPM Cycle key switch to
t o clear.
LPA is not receiving encoder [Lift Motor RPM]"
pulses. (page
(pa ge 6-8
6-80)
0)

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 6-6 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

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Code
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and Tes
ests
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Messages and Codes
Message: Load handler overheated, allow time to cool
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Load Handler Overheated, Allow "In

"Input
put A65 - LH Mr Tmp  Allow time for truck to cool.
 Time To Cool
Cool [Load Handler Motor
 The system has detected
detected an over  Temp]" (page 6-62)
6-62),,
temperature condition exists. "Tes
"Testt O2
O23
3 – Fa
Fans
ns""
(page
(pa ge 6-1
6-133)
33)

Message: Load handler stalled

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Load Handler Stalled Traverse:  Refer to applicable inputs/perform

No change in Load Handler "I
"Inp
nput
ut A8
A866 – Trv PoPosn
sn applicable tests.
position detected when a traverse [Traverse Position
or rotate command is present. Feedback Pot (VR5)]"
(page
(page 6-6
6-64)
4),,
"Test
"Test O5
O566 – SoSol9
l9A
A Di
DirA
rA
[Traverse
[Traverse DIR A
(SOL9A)]"
(SOL 9A)]" (page
(page 6-147)
6-147),,
"Te
"Test
st O5
O577 – SoSol9
l9B
B Di
DirB
rB
[Traverse DIR B
[Traverse
(SOL9B)]"
(SOL 9B)]" (page
(page 6-148)
6-148),,
"T
"Tes
estt O5
O588 – TraTrave
vers
rse
e
PWM [Traverse PWM
(SOL7)]"
(SOL 7)]" (page
(page 6-149)
Rotate:
"Inp
"Input
ut A8
A88 8 – RoRott Posn
Posn
[Rotate Position
Feedback Pot (VR6)]"
(page
(pa ge 6-6
6-66)6),,
"Te
"Test
st O5
O533 – So Sol1
l10A
0A Dr
DrAA
[Reach/Ro
[Rea ch/Rotate
tate DIR
DIR A
(SOL10A)]"
(SOL 10A)]" (page
(page 6-144)
6-144),,
"Te
"Test
st O5
O544 – So Sol1
l10B
0B Dr
DrBB
[Reach/Ro
[Rea ch/Rotate
tate DIR B
(SOL10B)]
(SOL 10B)]"" (page 6-145)
6-145),,
"T
"Tes
estt O5
O55
5 – Rc
Rch/
h/Ro
Rott
PWM [Reach/Rotate
PWM (SOL8)]"
(page
(page 6-1
6-146)
46)

Message: Lower disabled, use emergency lower valve to resume lowering

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Lower Disabled "T

"Tes
estt O6
O62
2 – Lo
Lowe
werr Sol
Sol Run test listed.
[Lower Solenoid (SOL1)]"
(page
(page 6-1
6-153)
53)

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-7

Se
Secction
tion 6. Me
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ges,
s, Co
Code
dess, a
and
nd Test
ests Mo
Mode
dell 960
9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes
Message: Lower sidegates to resume operation
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Lower Sidegates To Resume "I

"Inp
nput
ut I6
I67
7 – SG Rt S60
S60 Lower Sidegate(s) and resume operation.
Operation [Right Sidegate Switch
One or both sidegates are raised (S60)]"" (page
(S60)] (page 6-96)
6-96),,
 while attempting to operate the "Inp
"Input
ut I8
I83
3 – SG Lt S61
S61
truck. (Optional) [Left Sidegate Switch
(S61)]"" (page
(S61)] (page 6-100)

Message: Mismatched software versions

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Mismatched Software Versions None Verify/install correct TM and CM software

in FlashWare. Cycle key switch to clear.

Message: Overheated, allow time to cool

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Overheated, Allow Time To Cool "In

"Input
put A08 - Dr Mr Tmp  Allow time for truck to cool. If Traction

 Truck Overheated.
detected The system has
that an over-temperature [Traction
(page
(pa ge 6-4 Motor
6-42)
2),
, Temp]" Motor is overheated,
if Lift motor traction
is overheated, liftisisinhibited;
inhibited.
condition exists. "Input
"In put A09 - Lft Mr Tmp
[Lift Motor Temp]"
(page
(pa ge 6-4
6-43)
3)

Message: Press bypass switch to continue lifting

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Press Bypass Switch To Continue "Inp

"Input
ut I0
I04
4 – By
Bypa
pass
ss S7  Activate bypass switch to continue to lift.
Lifting [Lift/Lower Inhibit Check height settings in Configure Mode.
Calculated height of mast position Bypass Switch (S7)]"
has reached the point that lift (page
(pa ge 6-7
6-76)
6)
interrupt should occur.

Message: Press bypass switch to continue lowering

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Press Bypass Switch To Continue "I

"Inp
nput
ut I0
I04
4 – By
Bypa
pass
ss S7  Activate bypass switch to continue to
Lowering [Lift/Lower Inhibit lower. Check height settings in Configure
Calculated height of mast position Bypass Switch (S7)]" Mode.
has reached the point that lower (page
(pa ge 6-7
6-76)
6)
interrupt should occur.

Message: Reach not nested

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Reach Not Nested "I

"Inp
nput
ut I0
I04
4 – By
Bypa
pass
ss S7  Verify the reach is fully retracted.
During Learn Load Handler, the [Lift/Lower Inhibit
Carriage Manager did not see the Bypass Switch (S7)]"

expected values for Reach Prox. (page

(page 6-7
6-76)
6)
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 6-8 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

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Mess
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Code
des,
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and Tes
ests
ts
Messages and Codes
Message: Release buttons
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Release Buttons "I

"Inp
nput
ut A1
A177 – Li
Lift
ft Pnd
Pnd Cycle key switch to clear.
 The TM detects a Lift/Lower [Lift Pendant]" Note:  If message appears when the
Pendant button(s) was depressed (page
(pa ge 6-5
6-50)
0),, pendant is connected and no switches are
at Startup. "Inp
"Input
ut A1
A188 – Lw
Lwer
er Pnd
Pnd depressed, the pendant is bad.
[Lower Pendant]"
(page
(pa ge 6-5
6-51)
1),,

Message: Release bypass switch to continue lifting

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Release Bypass Switch to "I

"Inp
nput
ut I0
I04
4 – By
Bypa
pass
ss S7 Release switch.
Continue Lifting [Lift/Lower Inhibit
Lift/lower bypass switch (S7) has Bypass Switch (S7)]"
 been activated for an extended (page
(pa ge 6-7
6-76)
6)
period of time or was depressed at
Startup.

Message: Release lift select button to resume operation...Main lower is enabled

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Release Lift Select Button to "Inp

"Input
ut I1
I109
09 – Lf
LftS
tSel
el S6 Release switch.
Resume Operation...Main [Lift Select (S6)]"
Lower is Enabled (page
(pa ge 6-1
6-112)
12)
 The TM detects the Lift Select
Switch was depressed at Startup.

Message: Release lift to resume operation

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Release Lift To Resume "Inp

"Input
ut A0
A055 – L/
L/L
L Pot
Pot Release lift, step on deadman, resume
Operation [Lift/Lower Pot (VR2)]" operation.
Control handle (VR2) was moved (page
(pa ge 6-4
6-41)
1) Note:  After this message is displayed
 before deadman pedal was three times, "CODE 8F Inform Service"
depressed at Startup. (page
(page 6-2
6-25)
5) is
 is displayed.

Message: Release rotate to resume operation

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Release Rotate To Resume "I

"Inp
nput
ut A8
A87
7 – Ro
Rott Pot
Pot Release rotate pot, step on deadman,
Operation [Rotate Command Pot resume operation.
Rotate pot (VR3) was moved before (VR3)]"
(VR3)]" (page
(page 6-65) Note:  After this message is displayed
deadman pedal was depressed at three times, "CODE 8V Inform Service"
Startup. (page
(page 6-2
6-25)
5) is
 is displayed.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-9

Se
Secction
tion 6. Me
Messsa
sage
ges,
s, Co
Code
dess, a
and
nd Test
ests Mo
Mode
dell 960
9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes
Message: Release traction handle to resume operation
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Release Traction Handle To "I

"Inp
nput
ut A0
A044 – Th
Thrt
rtll Pot Release throttle, step on deadman,
Resume Operation [Throttle Pot (VR1)]" resume travel.
Control handle (VR1) was moved (page
(page 6-4
6-40)
0) Note:  After this message is displayed
 before deadman pedal was three times, "CODE 83 Inform Service"
depressed. (page
(page 6-2
6-24)
4) is
 is displayed.

Message: Release traverse handle to resume operation

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Release Traverse Handle To "I

"Inp
nput
ut A8
A85
5 – Trv Po
Pott Release Traverse handle, step on
Resume Operation [Traverse/Reach Pot deadman, resume operation.
 Traverse handle (VR4) was moved
moved (VR4)]"
(VR4)]" (page
(page 6-63) Note:  After this message is displayed
 before deadman pedal was three times, "CODE 8X Inform Service"
depressed at Startup. (page
(page 6-2
6-25)
5) is
 is displayed.

Message: Retract reach for full speed travel

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Retract Reach for Full Speed "I

"Inp
nput
ut I0
I04
4 – By
Bypa
pass
ss S7 Retract forks to allow full speed travel.
 Travel [Lift/Lower Inhibit
 Traverse handle (VR4) was moved
moved Bypass Switch (S7)]"
 before deadman pedal was (page
(pa ge 6-7
6-76)
6)
depressed at Startup.

Message: Rotate failed

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Rotate Failed "I

"Inp
nput
ut A8
A88
8 – RoRott Posn
Posn During Learn, the values saved are the
During the Learn Load Handler [Rotate Position feedback pot voltages at both ends of the
process, the Carriage Manager did Feedback Pot (VR6)]" function and the current required by the
not see the expected values for (page
(page 6-6
6-66)
6),, proportional valves to make the functions
Rotate. "Te
"Test
st O5
O53
3 – SoSol1
l10A
0A Dr
DrAA  begin to move and obtain the desired
[Reach/Rot
[Reac h/Rotate
ate DIR
DIR A speeds.
(SOL10A)]"
(SOL 10A)]" (page
(page 6-144
6-144)),
"Test
"Test O5
O54
4 – SoSol1
l10B
0B Dr
DrB
B
[Reach/Rot
[Reac h/Rotate
ate DIR B
(SOL10B)]
(SOL 10B)]"" (page 6-145
6-145)),
"Tes
"Testt O5
O55
5 – RcRch/
h/RoRott
PWM [Reach/Rotate
PWM (SOL8)]"
(page
(page 6-1
6-146)
46)

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 6-10 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Mai
aint
nten
enan
ance
ce Manu
Manual
al Se
Sect
ctio
ionn 6. Me
Mess
ssag
ages
es,, Co
Code
des,
s, and
and Tes
ests
ts
Messages and Codes
Message: Rotate and traverse failed
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Rotate and Traverse Failed Traverse:  During Learn, the values saved are the
During the Learn Load Handler "I
"Inp
nput
ut A8
A86 6 – Trv Po Posn
sn feedback pot voltages at both ends of the
process, the Carriage Manager did [Traverse Position functions and the current required by the
not see the expected values for Feedback Pot (VR5)]" proportional valves to make the functions
 both Rotate and Traverse. (page
(pa ge 6-6
6-64)4),,  begin to move and obtain the desired
"Te
"Test
st O5
O566 – So Sol9
l9AA Di
DirArA speeds.
[Traverse
[Traver se DIR A
(SOL9A)]"
(SOL 9A)]" (page
(page 6-147)
6-147),,
"Test
"Te st O5
O577 – So Sol9
l9BB Di
DirBrB
[Traverse
[Traver se DIR B
(SOL9B)]"
(SOL 9B)]" (page
(page 6-148)
6-148),,
"T
"Tes
estt O5
O588 – TraTrave
vers
rse
e
PWM [Traverse PWM
(SOL7)]"
(SOL 7)]" (page
(page 6-149)
Rotate:
"Inp
"Input
ut A8
A88 8 – RoRott Posn
Posn
[Rotate Position
Feedback Pot (VR6)]"
(page
(pa ge 6-6
6-66)6),,
"Te
"Test
st O5
O533 – So Sol1
l10A
0A Dr
DrA A
[Reach/Ro
[Rea ch/Rotatetate DIR
DIR A
(SOL10A)]"
(SOL 10A)]" (page
(page 6-144)
6-144),,
"Te
"Test
st O5
O544 – So Sol1
l10B
0B Dr
DrB B
[Reach/Ro
[Rea ch/Rotatetate DIR B
(SOL10B)]
(SOL 10B)]"" (page 6-145)
6-145),,
"T
"Tes
estt O5
O555 – Rc Rch/
h/RoRott
PWM [Reach/Rotate
PWM (SOL8)]"
(page
(pa ge 6-1
6-146)
46)

Message: Scheduled maintenance due

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Scheduled Maintenance Due None Reset or disable Mnt Mind in Configure

Displayed when Mnt Mind is Mode menu.
enabled in Configure Mode menu.

Message: Speed limited due to load handler

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Speed Limited Due To Load "I

"Inp
nput
ut A8
A866 – Trv Po
Posn
sn Return load handler to the nested
Handler [Traverse Position position to allow full speed travel.
Load handler is not nested. Feedback Pot (VR5)]"
(page
(page 6-6
6-64)
4),,
"I
"Inp
nput
ut A8
A888 – Ro
Rott Posn
Posn
[Rotate Position
Feedback Pot (VR6)]"
(page
(page 6-6
6-66)
6),,

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-11

Se
Secction
tion 6. Me
Messsa
sage
ges,
s, Co
Code
dess, a
and
nd Test
ests Mo
Mode
dell 960
9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes
Message: Speed limited due to unknown main height... lower main mast to floor then raise
to cross reference switch
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Speed Limited Due To Unknown "Inp

"Input
ut I0
I02
2 – LiLift
ft S11
S11 [Li
[Lift
ft Refer to display. If message does not go
Main Height Reference Prox (S11)]" away, refer to Inputs listed.
(page
(page 6-7
6-75)
5),,
"Inp
"Input
ut I2
I26
6 – MaMainin Ht Ct
[Main Lift Height
Encoder]"
Encod er]" (page
(page 6-85)

Message: Speed limited due to unknown mini height... completely lower mini mast, then lift
to reset height
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Speed Limited Due To Unknown "Inp

"Input
ut I1
I105
05 – Mi
Mini
ni Ht Ct Refer to display. If message does not go
Mini Height [Mini-Mast Height away, refer to Input listed.
Count]"
Count ]" (page
(page 6-108)

Message: Stalled, release control handle to resume operation

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action
Stalled, Release Control Handle Travel speed limited -  Travel speed or lift speed is limited when
 To Resume
Resume Operat
Operation
ion "Inp
"Input
ut I1
I19
9 – Tra
Trac c RPM
RPM the corresponding power amp is not
No encoder pulses are received by [Traction Motor RPM]" receiving encoder pulses. Cycle key switch
Power Amplifier. (page
(pa ge 6-7
6-79)
9) OFF/ON to clear.
Lift speed limited  -
"Inp
"Input
ut I2
I20
0 – Li
Lift
ft RPM
RPM
[Lift Motor RPM]"
(page
(pa ge 6-8
6-80)
0)

Message: Step on deadman

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Step on Deadman "I

"Inp
nput
ut I0
I00
0 – Dm
Dman
an S23
S23 Depress both Deadman pedals for Learn
One or all of the deadman switches [Carriage Deadman
are open during the Learn Load Switch (S23)]" to continue.
Handler process. (page
(page 6-7
6-74)
4),,
"I
"Inp
nput
ut I3
I32
2 – Dm
Dman
an S2
S2
[Brake Deadman Switch
(S2)]" (page 6-86)
6-86),,
"Input
"Input I1
I102
02 – Ld
LdDm
Dm S9S9
[Load Handler Deadman
(S9)]" (page 6-105)

Message: Travel cut-out

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

 Travel Cut-Out
Cut-Out None Lower forks below 24 in.
“Travel Cut-Out @ 24in,” option is
enabled and fork height is above
24 in
in.. https://www.forkliftpdfmanuals.com/
 6-12 Publication: 1089040, Re-issued: 15 Jun 2010

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and Tes
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Messages and Codes
Message: Traverse failed
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

 Traverse Failed
Failed "I
"Inp
nput
ut A8
A86 6 – Trv PoPosn
sn During Learn, the values saved are the
During the Learn Load Handler [Traverse Position feedback pot voltages at both ends of the
process, the Carriage Manager did Feedback Pot (VR5)]" function and the current required by the
not see the expected values for (page
(pa ge 6-6
6-64)4),, proportional valves to make the functions
 Traverse. "Test
"Te st O5
O566 – So Sol9
l9A
A Di
DirA
rA  begin to move and obtain the desired
[Traverse
[Traver se DIR A speeds.
(SOL9A)]"
(SOL 9A)]" (page
(page 6-147)
6-147),,
"Te
"Test
st O5
O577 – So Sol9
l9B
B Di
DirB
rB
[Traverse
[Traver se DIR B
(SOL9B)]"
(SOL 9B)]" (page
(page 6-148)
6-148),,
"T
"Tes
estt O5
O588 – TraTrave
vers
rse
e
PWM [Traverse PWM
(SOL7)]"
(SOL 7)]" (page
(page 6-149)

Message: Waiting for download command

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

 Waiting
 Waiting For Download Command None Per form Graphics Database Download.
Display Interface Card does not Refer to “Graphics Database Download”
contain a valid Graphic Database on page
page 3-3
3-39
9. If unable to perform, check
Download. communications between TM and CM
using FlashWare.
FlashWare. If OK, replace Display
Interface Card.

CODE 1H Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 1H: TPA Out-of-Range "I

"Inp
nput
ut A10
A10 - TA Temp
Temp Cycle key switch to clear after TPA has
 The TPA has reported its internal [TPA Temp]"
Temp]" (page
(page 6-44) cooled.
temperature is less than –40°F
(–40°C) or greater than +203°F
(+95°C).

CODE 1K Platform Hung Lift Slowly 

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 1K: Platform Hung Lift "I

"Inp
nput
ut I4
I45
5 – Sl
Slk
k Ch
Ch S5
S50
0 Lift platform if it is hung up to clear.
Slowly [Slack Chain 1 Switch
Slack chain switch has (S50)]"
(S50)]" (page
(page 6-92)
6-92),,
transitioned during operation. "I
"Inp
nput
ut I4
I46
6 – Sl
Slk
k Ch
Ch S5
S51
1
[Slack Chain 2 Switch
(S51)]"
(S51)]" (page
(page 6-93)

CODE 2A Overheated, Allow time to cool

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 2A: Traction Motor "Input

"Input A08 - Dr Mr Tmp  Travel speed is linearly de-rated starting
starting
 Approaching
 Approaching Overtem
Overtempp [Traction Motor Temp]" at 284°F (140°C). Travel speed is limited
 The TPA senses the traction motor (page
(page 6-4
6-42)
2) to 1 mph at 311
mohttps://www.forkliftpdfmanuals.com/
tor 311°F
°F (155
(155°C).
°C).
is approaching overtemperature.
 Publication: 1089040, Re-issued: 15 Jun 2010 6-13

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970
Messages and Codes
CODE 2E Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 2E: Traction Motor Temp "In

"Input
put A08 - Dr Mr Tmp Clears when reason for fault is corrected.
Sensor Out-of-Range [Traction Motor Temp]"
 The traction motor temperature (page
(pa ge 6-4
6-42)
2)
sensor is open or shorted.

CODE 2G Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 2G: Phase Open on "T

"Tes
estt O2
O299 – Tra
Tract
ctio
ion
n Cycle key switch to
t o clear.
 Traction Motor
Motor RPM [Ramp Traction
 The TPA detects no current draw in Motor]"" (page
Motor] (page 6-135)
one of the three phases of the
motor.

CODE 2H Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 2H: Failure

 Traction Motor Detected
Motor in
Speed Sensor "Inp
"Input
ut I1
I19
[Traction9Motor
– Tra
Trac
cRPM]"
RPM
RPM If a single during
displayed channelRun.
is bad, this
If one orcode
bothis
(page
(page 6-7
6-79)
9) channels are bad at SelfTest, STALLED is
displayed. Cycle key switch to clear.

CODE 2M Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 2M: TPA Pre-Charge Failed None Check for B+ at TPA+. Cycle key switch to
 TPA failed to precharge correctly. clear. If code does not clear, replace TPA.
clear.
Note:  The TM cannot cause this code.

CODE 2T Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 2T: TPA Current None Cycle key switch to clear. If code does not
Calibration Error clear, replace TPA.
 The TPA has sensed a current
current Note:  The TM cannot cause this code.
calibration error.

CODE 2U Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 2U: TPA Overcurrent or "T

"Tes
estt O2
O299 – Tra
Tract
ctio
ion
n Cycle key switch to clear. Check for
Short Circuit RPM [Ramp Traction shorted traction motor power cables. If
 The TPA has sensed current
current in Motor]"" (page
Motor] (page 6-135) code does not clear, replace TPA.
excess of 450A. Note:  The TM cannot cause this code.

https://www.forkliftpdfmanuals.com/
 6-14 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

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and Tes
ests
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Messages and Codes
CODE 2V Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 2V: TPA High DC BUS "I

"Inp
nput
ut A1
A155 – Ba
Batt
ttVVol
oltt If the problem is intermittent and only
 Voltage
 Voltage [Battery Voltage]" occurs during plugging, it indicates a bad
 The TPA detects an overvoltage (page
(page 6-4
6-49)
9)  battery or possible loos
loose
e connec
connection
tion in the
condition at the + terminal. power circuit connections for the traction
system. Check all associated power cables
for correct torque and contactor tips for
excessive wear.
wear. If the error is a hard code,
re-flash the TPA. If the code persists,
replace the TPA.
Note:  The TM cannot cause this code.

CODE 2W Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 2W: TPA Internal Fault None Cycle key switch to clear. Re-flash TPA. If
 TPA internal circuitry has code does not clear, replace TPA.
malfunctioned.

CODE 2X Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 2X: TPA Power Supply None Cycle key switch to clear. Disconnect (+)
Out-of-Range  wire to temperature and speed sensors.
sensors.
 The power supply output in the Cycle key switch. If code changes,
 TPA is less than 4.5V, greater than troubleshoot wires and sensors. If not OK,
5.5V, or too much current is being replace TPA.
drawn by an external component. Note:  The TM cannot cause this code.

CODE 42 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 42: LPC Detected Closed "Test

"Test O0
O02
2 – LP
LPC
C Ctr
Ctr [L
[Lift
ift Cycle key switch to clear.
 When Commanded
Commanded O Open
pen Power Contactor]" Note:  Low battery voltage can contribute
LPA detected an incorrect voltage (page
(page 6-1
6-126)
26) to burnt tips. If contactor tips are welded
at LPA+ during SelfTest. or burnt, check the BSOC setting in
Config Mode menu.
Note:  The TM cannot cause this code.

CODE 43 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 43: LPC Detected Open "Test

"Test O0
O02
2 – LP
LPC
C Ctr
Ctr [L
[Lift
ift Cycle key switch to clear. Check contactor
 When Commanded
Commanded C Closed
losed Power Contactor]" for mechanical binding.
LPA detected <12VDC at LPA+ after (page
(page 6-1
6-126)
26) Note:  The TM cannot cause this code.
the LPC coil was energized.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-15

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970
Messages and Codes
CODE 49 Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 49: Load Handler Contactor "I

"Inp
nput
ut I1
I112
12 – FUFU4
4 sen
sense
se Cycle key switch to
t o clear.
Detected Closed When [FU4 Sense]"
Commanded Open (page
(pa ge 6-1
6-115)
15),,
"Tes
"T estt O0
O033 – LH
LHCC Ctr
Ctr
[Load Handler
Contactor]
Conta ctor]"" (page 6-127)

CODE 4A Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 4A: Load Handler "Inp

"Input
ut I1
I112
12 – FUFU4
4 sen
sense
se Cycle key switch to
t o clear.
Contactor Detected Open When [FU4 Sense]"
Commanded Closed (page
(pa ge 6-1
6-115)
15),,
"T
"Tes
estt O0
O033 – LH
LHCC Ctr
Ctr
[Load Handler
Contactor]
Conta ctor]"" (page 6-127)

CODE 4B Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 4B: Steer Contactor "Inp

"Input
ut I1
I14
4 – FUFU1
1 Sen
Sensese"" Cycle key switch to clear. Check contactor
Detected Closed At Start-Up (page
(pa ge 6-7
6-77)
7),, for mechanical binding.
"T
"Tes
estt O0
O011 – STSTR
R Ct
Ctrr
[Steer Power Contactor]"
(page
(pa ge 6-1
6-125)
25)

CODE 4C Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 4C: FU1 Sense Validation "Inp

"Input
ut I1
I14
4 – FUFU1
1 Sen
Sensese"" Check FU1, FU1 Sense line (JPT22-19). If
Steer contactor detected open (page
(pa ge 6-7
6-77)
7),, FU1 opens during Run Mode, Code G4 is
 when commanded closed.
closed. "T
"Tes
estt O0
O011 – STSTR
R Ct
Ctrr displayed. Cycle key switch to clear.
[Steer Power Contactor]"
(page
(pa ge 6-1
6-125)
25)

CODE 4F Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 4F: TPC Detected Closed "Tes

"Testt O0
O000 – TP
TPCC Ct
Ctrr Cycle key switch to clear. Check contactor
 When Commanded
Commanded O Open
pen [Traction Power for mechanical binding.
 The TPA detects an incorrect Contactor]
Conta ctor]"" (page 6-124)
 voltage at the B+ terminal on the
amplifier.

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 6-16 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

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and Tes
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Messages and Codes
CODE 4G Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 4G: TPC Detected Open "T

"Tes
estt O0
O000 – TP
TPCC Ct
Ctrr Cycle key switch to clear.
 After Power-Up
Power-Up [Traction Power
 The TPA detects the TPC open after Contactor]"
Conta ctor]" (page
(page 6-124)
power-up.

CODE 4H Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 4H: TPA, TPC Contactor "T

"Tes
estt O0
O000 – TP
TPCC Ct
Ctrr Cycle key switch to clear.
Coil or Coil Driver Open or [Traction Power
Shorted Contactor]"
Conta ctor]" (page
(page 6-124)

CODE 4K Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 4K: LPA, LPC Contactor "Te

"Test
st O0
O02
2 – LP
LPC
C Ctr
Ctr [L
[Lift
ift Cycle key switch to clear.
Coil or Coil Driver Open or Power Contactor]"
Shorted (page
(page 6-1
6-126)
26)

CODE 50 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 50: No TM "Inp

"Input
ut I2
I23
3 – Ca
Can
n Bus
Bus See “Troubleshooting Communication
Communications Received by [CAN Communication]" Error Codes (5x Series)” on page 5-19
5-19..
CM (page
(page 6-8
6-81)
1) Cycle key switch to clear.
 The Carriage Manager
Manager has not
received correct communications
from the TM.

CODE 51 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 51: No CM Refer to Cycle key switch to clear.

Communications Received by “Troubleshooting Code
 TM 51” on page
page 5-19
5-19..
 The Tractor Manager has not
received correct communications
from the CM.

CODE 55 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 55: CAN Bus 1Transmission "I

"Inp
nput
ut I2
I23
3 – Ca
Cann Bus
Bus Cycle key switch to clear.
clear.
Buffer Error [CAN Communication]"
 The Tractor Manager has detected (page
(pa ge 6-8
6-81)
1)
a CAN transmission buffer error on If intermittent, refer to
CAN Bus 1. “Troubleshooting

https://www.forkliftpdfmanuals.com/
Communication Error
Codes (5x Series)” on
page
page 5-
5-19
19..
 Publication: 1089040, Re-issued: 15 Jun 2010 6-17

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970
Messages and Codes
CODE 56 Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 56: CAN Bus 1 Error "I

"Inp
nput
ut I2
I23
3 – Ca
Cann Bus
Bus Cycle key switch to
t o clear.
Overflow  [CAN Communication]"
CAN BUS error overflow detected (page
(pa ge 6-8
6-81)
1)
 by TM on CAN Bus 1. If intermittent, refer to
“Troubleshooting
Communication Error
Codes (5x Series)” on
page
pa ge 5-
5-19
19..

CODE 57 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 57: No Communications Refer to Cycle key switch to

t o clear.
Received by Display Interface “Troubleshooting Code Note:  This code is displayed when
Card 57” on page
page 5-2
5-20
0. FlashWare
FlashW are is connected ttoo truck.

CODE 59 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action
Code 59: CAN Bus 0 "Input
"Inp ut I2
I23
3 – Ca
Cann Bus
Bus Cycle key switch to
t o clear.
 Transmission Buffer Error [CAN Communication]"
 The Tractor Manager has detected (page
(pa ge 6-8
6-81)
1)
a CAN transmission buffer error on If intermittent, refer to
CAN Bus 0. “Troubleshooting
Communication Error
Codes (5x Series)” on
page
pa ge 5-
5-19
19..

CODE 5A Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 5A: CAN Bus 0 Error "Inp

"Input
ut I2
I23
3 – Ca
Cann Bus
Bus Cycle key switch to
t o clear.
Overflow  [CAN Communication]"
CAN BUS error overflow detected (page
(pa ge 6-8
6-81)
1)
 by TM on CAN Bus 0. If intermittent, refer to
“Troubleshooting
Communication Error
Codes (5x Series)” on
page
pa ge 5-
5-19
19..

CODE 5E Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 5E: No Guidance Manager "I

"Inp
nput
ut I2
I23
3 – Ca
Cann Bus
Bus  Travel disabled in AUTO mode. Travel
CAN Communications Received [CAN Communication]" allowed in MANUAL mode. Cycle key
 by TM (page
(pa ge 6-8
6-81)
1) switch to clear.
If intermittent, refer to
“Troubleshooting
https://www.forkliftpdfmanuals.com/
Communication Error
Codes (5x Series)” on
 page
page 5-
5-19
19..

6-18 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

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Code
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and Tes
ests
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Messages and Codes
CODE 5G Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 5G: No Communications "I

"Inp
nputut I2
I23
3 – Ca
Can
n Bus
Bus Cycle key switch to clear.
clear.
Received by TM from TPA  [CAN Communication]"
 The Tractor Manager has not (page
(pa ge 6-8
6-81)
1)
received CAN communications If intermittent, refer to
from the TPA. “Troubleshooting
Communication Error
Codes (5x Series)” on
page
pa ge 5-
5-19
19..

CODE 5J Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 5J: No communications "Inp

"Inputut I2
I23
3 – Ca
Can
n Bus
Bus Cycle key switch to clear.
clear.
Received by TM from LPA  [CAN Communication]"
 The Tractor Manager has not (page
(pa ge 6-8
6-81)
1)
received CAN communications If intermittent, refer to
from the LPA. “Troubleshooting
Communication Error
Codes (5x Series)” on
page
pa ge 5-
5-19
19..

CODE 5M Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 5M: TPA Start Timeout None Re-Flash TPA software via FlashWare. If
Occurs 1 minute after TPA is code does not clear, replace TPA.
powered ON if TM does not send a
message. This code is not likely to
show on the truck display if there
is truly a broken line between the
 TM and the TPA.

CODE 5P Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 5P: LPA Start Timeout None Re-Flash LPA software via FlashWare. If
Occurs 1 minute after LPA is code does not clear, replace LPA.
powered ON if TM does not send a
message. This code is not likely to
show on the truck display if there
is truly a broken line between the
 TM and the LPA.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-19

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tion 6. Me
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ges,
s, Co
Code
dess, a
and
nd Test
ests Mo
Mode
dell 960
9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes
CODE 5Q Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 5Q: Display Interface Card Refer to Note:  Code 5Q is recorded in the error log.
Not Responding “Troubleshooting Code  The Operator Display will most
most likely
 The TM is not receiving 57” on page
page 5-2
5-20
0. display Code 57.
communication from the Display
Interface Card.
 This code appears in the error log
 but not on the Operator Display.

CODE 64 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 64: Main Mast Height "Inp

"Input
ut I2
I26
6 – Ma
Main
in Ht Ct Cycle key switch to
t o clear.
System Error [Main Lift Height
 While lifting or lowering at >500 Encoder]"
Encod er]" (page
(page 6-85)
rpm, no pulses or missing pulses
are seen from the mast height
encoder.

CODE 65 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 65: Mini-Mast Height "I

"Inp
nput
ut I1
I105
05 – Mi
Mini
ni Ht Ct Cycle key switch to
t o clear.
System Error [Mini-Mast Height
 While lifting or lowering at >300 Count]"
Count ]" (page
(page 6-108)
rpm, no pulses or missing pulses
are seen from the mini height prox
switches or calculated height does
not match.

CODE 67 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 67: Main Mast Count Error "Inp

"Input
ut I0
I02
2 – LiLift
ft S11
S11 [Li
[Lift
ft Cycle key switch to
t o clear.
Calculated height does not match Reference Prox (S11)]"
at main mast reference switch (page
(page 6-7
6-75)
5),,
 when lowering. "I
"Inp
nput
ut I2
I26
6 – MaMainin Ht Ct
[Main Lift Height
Encoder]"
Encod er]" (page
(page 6-85)

CODE 6D Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 6D: Main Lift Pressure "I

"Inp
nput
ut A1
A13 3 – Ma
Main
inPr
Pres
es Cycle key switch to
t o clear.
Sensor Out-of-Range [Main Lift Pressure
 The Tractor Manager has Sensor]"
Sens or]" (page
(page 6-47)
determined that the pressure
sensor voltage is out-of-range.

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 6-20 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Mai
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Manual
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Mess
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es,, Co
Code
des,
s, and
and Tes
ests
ts
Messages and Codes
CODE 6E Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 6E: Mini Lift Pressure "I

"Inp
nput
ut A8
A89 9 – Mi
Mini
niPr
Pres
es Cycle key switch to clear.
Sensor Out-of-Range [Mini-Mast Pressure
 The Tractor Manager has Sensor]"
Sens or]" (page
(page 6-67)
determined that the pressure
sensor voltage is out-of-range.

CODE 6F Overheated, Allow Time To Cool

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 6F: Lift Motor Overheated "Input

"In put A09 - Lft Mr Tmp  Allow time to cool. Cycle key switch
switch to
Lift motor temperature has [Lift Motor Temp]" clear.
exceeded 311°F (155°C). (page
(pa ge 6-4
6-43)
3) Note:  The TM cannot cause this code.

CODE 78 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 78: Lower Continues After "Inp

"Input
ut A2
A23
3 – L/
L/L
L% Cycle key switch to clear.
Request is Removed [Lift/Lower Request]" Note:  This code appears in the error log
(page
(pa ge 6-5
6-55)
5),, only.
"I
"Inp
nput
ut I2
I20
0 – LiLift
ft RPM
RPM
[Lift Motor RPM]"
(page
(pa ge 6-8
6-80)
0),,
"T
"Tes
estt O6
O622 – LoLowe
werr Sol
Sol
[Lower Solenoid (SOL1)]"
(page
(pa ge 6-1
6-153)
53)

CODE 79 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 79: Regen Lower Fault "I

"Inp
nput
ut A2
A233 – L/L/LL% Cycle key switch to clear. If code occurs
[Lift/Lower Request]" after lift pump replacement, make sure
(page
(pa ge 6-5
6-55)
5),, correct pump was installed.
"I
"Inp
nput
ut I2
I20
0 – LiLift
ft RPM
RPM
[Lift Motor RPM]"
(page
(pa ge 6-8
6-80)
0),,
"T
"Tes
estt O6
O622 – LoLowe
werr Sol
Sol
[Lower Solenoid (SOL1)]"
(page
(pa ge 6-1
6-153)
53)

CODE 7E Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 7E: Lift Motor Temperature "Input

"In put A09 - Lft Mr Tmp Cycle key switch to clear.
Sensor Out-of-Range [Lift Motor Temp]" Note:  The TM cannot cause this code.
Lift motor temperature sensor (page
(pa ge 6-4
6-43)
3)
 voltage is out-of-range.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-21

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ests Mo
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9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes
CODE 7F Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 7F: LPA Temp Out-of-Range "Inp

"Input
ut A19
A19 - LA Temp
Temp Cycle key switch to
t o clear.
 The LPA temperature is less than
than [LPA Temp]"
Temp]" (page
(page 6-52) Note:  The TM cannot cause this code.
 –40°F (–40°C) or greater than
+203°F (+95°C).

CODE 7G Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 7G: LPA Motor Phase Open "T

"Tes
estt O2
O28
8 – Li
Lift
ft RP
RPM
M Cycle key switch to
t o clear.
 The LPA detects no current draw in [Ramp Lift Motor]" Note:  The TM cannot cause this code.
one of the three phases of the (page
(page 6-1
6-134)
34)
motor.

CODE 7H Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 7H: Lift Motor Speed "Inp

"Input
ut I2
I20
0 – Li
Lift
ft RPM
RPM Cycle key switch to
t o clear.
Sensor Failure Detected [Lift Motor RPM]" Note:  The TM cannot cause this code.
 The LPA detects incorrect pulses (page
(pa ge 6-8
6-80)
0)
from the lift motor speed sensor.

CODE 7M Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 7M: LPA Failed to "T

"Tes
estt O0
O033 – LH
LHCC Ctr
Ctr Check for B+ at TPA+ or welded LHC tips.
Precharge [Load Handler Cycle key switch to clear. If code will not
 The LPA failed to precharge. Contactor]
Conta ctor]"" (page 6-127) clear, replace LPA.
Note:  The TM cannot cause this code.

CODE 7T Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 7T: LPA Current Sensor None If cycling the key switch does not clear
Fault this code, replace the LPA.
Internal LPA circuitry detects a Note:  The TM cannot cause this code.
fault.

CODE 7U Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 7U: LPA Overcurrent or "Testt O2

"Tes O28
8 – Li
Lift
ft RP
RPM
M Check for shorted lift motor power cables.
Short Circuit [Ramp Lift Motor]" Cycle key switch to
t o clear.
 The LPA senses current in excess
excess (page
(page 6-1
6-134)
34) Note:  The TM cannot cause this code.
of 650A.

https://www.forkliftpdfmanuals.com/
 6-22 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

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and Tes
ests
ts
Messages and Codes
CODE 7V Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 7V: LPA High Voltage on DC None If the problem is intermittent and only
BUS occurs while lowering the main mast, it
 The LPA detects an overvoltage indicates a bad battery or possible loose
condition at the + terminal. connection in the power circuit
connections for the lift/lower system.
Check all associated power cables for
correct torque and contactor tips for
excessive wear.
wear. If the error is a hard code,
re-flash the LPA. If the code persists,
replace the LPA.
Note:  The TM cannot cause this code.

CODE 7W Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 7W: LPA Internal Fault None Cycle key switch to clear. Re-flash the
Internal malfunction. LPA. If code does not clear, replace LPA.
Note:  The TM cannot cause this code.

CODE 7X Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

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

CODE 80 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 80: Throttle Pot Voltage "Inp

"Input
ut A0
A044 – Th
Thrt
rtll Pot Cycle key switch to clear.
Out-of-Range [Throttle Pot (VR1)]"
 VR1 voltage at pin JPC12-3 (page
(page 6-4
6-40)
0)
out-of-range.

CODE 81 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 81: Lift/Lower Pot Voltage "Inp

"Input
ut A0
A055 – L/
L/L
L Pot
Pot Cycle key switch to clear.
Out-of-Range [Lift/Lower Pot (VR2)]"
 VR2 voltage at pin JPC12-2 (page
(pa ge 6-4
6-41)
1)
out-of-range.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-23

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ests Mo
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9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes
CODE 83 Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 83: Throttle Pot "I

"Inp
nput
ut A0
A044 – Th
Thrt
rtll Pot Cycle key switch to clear. Check throttle
Out-of-Neutral [Throttle Pot (VR1)]" pot spring for excessive play.
 VR1 out of learned neutral value (page
(page 6-4
6-40)
0) Note:  This code is displayed if the Throttle
during SelfTest. is out-of-neutral and the “Release handle”
message has scrolled three times.

CODE 84 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 84: Brake Inoperable - Not "T

"Tes
estt O3
O30
0 – Br
Brak
ake"
e" Make sure brake release bolts are
 Applied (page
(page 6-1
6-136)
36) removed from brake assembly. Cycle key
 The traction motor speed sensor switch to clear.
indicated movement during
Selftest.

CODE 88 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 88: +5V Power Supply "Input

"Input A26 - CM 5V PS Cycle key switch to
t o clear.
Out-of-Range [+5VDC Pot Supply]"
Control handle +5V power supply (page
(pa ge 6-5
6-56)
6)
located in Carriage Manager
out-of-range.

CODE 8A Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 8A: Rotate Pot Voltage "I

"Inp
nput
ut A8
A87
7 – Ro
Rott Pot
Pot Cycle key switch to
t o clear.
Out-of-Range [Rotate Command Pot
 VR3 voltage at JPC12-5 (VR3)]"
(VR3)]" (page
(page 6-65)
out-of-range.

CODE 8B Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 8B: Traverse Pot Voltage "Inp

"Input
ut A8
A85
5 – Trv Po
Pott Cycle key switch to
t o clear.
Out-of-Range [Traverse/Reach Pot
 VR4 voltage at JPC4-4 (VR4)]"
(VR4)]" (page
(page 6-63)
out-of-range.

CODE 8C Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 8C: Deadman Pedal Switch "I

"Inp
nput
ut I0
I00
0 – DmDman
an S23
S23 Check for debris under deadman pedals.
Error [Carriage Deadman Cycle key switch to
t o clear.
Signals do not agree from the Switch (S23)]"
Deadman pedals (S2 and S23). (page
(page 6-7
6-74)
4),,
https://www.forkliftpdfmanuals.com/
"I
"Inp
nput
ut I3
I32
2 – Dm
Dman
an S2
S2
[Brake Deadman Switch
 (S2)] (page 6-86)

6-24 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

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and Tes
ests
ts
Messages and Codes
CODE 8F Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 8F: Lift/Lower Pot "I

"Inp
nput
ut A0
A055 – L/
L/L
L Pot
Pot Check lift/lower pot spring for excessive
Out-of-Neutral [Lift/Lower Pot (VR2)]" play. Cycle key switch to clear.
 VR2 out of learned neutral value (page
(pa ge 6-4
6-41)
1) Note:  This code is displayed if the Lift pot
during SelfTest. is out-of-neutral and the “Release handle”
message has scrolled three times.

CODE 8L Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 8L: Brake Feedback "In

"Input
put A35 - Brk
BrkSen
Sense
se Cycle key switch to clear.
Current Out-of-Range [Brake Voltage]"
 The TM senses brake coil current is (page
(pa ge 6-5
6-57)
7)
incorrect.

CODE 8M Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 8M: Mini Power Supply "Te

"Test
st O6
O63
3 – Mi
Mini
niPw
PwrS
rSup
up Cycle key switch to clear.
 Voltage
 Voltage Out-of-Range
Out-of-Range [Mini Power Supply]"
Mini power supply voltage on load (page
(pa ge 6-1
6-154)
54),,
handler is <9.0 or >20.0V  "In
"Input
put A40 - Min
MiniSp
iSply
ly
[Mini Power Supply]"
(page
(pa ge 6-5
6-59)
9)

CODE 8V Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 8V: Rotate Pot "Inp

"Input
ut A8
A87
7 – Ro
Rott Pot
Pot Check rotate pot spring for excessive play.
Out-of-Neutral [Rotate Command Pot Cycle key switch to clear.
 VR3 out of learned neutral value (VR3)]"
(VR3)]" (page
(page 6-65) Note:  This code is displayed if the Rotate
during SelfTest. pot is out-of-neutral and the “Release
handle” message has scrolled three times.

CODE 8X Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 8X: Traverse Pot "I

"Inp
nput
ut A8
A85
5 – Trv Po
Pott Check traverse pot spring for excessive
Out-of-Neutral [Traverse/Reach Pot play. Cycle key switch to clear.
 VR4 out of learned neutral value (VR4)]"
(VR4)]" (page
(page 6-63) Note:  This code is displayed if the
during SelfTest.  Traverse pot is out of neutral and the
“Release handle” message has scrolled
three times.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-25

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and
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ests Mo
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9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes
CODE 91 Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

>10° 
Code 91: Drive Unit Turned >10° "Inp
"Input
ut I2
I244 – St
Strr Home
Home Cycle key switch to
t o clear.
 While On Wire [Home Steer Proximity
Sensor]"
Sens or]" (page
(page 6-83)
6-83),,
"Inp
"Input
ut I2
I255 – St
Strr En
Encd
cdrr
[Steer Motor Encoder]"
(page
(page 6-8
6-84)
4)

CODE 92 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 92: Tracking Limits None Run Wire Guidance Lear n. See “Learn
Exceeded  Wire Guidance” on page
page 3-34.
3-34. Cycle
 Cycle key
switch to clear.

CODE 93 Lost TCP Lost Wire

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 93: Not Near Wire - Tractor None Refer to “Wire Guidance Troubleshooting”
Coil Pair on page
page 5-2
5-21
1.

CODE 94 Lost LCP Lost Wire

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 94: Not Near Wire - Load None Refer to “Wire Guidance Troubleshooting”
Coil Pair on page
page 5-2
5-21
1.

CODE 9A Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 9A: Bad WG Learn None Run Wire Guidance Lear n. See “Learn
Procedure  Wire Guidance” on page
page 3-34.

CODE 9B Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 9B: Incorrect Firmware in None Install correct TM software via FlashWare
Guidance Manager or correct firmware
fir mware in Guidance Manager
Manager..
 V
 Version
ersion of firmware installed in Cycle key switch to
t o clear.
Guidance Manager is not
compatible with TM software.

CODE 9E Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 9E: Track and Hold Signal Check for shorts to Check static straps. AUTO/MAN switch to
Failed frame. Refer to “Shorts Manual. Cycle key switch to clear
clear.. Replace
 The truck is moving on the wire to Frame Test” on Guidance Manager.
and the guidance signals are not https://www.forkliftpdfmanuals.com/
page
pa ge 5-
5-3
3.
 fluctuating.

6-26 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

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es,, Co
Code
des,
s, and
and Tes
ests
ts
Messages and Codes
CODE 9F Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 9F: Filter Card Not None Cycle key switch to clear. Check
Connected to Guidance connection between Filter Card and
Manager Guidance Manager.
Manager. Replace Filter Card
 AUTO/MAN switch is switched
switched to first, then Guidance Manager
Manager..
 Auto and the Guidance Manager
Manager
does not sense the Filter Card.

CODE 9G Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 9G: No Signal - Load None Cycle key switch to clear. Line driver
 Antenna  output interrupted. Refer to “Wire
Guidance
Guida nce Troubleshooting
Troubleshooting”” on page 5-21
5-21..

CODE 9H Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 9H: No Signal - Tractor None Cycle key switch to clear. Line driver
 Antenna  output interrupted. Refer to “Wire
Guidance
Guida nce Troubleshooting
Troubleshooting”” on page 5-21
5-21..

CODE 9J Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 9J: Load Antenna Input None AUTO/MAN switch to Manual. Cycle key
 Too High
High switch to clear.

CODE 9K Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code 9K: Tractor Antenna Input None Refer to “Wire Guidance Troubleshooting”
 Too High
High on page
page 5-2
5-21
1.

CODE A0 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code A0: Incorrect Software None Travel, lift, and lower disabled. Cycle key
Incorrect Tractor Manager installed switch to clear. If this code appears,
in truck or Flashed with incorrect upgrade the software in the truck using
software. FlashWare.

CODE A2 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code A2: Software Compatibility None Upgrade software via FlashWare. Cycle
Issue with TM and TPA  key switch to clear.
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 Publication: 1089040, Re-issued: 15 Jun 2010 6-27

Se
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dess, a
and
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ests Mo
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dell 960
9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes
CODE A4 Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code A4: Software Compatibility None Upgrade software via FlashWare. Cycle
Issue with TM and LPA  key switch to clear
clear..

CODE AP Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code AP: TPA Software Fault None Cycle key switch to clear. If code does not
clear, upgrade TPA software via
FlashWare.

CODE AT Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code AT: LPA Software Fault None Cycle key switch to clear. If code does not
clear, upgrade LPA software via
FlashWare.

CODE AV
AV Inform Service
Ser vice
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code AV: Primary Memory None Cycle key switch to clear. Install a
Mismatch pre-programmed TM and CM.
 The three primary memory
locations do not agree.

CODE B0 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code B0: Rotate Position "Inp

"Input
ut A8
A888 – Ro
Rott Posn
Posn Cycle key switch to
t o clear.
Feedback Pot Out-of-Range [Rotate Position
Feedback Pot (VR6)]"
(page
(page 6-6
6-66)
6)

CODE B1 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code B1: Traverse

T raverse Position "I
"Inp
nput
ut A8
A866 – Trv Po
Posn
sn Cycle key switch to
t o clear.
Feedback Pot Out-of-Range [Traverse Position
Feedback Pot (VR5)]"
(page
(page 6-6
6-64)
4)

CODE FE Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code FE: Internal TM Circuit for None Code is displayed for 30 seconds. Replace
BSOC Not Calibrated  TM.
https://www.forkliftpdfmanuals.com/
 6-28 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

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Mess
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Code
des,
s, and
and Tes
ests
ts
Messages and Codes
CODE FG Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code FG: TM Power Supply "In

"Input
put A14 - TM +12 [TM Cycle key switch to clear.
Out-of-Range +12VDC Power Supply]"

(page
(page 6-4
6-48)
8)

CODE FH Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code FH: Battery Voltage "I

"Inp
nput
ut A1
A155 – Ba
Batt
ttVVol
oltt Cycle key switch to clear.
Out-of-Range [Battery Voltage]"
 Wrong voltage battery or voltage
voltage (page
(page 6-4
6-49)
9)
out-of-range.

CODE FK Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code FK: CM Power Supply "I

"Inp
nput
ut A12
A12 - CM +12
+12 Cycle key switch to clear.
Out-of-Range [CM +12VDC Power
Supply]"
Supply]" (page
(page 6-46)

CODE FN Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code FN: Relays Did Not Open at "Tes

"Testt O3
O32
2 – Re
Rela
lay
y Tog Cycle key switch to clear.
Power Off  [Toggle Relay Enable]"
(page
(page 6-1
6-137)
37)

CODE FP Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code FP: TM In-Circuit Hardware None If code is displayed at Startup, replace

Failure  TM. If intermittent, check static straps
and for shorts to frame. Refer to "Shorts
to Frame"
Frame" (page
(page 5-2)
5-2).. Cycle key switch to
clear.

CODE FT Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code FT: TM Internal Software None Cycle key switch to clear. If code does not
Error clear, upgrade TM software via FlashWare.

CODE FX Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code FX: CM In-Circuit Hardware None If code is displayed at Startup, replace

Failure CM. If intermittent, check static straps
and for shorts to frame. Refer to "Shorts
https://www.forkliftpdfmanuals.com/
to Frame"
Frame" (page
(page 5-2)
5-2).. Cycle key switch to
 clear.

Publication: 1089040, Re-issued: 15 Jun 2010 6-29

Se
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tion 6. Me
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Code
dess, a
and
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ests Mo
Mode
dell 960
9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes
CODE FY Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code FY: CM Internal Software None Cycle key switch to clear. If code does not
Error clear, upgrade CM software via

FlashWare.

CODE G0 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code G0: Steer Tiller Encoder 1 "I

"Inp
nput
ut I3
I355 – St
Strr Enc1
Enc1 Cycle key switch to
t o clear.
Bad [Steering Encoder
Channel
Chan nel E1]" (page
(page 6-89)

CODE G2 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code G2: Auto Steer Center Refer to Step off, then back on the deadman pedal
Failed “Troubleshooting to allow travel again. Cycle key switch to
1. Ho
Home
me swi
switc
tch
h is >10° from the
>10 Steering Fault Codes (G clear.
initial value saved during a Series)”
Series)” on page 5-23
5-23..
successful Auto Steer Center.
Center.
2. Aut
Auto
o Steer
Steer Cente
Centerr time-
time-out
out
>2 sec
second
onds.
s.
3. No e
enco
ncoder
der puls
pulses
es se
sense
nsed
d
during Auto Steer Center.

CODE G3 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code G3: Home Prox Switch Not Refer to  All steer indicator lights will flash. Cycle
Cycle
Functioning Correctly “Troubleshooting key switch to clear
clear..
Steering Fault Codes (G
Series)”
Series)” on page 5-23
5-23..

CODE G4 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code G4: Open Detected in Steer Refer to Step off, then back on the deadman pedal
Control Circuit “Troubleshooting to allow travel again. Cycle key switch to
No neutral pulses detected when Steering Fault Codes (G clear.
the truck is not moving and the Series)”
Series)” on page 5-23
5-23..
deadman pedal is depressed.

https://www.forkliftpdfmanuals.com/
 6-30 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Mai
aint
nten
enan
ance
ce Manu
Manual
al Se
Sect
ctio
ionn 6. Me
Mess
ssag
ages
es,, Co
Code
des,
s, and
and Tes
ests
ts
Messages and Codes
CODE G5 Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code G5: Short Detected In Steer "Input

"Input A37 - Str Cur
Currr Step off, then back on the deadman pedal
Power Circuit [Steer Motor Current]" to allow travel again. Cycle key switch to

No command
encoder and
pulses steer motor
detected. (page
(pa
"Inp
"I ge
ut6-5
nput 6-58)
58),–, St
I25
I2 Strr En
Encd
cdrr clear.
[Steer Motor Encoder]"
(page
(pa ge 6-8
6-84)
4),,
"Tes
"T estt O4
O444 – St Stee
eerr Mtr
Mtr
[Steer Motor]"
(page
(pa ge 6-1
6-140)
40)

CODE G7 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code G7: Steer Tiller Encoder 2 "Inp

"Input
ut I3
I366 – St
Strr Enc2
Enc2 Cycle key switch to clear.
Bad [Steering Encoder
Channel
Chan nel E2]"
E2]" (page 6-90)

CODE GD Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code GD: No Steer Motor "I

"Inp
nput
ut I2
I25
5 – St
Strr En
Encd
cdrr Cycle key switch to clear.
Encoder Pulses Seen [Steer Motor Encoder]"
No steer motor encoder pulses seen (page
(page 6-8
6-84)
4)
 when requesting
requesting a steer c
correction,
orrection,
travel is >0.1 mph, or during Auto
Steer Center.

CODE GE Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code GE: Both Steer Tiller "Inp

"Input
ut I3
I35
5 – St
Strr Enc1
Enc1 Cycle key switch to clear.
Encoders Bad [Steering Encoder

 The
 bothconnect detect
steer tiller circuitare
encoders sens
senses
es
bad. Channel
(page
(page 6-8 E1]"
6-89)
9),,
"Inp
"Input
ut I3
I366 – St
Strr Enc2
Enc2
[Steering Encoder
Channel
Chan nel E2]"
E2]" (page 6-90)

CODE GF Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code GF: Wire Guidance Position None Run Wire Guidance Lear n. See “Learn
Out-of-Range  Wire Guidance” on page
page 3-34.
3-34. Cycle
 Cycle key
switch to clear.

https://www.forkliftpdfmanuals.com/
 Publication: 1089040, Re-issued: 15 Jun 2010 6-31

Se
Secction
tion 6. Me
Messsa
sage
ges,
s, Co
Code
dess, a
and
nd Test
ests Mo
Mode
dell 960
9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes
CODE J2 Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code J2: Aisle Exit Error "I

"Inp
nput
ut I7
I72
2 – EO
EOA1
A1,, Rig
Right
ht  While out of the aisle, switch the
Only one magnet was sensed when [End-of-Aisle Sensor 1  AUTO/MAN switch to Manual.
Manual. Turn the

the aisle was exited. (Right

(page
(pa Side)]"
ge 6-9
6-98)
8),, drive unit >10° and travel until the code
clears.
"Inp
"Input
ut I7
I73
3 – EO EOA2
A2,, Le
Left
ft Note:  Inputs displayed are dependant on
[End-of-Aisle Sensor 2 EOA selection in FlashWare.
(Left Side)]"
Side)]" (page
(page 6-99)
6-99),,
"Input
"Inp ut I1
I117
17 – EO EOA1 A1
Inner [Alternate Sensor
2]" (page
(page 6-1
6-121)21),,
"Input
"Inp ut I1
I118
18 – EO EOA2 A2
Outer [Alternate Sensor
1]" (page
(page 6-1
6-122)22)

CODE J4 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code J4: End-of-Aisle Sensor "I

"Inp
nput
ut I1
I100
00 – EO
EOA1
A1 On
On Check sensor wiring. Cycle key switch to
Fault [End-of-Aisle Connect clear.
 The connect/detect circuit senses
senses Detect
Dete ct 1 (Right Side
Side)]"
)]"
one or both sensors are bad. (page
(page 6-1
6-103)
03),,
"I
"Inp
nput
ut I1
I101
01 – EO
EOA2
A2 On
On
[End-of-Aisle Connect
Detect
Dete ct 2 (Left
(Left Side)
Side)]"
]"
(page
(page 6-1
6-104)
04)

CODE T4 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code T4: Traverse Proportional "Tes

"Testt O5
O58 8 – Tra
Trave
vers
rse
e Cycle key switch to
t o clear.
 Valve
 Valve Solenoid
Solenoid Open PWM [Traverse PWM
(SOL7)]"
(SOL 7)]" (page
(page 6-149)

CODE T5 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code T5: Rotate/Reach "T

"Tes
estt O5
O55
5 – Rc
Rch/
h/Ro
Rott Cycle key switch to
t o clear.
Proportional Valve Solenoid PWM [Reach/Rotate
Open PWM (SOL8)]"
(page
(page 6-1
6-146)
46)

CODE TE Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code TE: Load Handler Motor "Input

"Input A65 - LH Mr Tmp Cycle key switch to
t o clear.
 Temp Sensor
Sensor Out-
Out-of-Range
of-Range [Load Handler Motor
 Temp]" (page 6-62)
https://www.forkliftpdfmanuals.com/
 6-32 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® M

 Mai
aint
nten
enan
ance
ce Manu
Manual
al Se
Sect
ctio
ionn 6. Me
Mess
ssag
ages
es,, Co
Code
des,
s, and
and Tes
ests
ts
Messages and Codes
CODE TF Inform Service
Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code TF: Load Handler Motor "Input

"Input A65 - LH Mr Tmp Self-resetting after motor allowed to cool.
Overtemp [Load Handler Motor

 Temp]"
"Tes
"T (page
estt O2
O23 6-62),
6-62)
3 – Fans"" ,
Fans
(page
(page 6-1
6-133)
33)

CODE X6 Inform Service

Code Title/Reason Inputs/Tests to Run Notes/Corrective Action

Code X6: EPO Mismatch "Inp

"Input
ut A41
A41 - CM EPO
EPO Cycle key switch to clear.
Reading at JPT22-21 does not [CM EPO Sense]"
agree with reading at JPC22-21 (page
(page 6-6
6-60)
0)
regarding EPO position. "Inp
"Input
ut A42
A42 - TM EPO
EPO
[TM EPO Sense]"
(page
(page 6-6
6-61)
1)

https://www.forkliftpdfmanuals.com/
 Publication: 1089040, Re-issued: 15 Jun 2010 6-33

Se
Secction
tion 6. Me
Messsa
sage
ges,
s, Co
Code
dess, a
and
nd Test
ests Mo
Mode
dell 960
9600/
0/9700 Swing-Reach ® Maintenance Manual
970
Messages and Codes

https://www.forkliftpdfmanuals.com/
 6-34 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Electrical Inputs/Test
Inputs/Test Summary List

Electrical Inputs/T
In puts/Test
est Summary List
Section 6. Electrical Tests

 Analog Inputs
Inputs
Input A04 – Thrtl Pot [Throttle
[Throttle Pot (VR1)]
(VR1)] . . . . . . . . . . . . . . . . . . . . . 6-40
Input A05 – L/L Pot [Lift
[Lift/Lower
/Lower Pot (VR2)]
(VR2)] . . . . . . . . . . . . . . . . . . . . 6-41
Input A08
A08 - Dr Mr Tmp
Tmp [Traction
[Traction Motor Temp]
Temp] . . . . . . . . . . . . . . . . . 6-42
Input A09 - Lft Mr
Mr Tmp [Lift Motor Temp] . . . . . . . . . . . . . . . . . . . . 6-43
Input A10
A10 - TA Temp [TPA [TPA Temp]
Temp] . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Input A11 - Dr Curr
Curr [Tractio
[Traction n Motor
Motor Current]
Current] . . . . . . . . . . . . . . . . . 6-45
Input A12 - CM +12 [CM +12VDC +12VDC Power Suppl Supply] y] . . . . . . . . . . . . . . . 6-46
Input A13 – MainP
MainPresres [Main Lift Pressu
Pressurere Sensor]
Sensor] . . . . . . . . . . . . . . 6-47
Input A14 - TM +12 [TM +12VDC +12VDC Power
Power Supply
Supply]] . . . . . . . . . . . . . . . 6-48
Input A15 – BattV
BattVolt
olt [Batter
[Battery y Voltage]
Voltage] . . . . . . . . . . . . . . . . . . . . . . . 6-49
Input A17 – Lift Pnd
Pnd [Lift
[Lift Pendant]
Pendant] . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Input A18 – Lwer Pnd [Lower Penda Pendant]
nt] . . . . . . . . . . . . . . . . . . . . . . 6-51
Input A19
A19 - LA Temp [LPA [LPA Temp]
Temp] . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Input A20 - Lft Curr
Curr [Lift
[Lift Motor
Motor Current]
Current] . . . . . . . . . . . . . . . . . . . . . 6-53
Input A22 – Thrtl % [Travel
[Travel Reques
Request]t] . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Input A23 – L/L % [Lift/Lo
[Lift/Lowerwer Request]
Request] . . . . . . . . . . . . . . . . . . . . . . 6-55
Input A26 - CM 5V PS [+5VDC [+5VDC Pot Supply]
Supply] . . . . . . . . . . . . . . . . . . . 6-56
Input A35 - BrkS
BrkSense
ense [Brake
[Brake Volta
Voltage]
ge] . . . . . . . . . . . . . . . . . . . . . . . 6-57
Input A37 - Str Curr
Curr [Steer
[Steer Motor Curr
Current]
ent] . . . . . . . . . . . . . . . . . . . 6-58
Input A40 - MiniS
MiniSply
ply [Mini
[Mini Power
Power Supply
Supply]] . . . . . . . . . . . . . . . . . . . . 6-59
Input A41 - CM EPO [CM EPO EPO Sense]
Sense] . . . . . . . . . . . . . . . . . . . . . . . 6-60
Input A42
A42 - TM EPO [TM [TM EPO Sense]
Sense] . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Input A65 - LH Mr Tmp [Load [Load Handl
Handlerer Motor
Motor Temp]
Temp] . . . . . . . . . . . . 6-62
Input A85 – Trv Pot
Pot [Traver
[Traverse/Rea
se/Reachch Pot (VR4)
(VR4)]] . . . . . . . . . . . . . . . . 6-63
Input A86 – Trv Posn [Trave
[Traverse
rse Positi
Position
on Feedba
Feedback ck Pot
Pot (VR5)] . . . . . . 6-64
Input A87 – Rot Pot [Rotate Comma Command nd Pot (VR3)] . . . . . . . . . . . . . . . 6-65
Input A88 – Rot Posn [Rotat
[Rotate e Positio
Positionn Feedba
Feedback ck Pot (VR6)] . . . . . . . 6-66
Input A89 – MiniP
MiniPres
res [Mini-Ma
[Mini-Mast st Pressure
Pressure Sensor
Sensor]] . . . . . . . . . . . . . . 6-67
Input A90 – TM B+Key
B+Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68

Input
Input A91
A94 –- Trv
CM Curr
Burr
B+Key
C +Key . . .rse
[Traverse
[Trave . . .Solenoi
. . . . .d. .(SOL7)]
Solenoid . . L7)]
(SO . . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-69
6-70
Input A95 - Rot Curr
Curr [Rotate
[Rotate Solenoid
Solenoid (SOL8(SOL8)] )] . . . . . . . . . . . . . . . . . 6-71

Digital Inputs
Input I00 – Dman S23 [Car[Carriage
riage Deadma
Deadman n Switch
Switch (S23)
(S23)]] . . . . . . . . . 6-74
Input I02 – Lift S11
S11 [Lift
[Lift Referenc
Reference e Prox (S11)
(S11)]] . . . . . . . . . . . . . . . . . 6-75
Input I04 – Bypass
Bypas s S7 [Lift
[Lift/Lower
/Lower Inhib
Inhibit it Bypass
Bypass Switc
Switch h (S7)]
(S7)] . . . . . 6-76
Input I14 – FU1 Sense
Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Input I15 – Horn S3 [Horn
[Horn Switc
Switch h (S3)]
(S3)] . . . . . . . . . . . . . . . . . . . . . . 6-78
Input I19 – Trac RPM [Tracti
[Traction
on Motor
Motor RPM] RPM] . . . . . . . . . . . . . . . . . . . 6-79
Input I20 – Lift RPM
RPM [Lift
[Lift Motor
Motor RPM]
RPM] . . . . . . . . . . . . . . . . . . . . . . . 6-80
Input I23 – Can Bus [CAN
[CAN Communi
Communicatio cation]n] . . . . . . . . . . . . . . . . . . . 6-81
Input I24 – Str Home [Home Steer Proxim Proximity ity Sensor]
Sensor] . . . . . . . . . . . . 6-83
https://www.forkliftpdfmanuals.com/
Input I25 – Str Encdr [Steer Motor Encode
Encoder]
r] . . . . . . . . . . . . . . . . . . 6-84
 Input I26 Main Ht Ct [Main Lift Height Encode
Encoder]
r] . . . . . . . . . . . . . . 6 85
Input I32 – Dman S2 [Brake
[Brake Deadma
Deadman n Switch
Switch (S2)]
(S2)] . . . . . . . . . . . . . 6-86

Publication: 1089040, Re-issued: 15 Jun 2010 6-35

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Electrical Inputs/Test
Inputs/Test Summary List
Input I33 – Str Enc1On
Enc1On [Stee
[Steering
ring Encoder
Encoder Conne
Connect ct Detect
Detect 1] .. . . .. 6-87
Input I34 – Str Enc2On
Enc2On [Stee
[Steering
ring Encoder
Encoder Conne
Connect ct Detect
Detect 2] .. . . .. 6-88
Input I35 – Str Enc1
Enc1 [Steerin
[Steering
g Encoder
Encoder Channel
Channel E1] . . . . . . .. . .. . 6-89
Input I36 – Str Enc2
Enc2 [Steerin
[Steering
g Encoder
Encoder Channel
Channel E2] . . . . . . .. . .. . 6-90
Input I39 – Neut Pulse [Neutra
[Neutrall Pulses]
Pulses] . . . . . . . . . . . . . . . . .. . . .. 6-91
Input I45 – Slk Ch
Ch S50 [Slac
[Slack k Chain
Chain 1 Switch
Switch (S50)(S50)]] . . . . . . . . . . . . 6-92
Input I46 – Slk Ch
Ch S51 [Slac
[Slack k Chain
Chain 2 Switch
Switch (S51)(S51)]] . . . . . . . . . . . . 6-93
Input I65 – Rail Sense [Rail Guidan
Guidance ce Switch
Switch (S15)
(S15)]] . . . . . . . . . . . . 6-94
6-94
Input I66 – Auto/M
Auto/Man an [Auto/Ma
[Auto/Manual nual Switc
Switch h (S4)]
(S4)] . . . . . . . . . . . . . . 6-95
6-95
Input I67 – SG RtRt S60 [Righ
[Rightt Sidegate
Sidegate Switch (S60) (S60)]] . . . . . . . . . . . . 6-96
Raymond EOA Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
Input I72 – EOA1, Right [End-[End-of-Ai
of-Aisle
sle Sensor
Sensor 1 (Right (Right Side)]
Side)] . . . . . . 6-98
6-98
Input I73 – EOA2, Left [End-
[End-of-Ai
of-Aisle
sle Sensor
Sensor 2 (Left (Left Side)]
Side)] . . . . . . . . 6-99
6-99
Input I83 – SG Lt S61 [Left
[Left Sidegat
Sidegate e Switch
Switch (S61)]
(S61)] . . . . . . . . . . . . . 6-100
6-100
Input I87 – BG LtLt S57
S57 [Left
[Left Batter
Battery y Gate
Gate Switch
Switch (S57) (S57)]] . . . . . . . . . 6-101
Input I88 – BG Rt S58 [Right
[Right Batte
Battery ry Gate
Gate Switch
Switch (S58)] . . . . . . . . 6-102
Input
Inp ut I10
I100
0 – EOA
EOA1 1 On [End-
[End-of-of-Aisl
Aisle e Connec
Connectt Detect
Detect 1 (Rig (Right
ht Sid
Side)]
e)] 6-1
6-103
03
Input
Inp ut I10
I101
1 – EOA
EOA2 2 On [End
[End-of-of-Ai
-Aisle
sle Conn
Connect ect Detec
Detectt 2 (Left
(Left Sid
Side)]
e)] . 6-104
6-104
Input I102 – LdDm S9 S9 [Load Hand
Handler ler Deadman
Deadman (S9)] (S9)] . . . . . . . . . . . 6-105
6-105
Input I103 – LeftHn
LeftHndDM
dDM [Left
[Left Hand
Hand Deadman
Deadman (S26) (S26)]] . . . . . . . . . . . 6-106
6-106
Input I104 – ReachP
ReachProxrox [Reach
[Reach Proximi
Proximity ty Sensor]
Sensor] . . . . . . . . . . . . . 6-107
Input I105 – Mini Ht Ct [Mini-Ma
[Mini-Mast st Height
Height Count]
Count] . . . . . . . . . . . . . 6-108
Input I106 – Mini Sw A [Mini
[Mini-Mast
-Mast Heigh
Heightt Prox
Prox A] . . . . . . . . . . . . . 6-109
Input I107 – Mini Sw B [Mini-
[Mini-Mast
Mast Height Prox B] . . . . . . . . . . . . . 6-110
Input I108 – Mini Sw C [Mini-
[Mini-Mast
Mast Height Prox C] . . . . . . . . . . . . . 6-111
Input I109 – LftSe
LftSell S6 [Lift
[Lift Select (S6)] . . . . . . . . . . . . . . . . . . . . . . 6-112
Input I110 – Attach S5 [Attach
[Attachment
ment (S5)]
(S5)] . . . . . . . . . . . . . . . . . . . 6-113
Input I111 – In Aisle
Aisle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114
6-114
Input I112 – FU4 sense
sense [FU4
[FU4 Sense] . . . . . . . . . . . . . . . . . . . . . . . 6-115
Input I113 – CustomI
CustomIn1 n1 [Custom
[Custom Input
Input 1 (CM)] . . . . . . . . . . . . . . . 6-116 6-116
Input I114 – CustomI
CustomIn2 n2 [Custom
[Custom Input
Input 2 (CM)] . . . . . . . . . . . . . . . 6-117 6-117
Input I115 – CustomI
CustomIn3 n3 [Custom
[Custom Input
Input 3 (TM)] . . . . . . . . . . . . . . . 6-118
Input I116 – CustomI
CustomIn4 n4 [Custom
[Custom Input
Input 4 (TM)] . . . . . . . . . . . . . . . 6-119
 Alternate EOA Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
Input
Input I117
I118 –– EOA1
EOA2 Inner
uter [Alter
Outer
O [Alternate
nate
ate Senso
[Alternate
[Altern Sensor
r 2]
Sensor
Sensor 1] .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-122
6-121

Output Tests
 Test O00 – TPC Ctr [Traction PowerPower Contactor] . . . . . . . . . . . . . . . 6-124
 Test O01 – STR Ctr [Steer Power Contactor] . . . . . . . . . . . . . . . . . 6-125
 Test O02 – LPC Ctr [Lift Power Contactor]
Contactor] . . . . . . . . . . . . . . . . . . . 6-126
 Test O03 – LHC Ctr [Load Handler Contactor] . . . . . . . . . . . . . . . . 6-127
 Test O06 – Sol11Rch [Reach Select Solenoid (SOL11)] . . . . . . . . . . 6-128
 Test O11 – Sol1 Lwr [Lower Solenoid (SOL1)] (SOL1)] . . . . . . . . . . . . . . . . . 6-129
 Test O18 – Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-130
 Test O19 – Disp Alarm [Display Interface Card Card Horn] . . . . . . . . . . . 6-131
 Test O20 – Trav Alarm [Travel Alarm] . . . . . . . . . . . . . . . . . . . . . . 6-132
 Test O23 – Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-133
https://www.forkliftpdfmanuals.com/
 Test O28 – Lift RPM [Ramp Lift Motor] . . . . . . . . . . . . . . . . . . . . . . 6-134
  Test O29 – Traction RPM [Ramp Traction Motor] . . . . . . . . . . . . . . 6-135
 Test O30 – Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-136

6-36 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Electrical Inputs/Test
Inputs/Test Summary List
 Test O32 – Relay Tog [Toggle Relay Enable] . . . . . . . . . . . . . . . . . . 6-137
 Test O39 – Display Test [Cycle Display] . . . . . . . . . . . . . . . . . . . . . 6-138
 Test O43 – Sol5 MinLH [Mini Load Hold (SOL5)] . . . . . . . . . . . . . . . 6-139
 Test O44 – Steer Mtr [Steer Motor] . . . . . . . . . . . . . . . . . . . . . . . . . 6-140
 Test O50 – Sol6 MinSl [Mini Lift Select (SOL6)]
(SOL6)] . . . . . . . . . . . . . . . 6-141
 Test O51 – Sol3 ManLH [Main Load Hold (SOL3)] . . . . . . . . . . . . . . 6-142
 Test O52 – Sol4 ManSl [Main Lift Select
Select (SOL4)] . . . . . . . . . . . . . . . 6-143
 Test O53 – Sol10A DrA [Reach/Rotate DIR A (SOL10A)] . . . . . . . . . 6-144
 Test O54 – Sol10B DrB [Reach/Rotate DIR B (SOL10B)] . . . . . . . . 6-145
 Test O55 – Rch/Rot PWM [Reach/Rotate PWM (SOL8)] . . . . . . . . . 6-146
 Test O56 – Sol9A DirA [Traverse DIR A (SOL9A)] . . . . . . . . . . . . . . 6-147
 Test O57 – Sol9B DirB [Traverse DIR B (SOL9B)] . . . . . . . . . . . . . . 6-148
 Test O58 – Traverse PWM [Traverse PWM
PWM (SOL7)] . . . . . . . . . . . . . 6-149
 Test O59 – SuppDisp [Supplemental Display] . . . . . . . . . . . . . . . . 6-150
 Test O60 – Custom Out 1C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-151
 Test O61 – Custom Out 2T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-152
 Test O62 – Lower Sol [Lower Solenoid (SOL1)] . . . . . . . . . . . . . . . . 6-153
 Test O63 – MiniPwrSup [Mini Power
Power Supply] . . . . . . . . . . . . . . . . . 6-154

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-37

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Electrical Inputs/Test
Inputs/Test Summary List

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 6-38 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Analog Inputs

 Analog Inputs
Section 6. Electrical Tests

 A Diagnosis and Repair table is provided for

for
most inputs. If an input is not within the
specified limits, refer to the Diagnosis and
Repair table.

 Through the process of elimination, these tables

provide a step-by-step approach to diagnose a
problem and provide the necessary corrective
action. See the example below.

Example Diagnosis and Repair Table

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

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

 This column also

identifies the required
setting on the meter
for this step.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-39

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input A04 – Thrt
Thrtll Pot [Th
[Throt
rottle
tle PPot
ot ((VR1
VR1)]
)]

Input A04 – Thrtl Pot  The input is good if the value displayed is
 within these limits:
[Throttle Pot (VR1)]  Throttle
 Throttle Position Voltage
Voltage Displ
Displayed
ayed

Full FF <4.4V  
 The
fromvoltage the Carriage
the throttle Manager
pot (VR1) (CM) reads
is displayed. Neutral 2.25 to 2.75V  
NOTE: Run Learn after you replace, repair, or Full TF >0.4
adjust the throttle pot. Refer to Learn
Controls
Controls on page 3-33.
 Voltage fluctuation indicates a bad cable or pot.
 Voltage
If a message to “Release Traction handle to If the displayed voltages are outside these limits
resume operation” is displayed during SelfTest, or do not change in a smooth, linear fashion,
check the handle for excessive play. The handle refer to Diagnosis and Repair.
should not have movement that allows it to go
 beyond the values listed while in the neutral
position.

Move the throttle pot from full Forks-First (FF)

through
observingneutral to full Tractor-First
the Operator Display. (TF),

Diagnosis and Repair

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

1 Disconnect JPR1/DCV JR1-9 JR1-12 >4V Perform step 2 T/S wiring

Disconnect JPR1 and

2  JR1-11 JC12-3 0 Ohms Perform step 3 T/S wiring
 JPC12/Ohms

Disconnect JPC12. <1V should be displayed with A04 selected. If not, replace CM. If OK, connect a
3  jumper (at the CM) between JC12-3
JC12-3 and JC12-1. The display should read >4 with A04 selected. If
not, replace the CM. If the correct values are displayed, verify wiring to VR1. If OK, replace
r eplace pot.

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 6-40 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input A05 – L/L Pot [Lift/
[Lift/Low
Lower
er Po
Pott (V
(VR2)
R2)]]

Input A05 – L/L Pot  The input is good if the value displayed is
 within these limits:
[Lift/Lower Pot (VR2)]  Throttle Position Voltage Disp
Displayed
layed

Full Lift >0.4

 The voltage
(VR2) the CM reads from the lift/lower pot
is displayed. Neutral 2.25 to 2.75V  
NOTE: Run Learn after you replace, repair, or Full Lower <4.4V  
adjust the lift/lower pot. Refer to Learn
Controls
Controls on page 3-33
3-33..
 Voltage fluctuation indicates a bad cable or pot.
If message “Release Lift to resume operation” is If the voltage is outside these limits or does not
displayed during SelfTest, check the handle for change in a smooth, linear fashion, refer to
excessive play. The handle should not have Diagnosis and Repair.
movement that allows it to go beyond the values
listed while in the neutral position.

Move the lift/lower pot from full lift through

neutral to full lower, observing the Operator

Display.

Diagnosis and Repair

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

1 Disconnect JPR1/DCV JR1-9 JR1-13 >4V Per form step 2 T/S wiring

Disconnect JPR1 and

2  JR1-10 JC12-2 0 Ohms Perform step 3 T/S wiring
 JPC12/Ohms

Disconnect JPC12. <1V should be displayed with A05 selected. If not, replace CM. If OK, connect a
3  jumper (at the CM) between JC12-2
JC12-2 and JC12-1. The display sh should
ould read >4 with A05 selected. If
not, replace the CM. If the correct values are displayed, verify wiring to VR2. If OK, replace pot.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-41

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt A08 - Dr Mr Tmp [[Tra
Inpu Traction
ction M
Motor
otor TTemp]
emp]

Input A0
A08 - Dr Mr
Mr Tm
Tmp the temperatures are not within several
degrees, refer to Diagnosis and Repair.
[Traction Motor Temp]
 Traction Motor temperature is displayed.
 While operating, the TM continuously monitors
traction motor temperature. If the temperature
gets too high, performance is reduced until the
motor cools down.
• Norma
Normall opera
operati
tion
on:: ambi
ambien
entt to 28
284°
4°F
F
(140°C)
• Travel
Travel speed
speed red
reduced
uced lin
linear
early
ly bet
betwee
ween
n
285°F (141°C) and 310°F (154°C)
• Code
Code 2
2A
A is d
disp
ispla
laye
yed
d betw
between
een 31
311°
1°F
F
(155°C) and 373°F (189°C) and speed is
reduced to 1.0 mph
• Code
Code 2E is disp
display
layed
ed and
and travel
travel is llimi
imited
ted
to 1.0 mph at 374°F (190°C)

 With the lift truck at rest and at ambient

temperature, compare the temperature
displayed to the actual ambient temperature. If

Diagnosis and Repair

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

<1200 ohms if Replace Traction

Disconnect JPTA3/
1  JTA3-2 JTA3-1  Traction Motor Perform step 2 Motor Temp
Ohms
is cool to the Sensor 
touch.  T/S Traction
Disconnect JPTA1/  JTA1-8 (on >1200 ohms if
2  JTA1-7 Replace TPA  Motor Temp
Ohms connector) hot to the touch Sensor wires

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 6-42 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Inputt A09 - Lft Mr Tmp [[Lift
Inpu Lift M
Motor
otor TTemp]
emp]

Input A09 - Lft

Inp Lft Mr Tmp
Tmp
[Lift Motor Temp]
Lift Motor temperature is displayed.
 While operating, the TM continuously monitors
lift motor temperature. If the temperature gets
too high, performance is reduced until the
motor cools down.
• Norma
Normall opera
operati
tion
on:: ambi
ambien
entt to 31
310°
0°F
F
(154°C)
• Code
Code 6F displa
displayed
yed at 311°F
311°F (155°C
(155°C)) a
and
nd
lift is disabled. Lower is allowed
• Code
Code 7E displa
displayed
yed at 320°F
320°F (160°C
(160°C)) and
and
lift continues to be disabled. Lower is
allowed

 With the lift truck at rest and at ambient

temperature, compare the temperature
displayed to the actual ambient temperature. If
the temperatures are not within several
degrees, refer to Diagnosis and Repair.

Diagnosis and Repair

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

<1200 ohms if Replace Traction

Disconnect JPLA3/
1  JLA3-2 JLA3-1  Traction Motor Perform step 2 Motor Temp
Ohms
is cool to the Sensor 
touch. >1200
Disconnect JPLA1/ ohms if hot to  T/S Traction
2  JLA1-8 JLA1-7 Replace TPA  Motor Temp
Ohms the touch Sensor wires

NOTE: For extreme operating conditions where

trucks are subjected to repetitive
lift/lower cycles, short runs and/or
repetitive plugging cycles without time
for the amplifiers to cool, a cooling fan
kit is available through the parts
distribution center. Refer to the parts
manual.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-43

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt A10 - TA TTemp
Inpu emp [TP
[TPA
A TTemp]
emp]

Input A10
Inp A10 - TA Tem
Temp
p
[TPA Temp
Temp]]
 Traction Power Amplifier (TPA) temperature is
displayed.

 While operating,
operating, the
the TPA continuously monitors
its internal heatsink temperature. If the
temperature gets too high, performance is
reduced until the TPA cools down.
• Normal
Normal operat
operation
ion:: ambie
ambient
nt to 175°F
175°F (79
(79°C)
°C)
• At 185°
185°F
F (8
(85°C
5°C),
), torq
torque
ue is lin
linear
early
ly redu
reduced
ced
 by the TPA 
• Code
Code 1
1HH is
is disp
display
layed
ed when
when tempe
temperat
rature
ure
exceeds 203°F (95°C) or falls below –40°F
(–40°C)

 As the truck is operated, the TPA temperature

temperature
should increase evenly over time. If not, refer to
Diagnosis and Repair.

Diagnosis and Repair

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

Is TPA hot to If not hot,

1 Hot to touch Perform step 2
touch? replace TPA 
N/A N/A  
Not hot to Return to
2 Allow time to cool Replace TPA 
touch/no code service

NOTE: For extreme operating conditions where

trucks are subjected to repetitive
lift/lower cycles, short runs, and/or
repetitive plugging cycles without time
for the amplifiers to cool, a cooling fan
kit is available through the Parts
Distribution Center. Refer to the parts
manual.

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 6-44 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Inputt A11 - Dr Curr [[Tra
Inpu Traction
ction Moto
Motorr Curre
Current]
nt]

Input A1
A11 - Dr Cu
Curr
[Traction Motor Current]
 The current motor
the traction the TPA
is reads from one phase of
displayed.
• Maxi
Maximu
mum
m curr
curren
ent:
t: 45
450A 
0A 

 The input is good if the value displayed is

 within these limits:

System Condition Current Displayed

Static (at rest) <20A  

 Travel at Full Speed <150A 

NOTE: Because Input A11 measures only one

phase, the value displayed may not
always reveal a current problem.
Check the current on each phase (U, V, and W)
 with a AC clamp-on ammeter.
ammeter.
• The curren
currentt shou
should
ld ramp
ramp even
evenly
ly as the
truck accelerates and decelerates.
• Curren
Currentt s
shou
hould
ld be appr
approx.
ox. equal
equal for
for e
each
ach
phase. Gross differences indicate a
problem.

Diagnosis and Repair

If readings are not within specified limits,

perform the following steps.

1. If any
any one phase differs significantl
significantly
y from
from
the other two, check power cable
continuity. Replace cables as necessary.
Refer to Power Cable Terminals on
page
page 7-
7-52
52..
• If power
power cable
cable con
contin
tinuity
uity is OK,
troubleshoot the Traction
T raction Motor. Refer
to AC Motors
Motors on page
page 5-9.
• If all
all phas
phases
es g
give
ive hig
high
h re
readi
adings
ngs,, the
the
drive unit may be binding. Check drive
unit.
2. The TP
TPA A may
may be
be ba
bad.
d. Run
 Test O29 – Traction RPMhttps://www.forkliftpdfmanuals.com/
[Ramp Traction
Motor]] (page 6-135
Motor 6-135)).
 Publication: 1089040, Re-issued: 15 Jun 2010 6-45

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt A12 - CM +1
Inpu +12
2 [CM +12VD
+12VDC
C Pow
Power
er Sup
Supply]
ply]

Input A12 - CM +12

[CM +12VDC Power
Supply]
Output of the Carriage Manager’s internal
+12VDC power supply is displayed.

 With the truck at rest, the value displayed

should be 10.1 to 13.0V.

If the reading fluctuates by more than 0.8V in

10 seconds, refer to Diagnosis and Repair.

Diagnosis and Repair

Unplug all connectors supplying 12V from the
CM. Measure 10.1 to 13VDC between JC24-13
and JC10-9. If not OK, replace the CM. If OK,
plug in connectors one at a time. Troubleshoot
the circuit that pulls the +12V down.

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 6-46 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input A13 – Mai
MainPr
nPres
es [Ma
[Main
in Lift Pr
Press
essure
ure Se
Senso
nsor]
r]

Input A13 – MainPres

[Main Lift Pressure
Sensor]
 Voltage from the main lift pressure sensor is
displayed.

 The input is good if the value displayed is

 within these limits:

Load Weight Voltage Displayed

0 lb. (no load) - platform

 Approx. 2.2V 
raised 4 in. (102 mm)

 The voltage displayed should increase and

decrease linearly as the load weight is increased
or decreased. If it does not, refer to Diagnosis
and Repair.

Diagnosis and Repair

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

1  JPT20-5 JPT24-10 Perf

rfo
orm step
tep 2 Replace TM
DCV  10.5 to 13V 
2 JPS50-1 Perf
rfo
orm step
tep 3 T/S harne
rness
 JPS50-3 Replace Pressure
3  JPS50-2 1V at 0 psi. 1V Perform step 4
 Attach pressure  Transducer 
increase per
gauge to G1/DCV 
4 JPT24-18 JPT24-10 1000 psi Replace TM T/S harness

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-47

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt A14 - TM +12 [[TM
Inpu TM +12
+12VDC
VDC Po
Power
wer Su
Supply]
pply]

Input A14 - TM +12

[TM +12VDC Power
Supply]
Output of the Tractor Manager’s (TM) internal
+12VDC power supply is displayed.

 With the truck at rest, the value displayed

should be 10.1 to 13.0V.

If the reading fluctuates by more than 0.8V in

10 seconds, refer to Diagnosis and Repair.

Diagnosis and Repair

Unplug all connectors supplying 12V from the
 TM. Measure 10.1 to 13VDC between JPT14-5
and TP4. If not OK, replace the TM. If OK, plug
in connectors one at a time. Troubleshoot the
circuit that pulls the +12V down.

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 6-48 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input A15 – Bat
BattV
tVolt
olt [B
[Batt
attery
ery V
Volt
oltage
age]]

Input A15 – BattVolt

[Battery Voltage]
 The voltageat
SENSE_IN the TM reads
JPT24-24 is from BATTERY_
displayed.
NOTE:  This voltage is used by the TM to
calculate Battery State-of-Charge
(BSOC).

 The input is good if the value displayed is

 within these limits:

Nominal Battery  Voltage Displayed

 Voltage Displayed
 Voltage
 Voltage (while stationary)

48V 44 to 52V  

If the voltage
range displayed
or the reading is not within
fluctuates the than
by more correct
0.8V in 10 seconds with the truck not moving or
lifting, refer to Diagnosis and Repair.

Diagnosis and Repair

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

Check battery water level and

1  TP1 Perform step 2 specific gravity. Replace
 battery. T/S battery cables

 T/S harness from TP1 to

2 DCV  JPF4-1  TP4 44 to 52V  Perform step 3
 JPF4-1

3 JPF4-7 Perform step 4 Replace Fuse/Relay Card

 T/S harness from Fuse

Fuse/Relay
/Relay
4 JPT24-24 Replace TM
Card to TM

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-49

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input A17 – Lif
Liftt Pnd [Li
[Liftft Pen
Pendan
dant]
t]

Input A17 – Lift Pnd

[Lift Pendant]
 The voltage
Manager to the Lift Pendant from
is displayed. from the Tractor

NOTE:  The display should read approx. 5.0V

5.0V
 with the pendant disconnected.

If the voltage reads approx. 5V, refer to Input

 A18. If the display reads <1V at startup, refer to
Diagnosis and Repair.

Diagnosis and Repair

 Action/ Expected
Step (+) L
Le
ead (–) L
Le
ead Step Passed Step Failed
Meter Scale Results

1 DCV (pendant disconnected J1-4 J1-9 Replace TM Per form step 2

Extract JT12-5 from  Approx. 5V 
2 connector/DCV (pendant PT12-5 JPT12-12 T/S wiring Replace TM
disconnected)

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 6-50 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input A18 – Lwe
Lwerr Pnd
Pnd [Lo
[Lower
wer Pen
Pendan
dant]
t]

Input A18 – Lwer Pnd

[Lower Pendant]
 The voltage to the Lower Pendant from
from the
 Tractor Manager is displayed.
NOTE:  The display should read approx. 5.0V
5.0V
 with the pendant disconnected.

If the voltage reads approx. 5V, refer to Input

 A17. If the display reads <1V at startup, refer to
Diagnosis and Repair.

Diagnosis and Repair

 Action/ Expected
Step (+) Le
Lead (–) L
Le
ead Step Passed Step Failed
Meter Scale Results

1 DCV (pendant disconnected J1-3 J1-9 Replace TM Perform step 2

Extract JT12-6 from  Approx. 5V 
2 connector/DCV (pendant PT12-6 JPT12-12 T/S wiring Replace TM
disconnected)

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-51

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt A19 - LA TTemp
Inpu emp [LP
[LPA
A TTemp]
emp]

Input A19 - LA Temp

Inp emp
[LPA Temp]
Lift Power Amplifier (LPA) temperature is
displayed.

 While operating,
operating, the LPA continuously monitors
its internal heatsink temperature. If the
temperature gets too high, performance is
reduced until the LPA cools down.
• Normal
Normal operat
operation
ion:: ambie
ambient
nt to 175°F
175°F (79
(79°C)
°C)
• At 185°
185°FF (8
(85°C
5°C),
), s
spee
peed
d is lin
linear
early
ly redu
reduced
ced
to 0 fpm at 239°F (115°C), when lift is
disabled
• Code
Code 7
7FF iis
s disp
display
layed
ed whe
when
n temp
tempera
eratur
ture
e
exceeds 203°F (95°C) or falls below –40°F
(–40°C)

 As lift is operated, the LPA temperature should

increase evenly over time. If not, refer to
Diagnosis and Repair.

Diagnosis and Repair

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

Is LPA hot to If not hot,

1 Hot to touch Perform step 2
touch? replace LPA 
N/A N/A   Replace LPA if
 Allow time to cool. Not hot to Return to
2 code does not
Does code clear? touch/no code service
clear 

NOTE: For extreme operating conditions where

trucks are subjected to repetitive
lift/lower cycles, short runs, and/or
repetitive plugging cycles without time
for the amplifiers to cool, a cooling fan
kit is available through the Parts
Distribution Center. Refer to the parts
manual.

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 6-52 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Inputt A20 - Lft C
Inpu Curr
urr [L
[Lift
ift Mo
Motor
tor C
Current
urrent]]

Input A2
A20 - Lft Cu
Curr
[Lift Motor Current]
 The current the LPA reads from one phase
phase of
the lift motor is displayed.
• Maxi
Maximu
mum
m curr
curren
ent:
t: 65
650A 
0A 

 The input is good if the value displayed is

 within these limits:

System Condition Current Displayed

Static (at rest) <20A  

Full Lift Approx. 460A  

NOTE: Because Input A20 measures only one

phase, the value displayed may not
always reveal a current problem.

Check the current on each phase (U, V, and W)

 with a AC clamp-on ammeter.
ammeter.
• The curren
currentt shou
should
ld ramp
ramp even
evenly
ly as the
truck lifts.
• Curren
Currentt s
shou
hould
ld be appr
approx.
ox. equal
equal for
for e
each
ach
phase. Gross differences indicate a
problem.

Diagnosis and Repair

If readings are not within specified limits,

perform the following steps.

1. If any
any one phase differs significantl
significantly
y from
from
the other two, check power cable
continuity. Replace cables as necessary.
Refer to Power Cable Terminals on
page
page 7-
7-52
52..
• If power
power cable
cable con
contin
tinuity
uity is OK,
troubleshoot the Lift Motor. Refer to AC
Motors on page
page 5-9.
• If all
all phases
phases give high
high re
readi
adings
ngs,, the lift
lift
pump may be binding. Check lift pump.
2. Th
The
e LPA
LPA may
may be bad
bad.. Run Test O28 – Lift
Run
RPM [Ramp Lift
Lift Motor] (page
(page 6-13
6-134)
4)..
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 Publication: 1089040, Re-issued: 15 Jun 2010 6-53

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input A22 – Thrt
Thrtll % [Trav
[Travel
el Req
Reques
uest]
t]

Input A22 – Thrtl %

[Travel Request]
 The percentage of throttle request the TM sends
to the TPA is displayed. This value is based on
 VR1 position as calculated by the TM.
NOTE: Run Learn after you replace, repair, or
adjust the throttle pot. Refer to Learn
Controls on page 3-33.
Controls

 The input is good if the value displayed is

 within these limits:

 Throttle Position Percentag

Percentage
e Displayed

Full TF 0 to +100

Neutral 0

Full FF 0 to –100

 The values should change smoothly and evenly

as the handle moves from Full Tractor-First to
Full Forks-First. If these results are not
observed, refer to Diagnosis and Repair.

Diagnosis and Repair

Input
Refer to Input A04 – Thr
Thrtl
tl Pot [Th
[Throt
rottle
tle Pot
(VR1)] (page 6-40
6-40)).

Compare Input A04 with Input A22. Maximum

throw
replaceshould show
the TPA. maximum
If not, values. If
check traction so,
system
for speed limitations due to motor temperature,
limit switches, or configured speed.

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 6-54 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input A23 – L/L % [[Lif
Lift/L
t/Lowe
owerr Re
Reque
quest]
st]

Input A23 – L/L %

[Lift/Lower Request]
 The percentage of lift/lower request the TM
sends to the LPA is displayed. This value is
 based on VR2 position as calculated by the TM.
TM.
NOTE: Run Learn after you replace, repair, or
adjust the lift/lower pot. Refer to Learn
Controls
Controls on page 3-33
3-33..

 The input is good if the value displayed is

 within these limits:

 Throttle Position Percenta

Percentage
ge Displayed

Full Lower 0 to –100

Neutral 0

Full Lift 0 to +100

 The values should change smoothly and evenly

as the pot is moved from Full Lower to Full Lift.
If these results are not observed, refer to
Diagnosis and Repair.

Diagnosis and Repair

Refer to Input
Input A05 – L/L Pot [Li
[Lift/
ft/Low
Lower
er Pot
(VR2)] (page 6-41)
6-41)..

Compare Input A05 with Input A23. Maximum

throw
replaceshould show
the LPA. maximum
If not, values.
check lift If so,
system for
limitations due to motor temperature or
switches.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-55

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt A26 - CM 5V PS [+
Inpu [+5VDC
5VDC Pot Supp
Supply]
ly]

Input A2
A26 - CM 5V
5V PS
PS
[+5VDC Pot Supply]
Output of the Carriage Manager’s internal
+5VDC power supply is displayed. This voltage
is used for control handle pots.

 With the truck at rest, the value displayed

should be 5 ±0.25V.

If the reading fluctuates by more than 0.25V in

10 seconds, refer to Diagnosis and Repair.

Diagnosis and Repair

Disconnect JPC12 and JPC4. Measure
5 ±0.25VDC between PC12-1 an
and
d PC12-12. If
not OK, replace
connectors, one the
at aCM. If Troubleshoot
time. OK, plug in the
circuit that pulls the +5V down.

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 6-56 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Inputt A3
Inpu A35
5 - BrkSen
BrkSense
se [[Brake
Brake Voltage
oltage]]

Input A35 - BrkS

Inp BrkSen
ense
se
[Brake Voltage]
 The brake is activated by an internal TM coil
driver. The voltage measured at JPT20-14 is
displayed.

 The input is good if the value displayed is

 within these limits:

State of Brake Voltage Displayed

Deactivated B+

Deadman Pedal
7 to 11V for app
approx.
rox. 1 sec,
Depressed/Travel
increasing to 15 to 28V 
Requested

If these results
Diagnosis are notfor Test
and Repair observed,
for refer
 Test O30 to
– Brake
(Page
(Pa ge 6-1
6-136)
36)..

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-57

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt A37 - Str C
Inpu Curr
urr [S
[Steer
teer M
Motor
otor Curre
Current]
nt]

Input A37
Inp A37 - Str
Str Curr
Curr
[Steer Motor Current]
 The current the steer motor is drawing is
displayed.

 The input is good if the value displayed is

 within these limits:

State of Motor Current Displayed

 At rest <2A 

Clockwise (CW) Steering –30A to –50A  

Counterclockwise (CCW)
30A to 50A 
Steering

Note:  CW and CCW is drive unit direction. Open in

 wire at JPT6-3 equals –199A.

If these results are not observed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

 At rest: approx. 2.5V

Replace Steer
1 DCV JPT6-3 JPT6-4 Steering CCW: <V at rest  Replace TM
 Amplifier 
Steering CW: >V at rest 

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 6-58 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Inputt A4
Inpu A40
0 - MiniS
MiniSply
ply [Mini Power Supp
Supply]
ly]

Input A40 - MiniS

Inp iniSp
ply
[Mini Power Supply]
Output of the Carriage Manager’s internal
power supply is displayed. This voltage is used
to power the mini power supply located on the
mini-mast.

 With the truck at rest, the value displayed

should be 8.5 to 11V.

 The readings associated with this input vary

vary
depending on the load that is currently on
connection JPC12-7. If the voltage displayed is
not within the correct range, refer to
 Test O63 – MiniPwrSup [Mini Power Supply]
(page
(page 6-1
6-154)
54)..

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-59

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input A4
A41
1 - CM EP
EPO
O [CM EEPO
PO Se
Sense
nse]]

Input A4
A41 - CM EP
EPO
[CM EPO Sense]
 The status of the Emergency Power Off (EPO)
(EPO)
switch (S21), as sensed by the CM, is displayed.

 The input is good if the value displayed is

 within these limits:

State of Switch Voltage Displayed

Up (closed) B+

Down (open) <0.5V  

Code X6 is displayed when the truck cannot

determine EPO switch status. If the above
Inpu
results are observed, refer to Inputt A42
A42 - TM
EPO [TM EPO Sense]
Sense] (page
(page 6-61)
6-61)..
If these results are not observed, refer to
Diagnosis and Repair.

Diagnosis and Repair

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

Switch closed: B+  T/S wiring, switch,

1 DCV JPC22-21 JPC14-10 Replace CM
Switch open: <0.5V  and connections

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 6-60 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input A
A42
42 - TM EEPO
PO [T
[TM
M EPO Sen
Sense]
se]

Input A4
A42 - TM EPO
[TM EPO Sense]
 The status of the Emergency Power Off (EPO)
switch (S21), as sensed by the TM, is displayed.

 The input is good if the value displayed is

 within these limits:

State of Switch Voltage Displayed

Up (closed) B+

Down (open) <0.5V  

If these results are observed, the TM EPO

circuit from S21, the Over-the-Mast (OTM)
cable, the Fuse/Relay Card, and the wiring to
the TM are good.
Code X6 is displayed when the truck cannot
determine EPO switch status. If the above
results are observed, refer to Inpu
Inputt A41
A41 - CM
EPO [CM EPO
EPO Sense] (page
(page 6-60
6-60)).

If these results are not observed, refer to

Diagnosis and Repair.

Diagnosis and Repair

 Action/
Step (+) Le
Lead (–) Le
Lead Expected R
Re
esults Step P
Pa
assed Step F
Fa
ailed
Meter Scale

 With EPO switch  T/S OTM cable and

1 raised, disconnect  JF4-8 JF4-5 Approx. 0 ohms Perform step 2
connections
 JPF4/Ohms

Switch closed: B+
 T/S wiring and
2 DCV JPT22-21 TP4 Switch open: Replace TM
connections
<0.5V 

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-61

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input A65
A65 - LH Mr Tmp [L
[Load
oad Han
Handler
dler Mot
Motor
or TTemp]
emp]

Input A65 - LH Mr Tmp

Inp Tmp
[Load Handler Motor

Temp]
Load Handler Motor (LHM) temperature is
displayed.

 While operating, the TM continuously monitors

the load handler motor temperature. If the
temperature gets too high, the fan circuit is
activated by the TM. Fan activation should
occur at 120°F (49°C).
• Norma
Normall opera
operati
tion
on:: ambi
ambien
entt to 25
259°
9°F
F
(126°C)
• Out-
Out-of
of--ra
rang
nge
e code
code TE
• Code
Code TTF
F displ
displaye
ayed
d at 260
260°F
°F (127°C
(127°C)) a
and
nd
load handler functions are disabled

 With the lift truck at rest and at ambient

temperature, compare the temperature
displayed to the actual ambient temperature. If
the temperatures are not within several
degrees, refer to Diagnosis and Repair.

Diagnosis and Repair

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

Run  Test O23 – Fans (page 6-133) to verify fans are functional.

1  JPZ disconnected/ PZ-1 PZ-2 <1200 ohms if Perform step 2 Replace LHM
Ohms LHM is cool to  Temp Sensor 

 JPT24 the touch.

>1200 ohms if  T/S LHM Temp
2 disconnected/  JT24-23 JT24-11 Replace TM
hot to the touch Sensor wires
Ohms

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 6-62 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input A85 – Trv Po
Pott [T
[Trav
ravers
erse/R
e/Reac
eachh Pot (V
(VR4)
R4)]]

Input A85 – Trv Po

Pot  The input is good if the value displayed is
 within these limits:
[Traverse/Reach Pot Position Voltage Displayed

 Traverse Right (handle

<4.4V 
(VR4)]
 The voltage the CM reads from the
pulled back)

Neutral 2.25 to 2.75V  

traverse/reach pot (VR4) is displayed.
 Traverse Left (handle
NOTE: Run Learn after you replace, repair, or >0.4
pushed forward)
adjust the traverse/reach pot. Refer to
Learn Controls
Controls on page 3-33.
 Voltage fluctuation indicates a bad cable or pot.
If code 8X is displayed during SelfTest, check If the voltage is outside these limits or does not
the handle for excessive play. The handle change in a smooth, linear fashion, refer to
should not have movement that allows it to go Diagnosis and Repair.
 beyond the values listed while in the neutral
position.

Move the traverse/reach

right through pot traverse
neutral to full from fullleft,
traverse
observing the Operator Display.

Diagnosis and Repair

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

1 Disconnect JPL1/DCV JL1-9 JL1-12 >4V Per form step 2 T/S wiring

Disconnect JPL1 and

2  JL1-11 JC4-4 0 Ohms Perform step 3 T/S wiring
 JPC4/Ohms

Disconnect JPC4. <1V should be displayed with A85 selected. If not, replace CM. If OK, connect a
3  jumper (at the CM) between JC4-2
JC4-2 and JC4-4. The display should
should read >4 with A85 selected. If not,
replace the CM. If the correct values are displayed, verify wiring to VR4. If OK, replace pot.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-63

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt A86 – Trv PPosn
Inpu osn [[Tra
Traverse
verse Posit
Position
ion FFeedba
eedback
ck Po
Pott (VR
(VR5)]
5)]

Input A86 – Trv Posn

[Traverse Position

Feedback Pot (VR5)]

 The voltage the CM reads from the traverse
position feedback pot (VR5) is displayed.
NOTE: Run Learn after you replace, repair, or
adjust the traverse position feedback
pot. Refer to Learn Controls on
page
page 3-
3-33
33..

 Traverse the mini-mast from full right to full

left, observing the Operator Display.

 The input is good if the value displayed is

 within these limits:

Mini-Mast Position Voltage Displayed

Fully Left >0.2V  

Center 2.25 to 2.75V  

Fully Right <4.8V  

 Voltage fluctuation indicates a bad cable or pot.

If the voltage is outside these limits or does not
change in a smooth, linear fashion, refer to
Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect
1  JK2-1 JK2-3 Approx. 5V Perform step 2 T/S wiring
 VR5/DCV 

Disconnect JPC24
2  JC24-18 JK2-2 0 ohms Perform step 3 T/S wiring
and JPK-2/Ohms

Disconnect JPS27. <1V should be displayed with A86 selected. If not, replace CM. If OK, connect a
3  jumper between JS27-14 and JPC4-1.
JPC4-1. The display should read >4 with A86 selected. If not, replac
replace
e
the CM. If the correct values are displayed, replace pot.

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 6-64 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input A87 – Rot PPot
ot [R
[Rota
otate
te Co
Comm
mmand
and PPot
ot (V
(VR3)
R3)]]

Input A87 – Rot Pot

[Rotate Command Pot

(VR3)]
 The voltage the CM reads from the rotate
command pot (VR3) is displayed.
NOTE: Run Learn after you replace, repair, or
adjust the rotate pot. Refer to Learn
Controls
Controls on page 3-33
3-33..

If code 8V is displayed during SelfTest, check

the knob for excessive play. The knob should
not have movement that allows it to go beyond
the values listed while in the neutral position.

Move the rotate pot from full clockwise

clo ckwise through

neutral
OperatortoDisplay.
full counterclockwise, observing the

 The input is good if the value displayed is

 within these limits:

Rotate Position Voltage Displayed

Full Clockwise >0.4

Neutral 2.25 to 2.75V  

Full Counterclockwise <4.4V  

 Voltage fluctuation indicates a bad cable or pot.

If the voltage is outside these limits or does not
change in a smooth, linear fashion, refer to
Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect
1  JL1-9 JL1-13 >4V Perform step 2 T/S wiring
 JPL1/DCV 

Disconnect JPL1
2  JL1-10 JC12-5 0 ohms Perform step 3 T/S wiring
and JPC12/Ohms

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Disconnect JPC12 and JPC4. >4V should be displayed with A87 selected. If not, replace CM. If OK,
connect a jumper (at the CM) between PC12-5 and PC4-2. The display should read <1V with A87
 3 selected. If not, replace the CM. If the correct values are displayed, verify wiring to VR3. If OK, replace
pot.

Publication: 1089040, Re-issued: 15 Jun 2010 6-65

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input A88 – Rot Posn [Rot
[Rotate
ate Posit
Position
ion Feedba
Feedback
ck Pot
Pot (V
(VR6)]
R6)]

Input A88 – Rot Posn

[Rotate Position

Feedback Pot (VR6)]

 The voltage the CM reads from the rotate
position feedback pot (VR6) is displayed.
NOTE: Run Learn after you replace, repair, or
adjust the rotate position feedback pot.
Learn
Refer to Learn Controls
Controls on page 3-33
3-33..

Rotate the load handler from full clockwise to

full counterclockwise, observing the Operator
Display.

 The input is good if the value displayed is

 within these limits:

Rotate Position Voltage Displayed

Full Clockwise <4.5V  

Straight Ahead 2.25 to 2.75V  

Full Counterclockwise >0.5V  

 Voltage fluctuation indicates a bad cable or pot.

If the voltage is outside these limits or does not
change in a smooth, linear fashion, refer to
Diagnosis and Repair.

Diagnosis and Repair

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

1 Disconnect JP4/DCV J4-1 J4-3 >4V Perform step 2 T/S wiring

Disconnect JP4 and

2  J4-2 JC24-15 0 Ohms Perform step 3 T/S wiring
 JPC24/Ohms

Disconnect JPS27 and JPC12. <1V should be displayed with A88 selected. If not, replace CM. If OK,
3 connect a jumper (at the CM) between JC24-15 and JC12-1. The display should read >4 with A88
selected. If not, replace the CM. If the correct values are displayed, replace VR6.

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 6-66 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input A89 – Min
MiniPr
iPres
es [Min
[Mini-M
i-Mast
ast Pre
Pressu
ssure
re Sens
Sensor]
or]

Input A89 – MiniPres

[Mini-Mast Pressure

Sensor]
 Voltage from the mini-mast pressure sensor is
displayed.

 The input is good if the value displayed is

 within these limits:

Load Weight Voltage Displayed

0 lb. (no load) - Load Handler

 Approx. 1.5V 
raised 4 in. (102 mm)

 The voltage displayed should increase and

decrease linearly as the load weight is increased
or decreased. If it does not, refer to Diagnosis
and Repair.

Diagnosis and Repair

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

1  JPT20-4 JPT20-6 Perf

rfo
orm step
tep 2 Replace TM
DCV  10.5 to 13V 
2 JP46-1 Perf
rfo
orm step
tep 3 T/S harne
rness
 JP46-3 Replace Pressure
3  JP46-2 1V at 0 psi. 1V Perform step 4
 Attach pressure  Transducer 
increase per
gauge to G1/DCV 
4 JPT24-19 JPT24-6 1000 psi Replace TM T/S harness

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-67

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inpu
nput A9
A90
0 – TM B+
B+Ke
Keyy

Input A90 – TM B+Key 

 The voltage the TM is reading at JPT14-12
JPT14-12 is
displayed.

 The input is good if the value displayed is

 within these limits:

Nomi
Nomina
nall Bat
Batte
tery
ry Volta
oltage
ge Volta
oltage
ge Disp
Displa
laye
yed
d

48V 44.0 to 52.0V  

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 6-68 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Inpu
nput A91 – CM B+
B+K
Key

Input A91 – CM B+Key 

 The voltage the CM is reading at JPC14-12
JPC14-12 is
displayed.

 The input is good if the value displayed is

 within these limits:

Nomi
Nomina
nall B
Bat
atte
tery
ry Volta
oltage
ge Vol
olta
tage
ge Di
Disp
spla
laye
yed
d

48V 44.0 to 52.0V  

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-69

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt A94 - Trv Cu
Inpu Curr
rr [T
[Travers
raversee Solen
Solenoid
oid (SO
(SOL7)]
L7)]

Input A94
Inp A94 - Trv Curr
Curr
[Traverse Solenoid

(SOL7)]
 The current the traverse solenoid (SOL7) is
drawing, as read by the CM, is displayed in
milliamps.

 The input is good if the value displayed is

 within these limits:

State Current Displayed (mA)

Neutral 0 to 4

 Traverse Requested up to 650

If these results are not observed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

 T/S wiring,
Disconnect
1  JC20-20 JC20-17 Approx. 30 ohms Perform step 2 connections, and
 JPC20/Ohms
solenoid coil

 T/S wiring,
2 SOL7-1 B+ Perform step 3 connections, and
Fuse/Relay Card
DCV   JPC14-1
Ramp from B+ Check SOL7 for  T/S B+K2. If OK,
3 JC20-20 (OFF) to approx. mechanical
replace CM
31V (ON)  binding.

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 6-70 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Inputt A95 - Rot C
Inpu Curr
urr [R
[Rotat
otatee Sole
Solenoid
noid ((SOL8)
SOL8)]]

Input A95 - Rot

Inp Rot Curr
[Rotate Solenoid (SOL8)]
 The current the rotate solenoid (SOL8) is
drawing, as read by the CM, is displayed in
milliamps.

 The input is good if the value displayed is

 within these limits:

State Current Displayed (mA)

Neutral 0 to 4

 Traverse Requested up to 550

If these results are not observed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

 T/S wiring,
Disconnect
1  JC20-16 JC20-13 Approx. 30 ohms Perform step 2 connections, and
 JPC20/Ohms
solenoid coil

 T/S wiring,
2 SOL8-1 B+ Per form step 3 connections, and
Fuse/Relay Card
DCV   JPC14-1
Ramp from B+ Check SOL8 for
 T/S B+K2. If OK,
3 JPC20-16 (OFF) to approx. mechanical
replace CM
32V (ON)  binding.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-71

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt A95 - Rot C
Inpu Curr
urr [R
[Rotate
otate Solen
Solenoid
oid (S
(SOL8)]
OL8)]

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 6-72 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Digital Inputs

Digital Inputs
Section 6. Electrical Tests

 A Diagnosis and Repair table is provided for

for
most inputs. If an input is not within the
specified limits, refer to the Diagnosis and
Repair table.

 Through the process of elimination, these tables

provide a step-by-step approach to diagnose a
problem and provide the necessary corrective
action. See the example below.

Example Diagnosis and Repair Table

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

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

 This column
identifies the also
required
setting on the meter
for this step.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-73

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt I00 – Dman S23 [Car
Inpu [Carriage
riage Deadm
Deadman
an Switc
Switchh (S23)]
(S23)]

Input I00 – Dman S23

[Carriage Deadman

Switch (S23)]
 The status of the Carriage Deadman Switch
(S23), as seen by the CM, is displayed.

 The input is good if these values are displayed:

Pedal Position Value Displayed

Up Off  

Down On

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect
1 S23-1 S23-3 Approx. 12V Per for m step 2 T/S wiring
S23/DCV 

Pedal Up: Approx. 5V   T/S switch,

switch, wiring,
2 DCV JPC22-7 JPC22-11 Replace CM
Pedal Down: <1V  and connections

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 6-74 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I02 – Lift
Lift S11 [[Lif
Liftt Ref
Referen
erence
ce Pr
Prox
ox (S
(S11)
11)]]

Input I02 – Lift S11 [Lift

Reference Prox (S11)]
 The status of the Lift Reference Prox (S11), as
seen by the TM, is displayed.

 The display should indicate

indicate S11 is below (Belw)
(Belw)
 when near the mast crosstie and above (Abve) 
 when the telescopic is raised above the switch.

 Verify
 Verify clearance between the switch and
telescopic is 0.19 ±0.06 in. (4.8 ±1.5 mm).

 The input is good if these values are displayed:

Switch State Value Displayed

Near metal Belw  

 Away from metal Abve

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect
1 PS8-1 PS8-3 Approx. 12V Per form step 2 T/S wiring
 JPS8/DCV 

 Above: Approx. 5V   T/S switch, wiring,

2 DCV JPT22-7 JPF3-11 Replace TM
Below: <1V  and connections

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-75

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt I04 – Bypa
Inpu Bypass
ss S7 [Lift
[Lift/Low
/Lower
er Inh
Inhibit
ibit B
Bypas
ypasss Sw
Switch
itch (S7)]

Input I04 – Bypass S7

S7
[Lift/Lower Inhibit

Bypass Switch (S7)]

 The status of the Lift/Lower Inhibit Bypass
Bypass
Switch (S7), as seen by the CM, is displayed.

 The input is good if these values are displayed:

Switch State Value Displayed

Closed In

Open Out  

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect
Switch depressed:  T/S switch, wiring,
1  JPC12 and  JC12-8 JC4-2 Replace CM
0 ohms and connections
 JPC4/Ohms

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 6-76 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Inpu
Inputt I1
I14
4 – FU
FU1
1 Se
Sens
nsee

Input I14 – FU1 Sense

 The absence or presence of B+ to the load side
of the STR contactor is displayed.

 The input is good if these values are displayed:

STR State Value Displayed

Open <4V*  

Closed B+

* Allow approx. 7 minutes for voltage to drop be

below
low
4V after STR contactor opens.

If these values are not displayed, refer to

Diagnosis and Repair.

Code
open, 4B  - If >4V
check is displayed
for shorts withRemove
to frame. the contactor
the
sense wire from JPT22-19. If the voltage goes
away, locate the cause of the short. If the
 voltage remains >4V with the sense lead
disconnected, replace the TM.

Code 4C - Check FU1 and the STR contactor

tips.

Diagnosis and Repair

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

STR Contactor  T/S wiring,

1  JPT22-19 TP4 B+ Replace TM connections, and
pushed in
contactor 

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-77

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I15 – Hor
Hornn S
S3
3 [H
[Horn
orn Sw
Switc
itchh (S3)
(S3)]]

Input I15 – Horn S3

[Horn Switch (S3)]
 The status of the Horn Switch (S3), as seen by
the CM, is displayed.

 The input is good if these values are displayed:

Switch State Value Displayed

Out Out  

Depressed In

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Switch depressed:
Disconnect 0 ohms  T/S switch, wiring,
1  JC12-10 JC12-12 Replace CM
 JPC12/Ohms Switch not and connections
depressed: open

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 6-78 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I19 – Tr
Trac
ac RP
RPM
M [T
[Trac
ractio
tionn Mot
Motor
or RP
RPM]
M]

Input I19 – Trac RPM

[Traction Motor RPM]
 The output from the Traction Motor Encoder
(TME), as seen by the TPA, is displayed.

 The Display shows rpm as measured by the

 TPA. The RPM reading should show a linear
increase to maximum RPM.

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect
1  JPTA1-26 Perf
Perform
orm step
step 2 Repl
Replac
ace
e TPA 
TPA 
 JPTA4/DCV   JPTA1-7
4.5 to 5.5V 
2 Perform step 3
 JPTA2-1  T/S harness
3 JPTA2-4 Per for m step 4
DCV 
4 JPTA1-31  T/S wiring. If
Stationary: >3.5V or <0.5V 
 JPTA1-7 Replace TPA  OK, replace
5 JPTA1-32 Running: Approx. 2V 
 TME

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-79

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I20 – Lif
Liftt RP
RPM
M [L
[Lift
ift Mot
Motor
or RPM
RPM]]

Input I20 – Lift RPM

RPM [Lift
Motor RPM]
 The output from the Lift Motor Encoder (LME),
as seen by the LPA, is displayed.

 The Display shows rpm as measured by the

LPA. The RPM reading should show a linear
increase to maximum RPM.

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect
1  JPLA1-26 Perfo
Perform
rm s
ste
tep
p 2 Repl
Replac
ace
eLLPA 
PA 
 JPLA2/DCV   JPLA1-7
4.5 to 5.5V 
2 Perform step 3
 JPLA2-1  T/S harness
3 JPLA2-4 Per form step 4
DCV 
4 JPLA1-32 Perfo
Perform
rm step
step 5 T/
T/S
S wi
wire
re
Stationary: >3.5V or <0.5V 
 JPLA1-7 connections. If OK,
5 JPLA1-31 Running: Approx. 2V  Replace LPA   replace LME

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 6-80 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I23 – Can Bus [[CAN
CAN C
Com
ommun
munica
icatio
tion]
n]

Input I23 – Can Bus

[CAN Communication]
 Verification
 Verification that the TM is communicating with
the CM, TPA, LPA, Display Interface Card, and
GM is displayed.

 The information below is for a truck that

displays a code during SelfTest. If the code is
displayed after a successful SelfTest, refer to
“Troubleshooting Communication Error Codes
(5x Series)”
Series)” on
on page
page 5-19
5-19..

 The input is good if these values (letters) are

displayed:
• C - CM is communicating with the TM
• D - Display Interface Card is
communicating with the TM
• L - LPA is communicating with the TM
• T - TPA is communicating with the TM
• W - Guidance Manager is communicating
 with the TM (wire guidance only).
only).

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

L is missing

 T/S B+ from K2
1 DCV JPLA1-1 B– (on amp) B+ Per for m step 2
Relay 

2 JPLA1 and JPT14  JLA1-35 JT14-4 Perform step 3

Repair/replace
disconnected 0 ohms
3 JLA1-23 JT14-11 Replace LPA   harness
/Ohms

T is missing

 T/S B+ from K2
1 DCV JPTA1-1 B– (on amp) B+ Per form step 2
Relay 

2 JPTA1 and  JTA1-35 JT14-4 Perform step 3

 JPT14
https://www.forkliftpdfmanuals.com/ Repair/replace
0 ohms
 disconnected harness
3 /Ohms JTA1-23 JT14-11 Replace TPA  

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Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I23 – Can Bus [[CA
CAN
N Co
Comm
mmuni
unicat
cation
ion]]

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

W is missing

1 DCV JPS6-11 JPS6-24 B+ Perfor m step 2  T/S B+ from K2

Relay 

2 JPS4 and JPT14 PS4-5 JT14-4 Perform step 3

Repair/replace
disconnected 0 ohms
3 PS4-6 JT14-11 Perform step 4 harness
/Ohms

Disconnect JPW1 and JPW2. If the “ W” appears with the cables disconnected, troubleshoot wiring and
antenna coils to determine which sensor/cable is dragging the GM down. If the “W” still does not
4
display, inspect the GM firmware for correct installation. See “Guidance Manager Firmware
Replaceme
Repla cement”
nt” on page 7-56.
7-56.  If correctly installed, replace GM.

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 6-82 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Inputt I24 – Str Home [Hom
Inpu [Homee S
Steer
teer Proxi
Proximity
mity Sens
Sensor]
or]

Input I24 – Str Home

[Home Steer Proximity
Sensor]
 The state of the Home Steer Proximity Sensor,
Sensor,
as seen by the TM, is displayed.

 The input is good if these values are displayed:

 Value
 Value LED
Steer Prox
Displayed (on sensor)

Over metal On On

Not over metal Off Off  

If these values are not displayed, refer to

Diagnosis and Repair.
NOTE: If the input is bad, pass a screwdriver or
metal ruler under the sensor to activate
it. If this produces desired results,
adjust switch gap to 0.19 ±0.06 in.
(4.8
(4.8 ±1.5
±1.5 mm).
mm).

Diagnosis and Repair

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

1  JPA7-3 JPA7-2 Perf

rfo
orm step 3 Perf
rfo
orm step 2
10.5 to 13V  Replace/replace
2 JPT20-9 JPT22-11 harness Replace TM
DCV   Adjust/replace
3 JPA7-1 JPA7-2 Sensor over metal: Perform Step 4
<1V  sensor 
Sensor not over Repair/replace
4 JPT22-3 JPT20-11 metal: Approx. 5V  Replace TM harness

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-83

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I25 – Str EEncd
ncdrr [St
[Steer
eer M
Moto
otorr Enc
Encode
oder]
r]

Input I25 – Str Encdr

[Steer Motor Encoder]
 The Steer Motor feedback Encoder input
(counts) to the TM is displayed.

 A three digit number is displayed, representing

representing
the number of steer motor encoder counts.
 When the count exceeds 255,
255, it starts over at 0.
If the count goes below 0, it starts over at 255.

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

 Action/
Step Meter Scale (+) Lead (–) Lead Expected Results Step Passed Step Failed
1  JPE4-1 10.5 to 13V Perfor m step 2 Perform step 6

2 JPE4-3  JPE4-4 Perform step 3 Replace Steer Motor

Stationary: Encoder 
3 JPE4-2 >4V or <0.5V  Perfor m step 4

4 DCV  JPT22-9  Turning: Perform step 5

 Approx. 2.5V  Repair/replace
5 JPT22-10 Replace TM harness
 JPT10-9
Repair/replace
6 JPT20-7 10.5 to 13V   Replace TM
harness

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 6-84 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I26 – Mai
Mainn Ht Ct [[Mai
Mainn Lif
Liftt Heig
Height
ht En
Encod
coder]
er]

Input I26 – Main Ht Ct

[Main Lift Height
Encoder]
 The Main Lift Height Encoder input to the TM is
displayed.

 A three digit number is displayed, representing

representing
the number of pulses counted. The count
should increase during lower and decrease
during lift. When the count exceeds 255, it
starts over at 0. If the count goes below 0, it
starts over at 255.

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

1  JPE5A-1 JPE5A-4 10.5 to 13V Perform step 2 Repair/replace wiring

 JPE5A-3
2 Perform step 3
(Channel A) Replace Height
 JPE5A-4 Not lifting or
 JPE5A-2 lowering main Encoder 
3 mast: Approx. 5 or Perform step 4
DCV  (Channel B)
<1V 
 JPT22-5 Lifting or lowering
4 Perform step 5
(Channel A) main mast: Approx.
 JPT10-4 2.3V  Repair/replace wiring
5  JPT22-12 Replace TM
(Channel B)

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-85

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I32 – Dma
Dmann S2 [B
[Brak
rakee Dead
Deadman
man S
Swit
witch
ch (S
(S2)]
2)]

Input I32 – Dman S2

[Brake Deadman Switch
(S2)]
 The state of the Brake Deadman Switch (S2), as
seen by the TM (via over-the-mast cable), is
displayed.

 The input is good if these values are displayed:

Pedal Position Value Displayed

Up Up

Down Down

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect S2-1
1 10.1 to 13V Per form step 2 Perform step 4
S2/DCV  at cable S2-3
Disconnect S2-2 at cable
2  Approx. 4.5V Perform step 3 Perform step 5
S2/DCV  at cable

Deadman up: approx. 5V 

3 DCV JPT22-8 JPT14-3 Replace TM Replace S2
Deadman down: <1V 

4 S2-1  JPT14-5 Perform step 5

at cable

Disconnect S2-3 Repair/replace

5  JPT14-3  Approx. 1 ohm Perform step 6
S2/Ohms at cable  wiring

S2-2
6  JPT22-8 Perform step 3
at cable

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 6-86 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Inputt I33 – Str EEnc1On
Inpu nc1On [Stee
[Steering
ring EEncod
ncoder
er Co
Connect
nnect Detec
Detectt 1]

Input I33 – Str Enc1On

[Steering Encoder
Connect Detect 1]
 Verification
 Verification that the E1 channel of the S
Steering
teering
Encoder is connected is displayed.

 The input is good if these values are displayed:

Steering Encoder Value Displayed

Connected Yes

Not Connected No

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Check wiring. If
 JPE1 connected: Approx. 10V 
1 DCV JPC10-7 JPC18-5 Replace CM OK, replace
 JPE1 disconnected: Approx. 12V 
steering encoder 

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-87

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt I34 – Str EEnc2On
Inpu nc2On [Stee
[Steering
ring EEncod
ncoder
er Co
Connect
nnect Detec
Detectt 2]

Input I34 – Str Enc2On

[Steering Encoder
Connect Detect 2]
 Verification
 Verification that the E2 channel of the Steering
Encoder is connected is displayed.

 The input is good if these values are displayed:

Steering Encoder Value Displayed

Connected Yes

Not Connected No

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Check wiring. If
 JPE2 connected: approx. 10V 
1 DCV JPC10-6 JPC18-6 Replace CM OK, replace
 JPE2 disconnected: approx. 12V 
steering encoder 

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 6-88 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I35 – Str EEnc1
nc1 [S
[Stee
teerin
ring
g Enco
Encoder
der Ch
Chann
annel
el E1]

Input I35 – Str Enc1

[Steering Encoder
Channel E1]
 The input from the Steering Encoder Channel
Channel
E1 to the CM is displayed.

 The TM uses the input from the CM to

determine the rate and direction of steering
request. The number displayed varies between
0 and 255. The displayed value should change
as the steer tiller rotates.

If the number displayed does not vary or only

changes from 0 to 1 or 0 to 255, refer to
Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect JPE1
and JPE2. If voltage
goes to 12V, check
1  JPC10-7  Approx. 9V Perform step 2
 wiring. If OK,
replace steering
encoder 
DCV   JPC18-5
Check wiring. If OK,
 JPC22-12
2  Tiller stationary: Perform step 3 replace steering
(Ch B)
approx. 0 or 4.75V  encoder 

 Tiller moving: Check wiring. If OK,

 JPC22-5 approx. 2.5V 
3 Replace CM replace steering
(Ch A)
encoder 

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-89

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt I36 – Str Enc2 [Ste
Inpu [Steering
ering Enco
Encoder
der Chan
Channel
nel E2]

Input I36 – Str Enc2

[Steering Encoder
Channel E2]
 The input from the Steering Encoder Channel
Channel
E2 to the CM is displayed.

 The TM uses the input from the CM to

determine the rate and direction of steering
request. The number displayed varies between
0 and 255. The displayed value should change
as the steer tiller rotates.

If the number displayed does not vary or only

changes from 0 to 1 or 0 to 255, refer to
Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect JPE1
and JPE2. If voltage
goes to 12V, check
1  JPC10-6  Approx. 9V Perform step 2
 wiring. If OK,
replace steering
encoder 
DCV   JPC18-6
Check wiring. If
 JPC22-14
2  Tiller stationary: Perform step 3 OK, replace
(Ch B)
approx. 0 or 4.75V  steering encoder 

 Tiller moving: Check wiring. If

 JPC22-13 approx. 2.5V 
3 Replace CM OK, replace
(Ch A)
steering encoder.

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 6-90 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I39 – Neu
Neutt Pu
Pulse
lse [Ne
[Neutr
utral
al PPuls
ulses]
es]

Input I39 – Neut Pulse

[Neutral Pulses]
 The neutral pulses seen by the TM from the
Steer Amplifier (SA) are displayed.

Run Test O44 – Steer Mtr [Steer Motor]

Run Test
(page
(page 6-1
6-140)
40) to
 to check the power portion of the
steering system.

 The input is good if these values are displayed:

Deadman Value Displayed

Off Steady ON or OFF  

ON Quickly to
toggles be
between O
ON
N an
and O
OF
FF  

NOTE: ON/OFF continues to toggle after

deadman is released until STR contactor
opens.

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

1  JPT6-6 10.5 to 13V Perform step 2 Replace TM

DCV   JPT6-4 Deadman pedal down: Repair wiring/
2 JPT6-1 approx. 2.5V  Replace TM replace SA 

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-91

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I45 – Slk C
Chh S50 [[Sla
Slack
ck Ch
Chain
ain 1 Sw
Switc
itchh (S5
(S50)]
0)]

Input I45 – Slk Ch

Ch S50
[Slack Chain 1 Switch
(S50)]
 The state of the Slack Chain Switch 1 (S50
located on seated operator left side), as seen by
the TM, is displayed.

 The input is good if these values are displayed:

Switch Value Displayed

 Activated In

Deactivated Out  

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

Check lift chain tension. Make sure the switch
is activated and both main cylinder lift chains
are at the same tension. Inspect the
compression spring washers. Refer to “Main Lift
Chains
Chain s (9600)”
(9600)” on page 7-92
7-92 or
 or “Main Lift
Chains
Chain s (9700)”
(9700)” on page
page 7-94
7-94.. Also, the main lift
cylinders may require bleeding. See “Bleeding
the Hydraulic
Hydraulic System”
System” on page 7-74.

 Action/
Step (+) Lead (–) Lead Expected Results Step Passed Step Failed
Meter Scale
1  JT22-1 JF3-10 0 Ohms Perform step 2 Repair/replace wiring/sw
wiring/switch
itch
Disconnect
 JPT22 and Check wiring and Fuse/Relay
2  JPF3/Ohms PT22-1 PF3-10 Approx. 5V Replace TM Card. Make sure JPF3-10 is at
B– 

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 6-92 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I46 – Slk C
Chh S51 [[Sla
Slack
ck Ch
Chain
ain 2 Sw
Switc
itchh (S5
(S51)]
1)]

Input I46 – Slk Ch S51

[Slack Chain 2 Switch
(S51)]
 The state of the Slack Chain Switch
Switch 2 (S51
located on seated operator right side), as seen
 by the TM, is displayed.

 The input is good if these values are displayed:

Switch Value Displayed

 Activated In

Deactivated Out  

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

Check lift chain tension. Make sure the switch
is activated and both main cylinder lift chains
are at the same tension. Inspect the
compression spring washers. Refer to “Main Lift
Chains
Chain s (9600)”
(9600)” on page 7-92
7-92 or
 or “Main Lift
Chains
Chain s (9700)” on
on page 7-94
7-94.. Also, the main lift
cylinders may require bleeding. See “Bleeding
the Hydraulic
Hydraulic System”
System” on page 7-74
7-74..

 Action/
Step (+) L
Le
ead (–) Le
Lead Expected Results Step Passed Step Failed
Meter Scale
Disconnect JPT22 Repair/replace
1  JT22-2 JT4-2 0 Ohms Replace TM
and JPT4/Ohms  wiring/switch

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-93

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I65 – Rai
Raill Sens
Sensee [Rai
[Raill Guid
Guidanc
ancee Swit
Switch
ch (S
(S15)
15)]]

Input I65 – Rail Sense

[Rail Guidance Switch
(S15)]
 The state of the optional Rail Guidance Switch
(S15), as seen by the TM, is displayed.

 The input is good if these values are displayed:

Switch Value Displayed

Depressed In

Released Out  

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect JPT22 Switch depressed: 0 Ohms Repair/replace

1  JT22-4 JT24-5 Replace TM
and JPT24/Ohms Switch released: Open  wiring/switch

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 6-94 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I66 – Aut
Auto/M
o/Man
an [Au
[Auto/
to/Man
Manual
ual Sw
Switc
itchh (S4)]

Input I66 – Auto/Man

[Auto/Manual Switch
(S4)]
 The state of the optional Auto/Manual Switch
(S4), as seen by the CM, is displayed.

 The input is good if these values are displayed:

Switch Value Displayed

O (open) Auto

|(closed) Manu

If these values are not displayed, refer to

Diagnosis and Repair.
NOTE: If the wire between the AUTO/MANUAL
switch and the CM is disconnected, the
system defaults to AUTO.

Diagnosis and Repair

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

Disconnect  Auto: open circuit   T/S wiring and

1  JC12-11 JC12-12 Replace CM
 JPC12/Ohms Manual: 0 ohms switch

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-95

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt I67 – SG Rt S60 [Righ
Inpu [Rightt Sidegat
Sidegatee S
Switch
witch (S60)
(S60)]]

Input I67 – SG Rt S60

[Right Sidegate Switch
(S60)]
 The state of the optional Sidegate Right Switch
Switch
(S60), as seen by the CM, is displayed.

 The input is good if these values are displayed:

Sidegate Value Displayed

Up Up

Down Down

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect
1 S60-1 S60-3 Approx. 12V Per form step 2 T/S wiring
S60/DCV 

Sidegate up: 5V  T/S switch, wiring,

2 DCV JPC22-4 JPC18-7 Replace CM
Sidegate down: <1V  and connections

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 6-96 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Raymond EOA Sensor Location

Raymond EOA Sensor

Location
Figuree 6-1.
Figur 6-1.
9600_steer2.svg
Location
Location of Raymo
Raymond
nd End-of-Ai
End-of-Aisle
sle Sens
Sensors
ors and Relat
Related
ed Inputs
Inputs

S46A S46B S47A S47B

End-of-Aisle Sensor 1 End-of-Aisle Sensor 2

(Inpu
Inputt I7
I72
2 – EO
EOA1
A1,, Right
Right In
Inpu
putt I7
I73
3 – EO
EOA2
A2,, Left
Left
[End-of-Aisle Sensor 1 [End-of-Aisle Sensor 2
(Rightt Side)] (page
(Righ (page 6-98
6-98)) (Left Side)]
Side)] (page
(page 6-99
6-99))

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-97

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inputt I72 – EOA1, Right [End
Inpu [End-of-Ai
-of-Aisle
sle Sensor
Sensor 1 (Right Side)
Side)]]

Input I72 – EOA1, Right

[End-of-Aisle Sensor 1
(Right Side)]
 The input from the optional End-of-Aisle
End-of-Aisle
Sensor 1 (S46A and
and B), as seen by
by the TM is
displayed (ref
(refer
er to Figur
Figure
e 6-1 on
on page
page 6-9
6-97)
7)..
NOTE:  This input is displayed when Raymond
EOA is selected in FlashWare.

 While observing the display, drive the truck so

the sensor passes over a floor magnet. The
display should change from “OFF” to “ON”,

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect
1 PT10-6 PT24-8 Approx. 12V Perform step 2 Replace TM
 JPT10/DCV 

 T/S harness for

 JPT10-6  JPT24-8 opens and shorts. If
2 DCV    Approx. 8V Perform step 3
(Backprobe) (Backprobe) OK, replace sensor
S46A or S46B

Disconnect
3  JPT12 and PT12-10 PT24-8 Approx. 5V Perform step 4 Replace TM
 JPT24/DCV 

S46A or S46B
 T/S harness for
Closed (sees magnet):
 JPT12-10  JPT24-8 opens or shorts. If
4 DCV  <1V  Replace TM
(Backprobe) (Backprobe) OK, replace bad
Open (no magnet):
sensor 
 Approx. 5V 

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 6-98 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Inputt I73 – EOA2
Inpu EOA2,, Lef
Leftt [E
[End-of
nd-of-Aisl
-Aislee Se
Sensor
nsor 2 (L
(Left
eft S
Side)]
ide)]

Input I73 – EOA2, Left

[End-of-Aisle Sensor 2
(Left Side)]
 The input from the optional End-of-Aisle
End-of-Aisle
Sensor 2 (S47A and
and B), as seen by
by the TM is
displayed (re
(refer
fer to
to Figure
Figure 6-1 on
on page
page 6-9
6-97)
7)..
NOTE:  This input is displayed when Raymond
EOA is selected
selec ted in FlashWare.

 While observing the display, drive the truck so

the sensor passes over a floor magnet. The
display should change from “OFF” to “ON”,

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect
1 PT10-7 PT24-9 Approx. 12V Per for m step 2 Replace TM
 JPT10/DCV 

 T/S harness for opens

 JPT10-7  JPT24-9 and shorts. If OK,
2 DCV    Approx. 8V Perform step 3
(Backprobe) (Backprobe) replace sensor S47A or
S47B

Disconnect
3  JPT10 and PT24-17 PT24-9 Approx. 5V Perfor m step 4 Replace TM
 JPT24/DCV 

S47A or S47B
Closed (sees  T/S harness for opens
 JPT24-17  JPT24-9
4 DCV  magnet): <1V  Replace TM or shorts. If OK,
(Backprobe) (Backprobe)
Open (no magnet): replace bad sensor 
 Approx. 5V 

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-99

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I83 – SG Lt S6
S61
1 [Lef
[Leftt Side
Sidegat
gatee Swit
Switch
ch (S
(S61)
61)]]

Input I83 – SG Lt S61

[Left Sidegate Switch
(S61)]
 The state of the optional Sidegate Left Switch
(S61), as seen by the CM, is displayed.

 The input is good if these values are displayed:

Sidegate Value Displayed

Up Up

Down Down

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect
1 S61-1 S61-3 Approx. 12V Perform step 2 T/S wiring
S61/DCV 

Sidegate up: 5V  T/S switch, wiring,

2 DCV JPC22-6 JPC24-10 Replace CM
Sidegate down: <1V  and connections

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 6-100 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Inputt I87 – BG LLtt S
Inpu S57
57 [[Left
Left Batt
Battery
ery Gat
Gatee Sw
Switch
itch (S57)
(S57)]]

Input I87 – BG Lt S57

[Left Battery Gate Switch
(S57)]
 The state of the optional Left Battery Gate
Gate
Switch (S57), as seen by the TM, is displayed.

 The input is good if these values are displayed:

Battery Gate Value Displayed

Removed Out  

Installed In

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

Check for correct switch clearance. The sensor
should extend 0.23 in. (5.8 mm) beyond the
switch mounting plate.

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

Disconnect
1 PBSEN1-2 PBSEN1-3 Approx. 12V Perform step 2 T/S wiring
 JPBSEN1/DCV 

Gate removed: 5V  T/S switch, wiring,

2 DCV JPT22-6 JPT18-5 Replace TM
Gate installed: <1V  and connections

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-101

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input I88 – BG Rt S58 [Righ
[Rightt Ba
Battery
ttery G
Gate
ate Switc
Switchh (S58)]
(S58)]

Input I88 – BG Rt S58

[Right Battery Gate
Switch (S58)]
 The state of the optional Right Battery Gate
Gate
Switch (S58), as seen by the TM, is displayed.

 The input is good if these values are displayed:

Battery Gate Value Displayed

Removed Out  

Installed In

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

Check for correct switch clearance. The sensor
should extend 0.23 in. (5.8 mm) beyond the
switch mounting plate.

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

Disconnect
1 PBSEN2-2 PBSEN2-3 Approx. 12V Perfor m step 2 T/S wiring
 JPBSEN2/DCV 

Gate removed: 5V  T/S switch,

switch, wiring,
2 DCV JPT24-20 JPT18-5 Replace TM
Gate installed: <1V  and connections

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 6-102 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I10
I100
0 – EOA
EOA1
1 On [En
[End-o
d-of-A
f-Aisl
islee Con
Connec
nectt Dete
Detect
ct 1 (Rig
(Right
ht Sid
Side)]
e)]

Input I100 – EOA1 On

[End-of-Aisle Connect
Detect
Detect 1 (Rig
(Right
ht Side)]
Side)]
 Verification
 Verification that the Sensor 1 End-of
End-of-Aisle
-Aisle
switches (S46A and B) are connected is
displayed.
NOTE: S46A and B are located on the right side
of the Antenna Card bracket as you
stand on the platform facing the tractor.

 The input is good if these values are displayed:

Sensor 1 Switches Value Displayed

Connected Yes

Not Connected No

If these values are not displayed, refer to

Inp
Input
ut I72 – EOA
EOA1,
1, Right
Right [End-o
[End-of-A
f-Aisle
isle Sens
Sensor
or 1
(Right Side)] (page 6-98
6-98)) Diagnosis and Repair.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-103

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I10
I101
1 – EOA
EOA2
2 On [En
[End-o
d-of-A
f-Aisl
islee Con
Connec
nectt Det
Detect
ect 2 (L
(Left
eft Sid
Side)]
e)]

Input I101 – EOA2 On

[End-of-Aisle Connect
Detect
Detect 2 (Left
(Left Side)]
Side)]
 Verification
 Verification that the Sensor 2 End-of-
End-of-Aisle
Aisle
switches (S47A and B) are connected is
displayed.
NOTE: S47A and B are located on the left side
of the Antenna Card bracket as you
stand on the platform facing the tractor.

 The input is good if these values are displayed:

Sensor 2 Switches Value Displayed

Connected Yes

Not Connected No

If these values are not displayed, refer to

Inp
Input
ut I73 – EOA
EOA2,
2, Left
Left [End-
[End-of-
of-Aisl
Aisle
e Sensor
Sensor 2
(Left Side)]
Side)] (page
(page 6-99
6-99)) Diagnosis and Repair.
Repair.

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 6-104 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I10
I102
2 – LdD
LdDm
m S9 [L
[Load
oad H
Hand
andler
ler De
Deadm
adman
an (S
(S9)]
9)]

Input I102 – LdDm S9

[Load Handler Deadman
(S9)]
 The state of the Load Handler
Handler Deadman Switch
(S9), as seen by the CM, is displayed.

 The input is good if these values are displayed:

Switch Value Displayed

Open Off  

Closed On

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Disconnect
1 S9-1 S9-3 Approx. 12V Perfor m step 2 T/S wiring
S9/DCV 

Pedal up: 5V   T/S switch, wiring,

2 DCV JPC22-2 JPC10-9 Replace CM
Pedal down: <1V  and connections

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-105

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I10
I103
3 – Lef
LeftHn
tHndDM
dDM [[Lef
Leftt Hand
Hand Dead
Deadman
man ((S26
S26)]
)]

Input I103 – LeftHndDM

[Left Hand Deadman
(S26)]
 The state of the optional Left Hand Deadman
Switch (S26), as seen by the CM, is displayed.

 The input is good if these values are displayed:

Switch Value Displayed

Open Off  

Closed On

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Switch open: 5V   T/S switch, wiring

1 DCV JPC12-6 JPC4-2 Replace CM
Switch closed: <1V  and connections

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 6-106 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I10
I104
4 – Rea
ReachP
chProx
rox [Re
[Reach
ach Pro
Proxim
ximity
ity Sen
Senso
sor]
r]

Input I104 – ReachProx

[Reach Proximity
Sensor]
 The state of the Reach Proximity Sensor,
Sensor, as
seen by the CM, is displayed.

 The input is good if these values are displayed:

Reach P
Prrox Value Di
Displayed LED
(on sensor)

Over metal On On

 Away from
Off Off  
metal

If these values are not displayed, refer to

Diagnosis and Repair.
NOTE: If the input is bad, pass a screwdriver or
metal ruler under the sensor to activate
it. If this produces desired results,
adjust the switch gap to 0.09 ±0.03 in.
(2.3 ±0.7 mm).

Diagnosis and Repair

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

 T/S wiring. If OK, run

Disconnect  Test O63 – MiniPwrSu
1  JPC12-7 8.5 to 11V Per form step 2
 JP3/DCV  p [Mini Power Supply]
(page
(page 6-1
6-154)
54)
 JPC10-4
Sensor over metal:
Disconnect all approx. <1V   T/S wiring. If OK,
2  JPC22-1 Replace CM
 wires/DCV  Sensor not over replace sensor 
metal: approx. 5V 

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-107

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I10
I105
5 – Min
Minii Ht Ct [Mi
[Mini-
ni-Mas
Mastt Heig
Height
ht Co
Count
unt]]

Input I105 – Mini Ht Ct

[Mini-Mast Height Count]
 The mini-mast height count, calculated by the
 TM, is displayed. The displayed height
height should
increase during lift and decrease during lower.

 The mini-mast height count is determined by

the height proximity sensor inputs. When the
mini-mast is fully lowered, Height Prox A
(“In
“Input
put I10
I1066 – Min
Minii Sw A [Mini-
[Mini-Mas
Mastt Height
Height
Prox
Pr ox A]
A]””), Height Prox B (“I
(“Inp
nput
ut I1
I107
07 – Mi
Mini
ni Sw
B [Mini-Mast
[Mini-Mast Height
Height Prox
Prox B]”
B]”),
), and Height Prox
C (“In
(“Input
put I10I108
8 – Min
Minii Sw C [Mi
[Mini-
ni-Mas
Mastt Heigh
Heightt
Prox
Pr ox C]
C]””) are all ON. While lifting or lowering, if
all three inputs are present at the same time, a
fault code occurs. Also, if one of thet he inputs does
not change state while lifting or lowering, a fault
code occurs.

Navigate to the input menu and scroll until I06,

I07, and I08 are all displayed. Observe the
status of each input while lifting or lowering.

If one of the inputs remains ON, it may indicate

a shorted mast cable or wiring. If one of the
three inputs does not change from ON to OFF
 while lifting/lowering, refer to the input
input for the
switch that is not changing state.

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 6-108 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I10
I106
6 – Min
Minii S
Sw
w A [Mi
[Mini-
ni-Mas
Mastt H
Heig
eight
ht Pro
Proxx A]

Input I106 – Mini Sw A

[Mini-Mast Height
Prox A]
 The state of the Prox A channel of the
the
mini-mast height proximity sensor, as seen by
the CM, is displayed.

 The input is good if these values are displayed:

Reach Prox Value Displayed

Over metal On

Not over metal Of f  

 The value displayed should change as the

mini-mast is raised and lowered. If these results
are not observed, refer to Diagnosis and Repair.

Diagnosis and Repair

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

Run
 Test O63 – MiniPwrSup
1  JP5-3 Perform step 2
DCV   JPC10-4 Approx. 5V  [Mini Power Supply]
(page
(page 6-1
6-154)
54)

2 JP2-1 Perform step 3

 JP2 and
 JPC22  T/S wiring
3  JC22-9 P2-2 0 Ohms Perform step 4
disconnected/
Ohms

Near metal: 0.6V 

Replace mini-mast
4 DCV JPC22-9 JPC10-4 Not near metal: Replace CM
Height Prox Sensor 
approx. 3.2V 

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-109

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I10
I107
7 – Min
Minii S
Sw
w B [Mi
[Mini-
ni-Mas
Mastt H
Heigh
eightt Prox
Prox B]

Input I107 – Mini Sw B

[Mini-Mast Height
Prox B]
 The state of the Prox B channel of the
mini-mast height proximity sensor, as seen by
the CM, is displayed.

 The input is good if these values are displayed:

Reach Prox Value Displayed

Over metal On

 Away from metal Off 

 The value displayed should change as the

mini-mast is raised and lowered. If these results
are not observed, refer to Diagnosis and Repair.

Diagnosis and Repair

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

Run
 Test O63 – MiniPwrSup
MiniPwrSup  
1  JP5-3 Perform step 2
DCV   JPC10-4 Approx. 5V  [Mini Power Supply]
(page
(page 6-1
6-154)
54)

2 JP2-1 Per form step 3

 JP2 and
 JPC22  T/S wiring
3  JC22-10 P2-3 0 Ohms Perform step 4
disconnected
/Ohms

Near metal: 0.6V 

Replace mini-mast
4 DCV JPC22-10 JPC10-4 Not near metal: Replace CM
Height Prox Sensor 
approx. 3.2V 

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 6-110 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I10
I108
8 – Min
Minii S
Sw
w C [Mi
[Mini-
ni-Mas
Mastt H
Heig
eight
ht Prox
Prox C]

Input I108 – Mini Sw C

[Mini-Mast Height
Prox C]
 The state of the Prox C channel
channel of the
mini-mast height proximity sensor, as seen by
the CM, is displayed.

 The input is good if these values are displayed:

Reach Prox Value Displayed

Over metal On

 Away from metal Off 

 The value displayed should change as the

mini-mast is raised and lowered. If these results
are not observed, refer to Diagnosis and Repair.

Diagnosis and Repair

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

Run
 Test O63 – MiniPwrSup
MiniPwrSup  
1  JP5-3 Perform step 2
DCV   JPC10-4 Approx. 5V  [Mini Power Supply]
(page
(page 6-1
6-154)
54)

2 JP2-1 Perform step 3

 JP2 and
 JPC22  T/S wiring
3  JC24-20 P2-4 0 Ohms Perform step 4
disconnected
/Ohms

Near metal: 0.6V 

Replace mini-mast
4 DCV JPC24-20 JPC10-4 Not near metal: Replace CM
Height Prox Sensor 
approx. 3.2V 

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-111

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I109
I109 – Lft
LftSel
Sel S6 [[Lif
Liftt Se
Selec
lectt (S
(S6)]
6)]

Input I109 – LftSel S6

[Lift Select (S6)]
 The state of the Lift Select Switch (S6), as seen
 by the CM, is displayed.

 The input is good if these values are displayed:

Switch Position Value Displayed

Out Off  

Depressed On

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

 JPC12 and JPC4 Depressed: 0 ohms  T/S switch, wiring,

1  JC12-4 JC4-2 Replace CM
disconnected/Ohms Not depressed: open and connections

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 6-112 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I11
I110
0 – Att
Attach
ach S5
S5 [At
[Attac
tachme
hment
nt (S
(S5)]
5)]

Input I110 – Attach S5

[Attachment (S5)]
 The state of the optional Attachment Switch
(S5), as seen by the CM, is displayed.

 The input is good if these values are displayed:

Switch Position Value Displayed

Out Off  

Depressed On

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

Depressed: 0 ohms  T/S switch, wiring,

1 JPC12/Ohms JC12-9 JPC12-12 Replace CM
Not depressed: open and connections

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-113

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Inpu
Inputt I111
I111 – In Aisl
Aislee

Input I111 – In Aisle

 This test displays the End-of-Aisle status in the

truck’s memory.
 The display shows either IN  or OUT .

If these values are not displayed, refer to

Input
Input I72 – EOA
EOA1,
1, Right
Right [End-o
[End-of-A
f-Aisl
isle
e Sensor
Sensor 1
(Rightt Side)]
(Righ Side)] (page 6-98
6-98)) or In
Inpu
putt I1
I117
17 – EO
EOA
A1
Inner [Alternate
[Alternate Sensor
Sensor 2] (page 6-12
6-121)
1) and
 and
Input
Inp ut I73 – EOA
EOA2,
2, Left
Left [End-
[End-of-
of-Aisl
Aislee Sensor
Sensor 2
(Left Side)] (page 6-99
6-99)) or In
Inpu
putt I1
I118
18 – EO
EOA2
A2
Outer [Alternate
[Alternate Sensor
Sensor 1] (page 6-122
6-122)).

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 6-114 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I11
I112
2 – FU4 sen
sense
se [FU
[FU4
4 Sen
Sense]
se]

Input I112 – FU4 sense

[FU4 Sense]
 The absence or presence of B+ to the load side
of the Load Handler Contactor (LHC) is
displayed.
NOTE: Manually activate the contactor to see
the transition.

 The input is good if these values are displayed:

STR State Value Displayed

Open Out  

Closed In

If these values are not displayed, refer to

Diagnosis and Repair.

Code 49 - If >4V is displayed with the contactor

contacto r
open, check for shorts to frame. Remove the
sense wire from JPT22-20. If the voltage goes
away, locate the cause of the short. If the
 voltage remains >4V with the sense lead
disconnected, replace the TM.

Code 4A - Check FU4 and the LHC contactor

tips.

Diagnosis and Repair

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

LPC and LHC  T/S wiring,

1 Contactor  JPT22-20 TP4 B+ Replace TM connections, and
pushed in contactor 

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-115

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I11
I113
3 – Cu
Custo
stomIn
mIn1
1 [Cu
[Custo
stom
m Inp
Input
ut 1 (CM
(CM)]
)]

Input I113 – CustomIn1

[Custom Input 1 (CM)]
 This option must be enabled in FlashWare.
FlashWare. It is
designed to support “Custom” inputs. This
input displays the status of the associated
circuit to the CM.
NOTE: Refer to the attached device
manufacturer’s documentation for
specific troubleshooting information
regarding that device.

Refer to Table
to Table 3-2, “Configure Mode Menu,”
Menu,” on
page
page 3-
3-27
27..

 The input is good if these values are displayed:

 JPC10-8 to JPC24-8
JPC24-8 Val
Value
ue Displayed
0 ohms On

Open OUT  

If these results are not observed, refer to

Diagnosis and Repair.

Diagnosis and Repair

Carefully complete the circuit between JPC10-8
and JPC24-8. If “ON” is displayed, troubleshoot
the attached device and associated wiring. If
“ON” is not  displayed,
 displayed, replace the CM.

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 6-116 Publication: 1089040, Re-issued: 15 Jun 2010

Model 9600/9700 Swing-Reach ® Ma

 Maintenance Manual Section 6. Electrical Tests
Input
Input I11
I114
4 – Cus
Custom
tomIn2
In2 [C
[Cus
ustom
tom IInpu
nputt 2 (CM)]

Input I114 – CustomIn2

[Custom Input 2 (CM)]
 This option must be enabled in FlashWare.
FlashWare. It is
designed to support “Custom” inputs. This
input displays the status of the associated
circuit to the CM.
NOTE: Refer to the attached device
manufacturer’s documentation for
specific troubleshooting information
regarding that device.

Refer to Table
to Table 3-2, “Configure Mode Menu,” on
page
page 3-
3-27
27..

 The input is good if these values are displayed:

 JPC10-2 to JPC24-9 Va
Value
lue Displaye
Displayed
d
0 ohms ON

Open OUT  

If these results are not observed, refer to

Diagnosis and Repair.

Diagnosis and Repair

Carefully complete the circuit between JPC10-2
and JPC24-9. If “ON” is displayed, troubleshoot
the attached device and associated wiring. If
“ON” is not  displayed,
 displayed, replace the CM.

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 Publication: 1089040, Re-issued: 15 Jun 2010 6-117

Section 6. Electrical Tests Model 9600/9700 Swing-Reach ® Maintenance Manual

Input
Input I11
I115
5 – Cus
Custom
tomIn3
In3 [[Cus
Custom
tom IInpu
nputt 3 (TM)]

Input I115 – CustomIn3

[Custom Input 3 (TM)]
 This option must be enabled in FlashWare.
FlashWare. It is
designed to support “Custom” inputs. This
input displays the status of the associated
circuit to the TM.
NOTE: Refer to the attached device
manufacturer’s documentation for
specific troubleshooting information
regarding that device.

Refer to Table
to Table 3-2, “Configure Mode Menu,”
Menu,” on
page
page 3-
3-27
27..

 The input is good if these values are displayed:

 JPT10-8 to JPT24-3
JPT24-3 Va
Value
lue Displayed
Displayed
0 ohms ON

Open OUT  

If these results are not observed, refer to

Diagnosis and Repair.

Diagnosis and Repair

Carefully complete the circuit between JPT10-8
and JPT24-3. If “ON” is displayed, troubleshoot
the attached device and associated wiring. If
“ON” is not  displayed,
 displayed, replace the TM.

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