Maintenance Manual

High-Level Orderpicker Lift Truck

Models Serial Numbers

5400 00100 & Up
5500, 5600 00100 to 44000

Publication: 1031794/001E Revised: 04 Dec 2019

This publication, 1031794/001E, applies to High-Level Orderpicker Models 5400, 5500, and 5600,
S/N 00100 to 44000, and to all subsequent releases of this product until otherwise indicated in new
editions or bulletins. Changes occur periodically to the information in this publication.

If you need assistance with your lift truck, or to order additional copies of this manual, contact your local
authorized Raymond Sales and Service Center.

To locate your local authorized Raymond Sales and Service Center, go to www.raymondcorp.com.

©2019 The Raymond Corporation.

The following terms are trademarks of The Raymond Corporation: The ACR System, intellidrive,
intellispeed, iPort, iBattery, and Raymond. All other brand and product names are trademarks or registered
trademarks of their respective companies.
Models 5400/5500/5600 Maintenance Manual Table of Contents

Table of Contents
Document Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-v
Service Information List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-vi
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Interactive Electronic Technical Manuals . . . . . . . . . . . . . . . . . . . . . . 1-3
Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Emergency Lower Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Tie-Down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
FlashWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Wire Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
UL Label “EE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Minder ™ Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial 90 Day/250 Deadman Hours (HD) Maintenance . . . . . . . . . . . 4-5
Every 180 Days or 500 Deadman Hours (HD) . . . . . . . . . . . . . . . . . . 4-6
Every 360 Days or 2000 Deadman Hours (HD) . . . . . . . . . . . . . . . . 4-10
Chain Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Contactor Tip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drive Unit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Communication Error Code (50 Series) Troubleshooting . . . . . . . . . 5-25
Troubleshooting Aisle Exit Error Code J2 . . . . . . . . . . . . . . . . . . . . . 5-27
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . 5-29
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . 5-33
Messages, Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Power Amp LED Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Summary List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Analog Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

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Table of Contents Models 5400/5500/5600 Maintenance Manual

Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77

Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-127
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Special Tools and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Decals and Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Steering and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Steer Motor/Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Home Proximity Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Control Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Deadman Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Drive Unit - Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Drive Unit - Heavy Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
Battery Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
AC Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Power Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Carriage Control Card Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
EPROM/Microprocessor Removal/Replacement . . . . . . . . . . . . . . . . 7-84
Wiring and Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
Flow Sensor Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-96
High Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . 7-99
Lift/Lower and Load Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . 7-100
Bleeding Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101
Lift Pump and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102
Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-103
Side Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104
Center Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-108
Mast Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-111
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112
Mast Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115
Upper Mast Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 7-117
Lift Chains, Three-Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122
Center Cylinder Ride Spring Chain Anchors . . . . . . . . . . . . . . . . . . 7-124
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
Pallet Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-126
Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127
Skid Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-128
Lift Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-129
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

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Models 5400/5500/5600 Maintenance Manual Table of Contents

Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Wire Guidance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Pin-Out Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Component Specific Service/Torque Chart . . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Torque Chart - Straight Thread Face Seal O-Rings . . . . . . . . . . . . . . . A-7
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Torque Chart - Metric (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Torque Chart - Thread-Forming Screws . . . . . . . . . . . . . . . . . . . . . . A-12
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

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Table of Contents Models 5400/5500/5600 Maintenance Manual

iv Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual

Document Revision History

Document Revision History

Revision Date Description of Changes

1013794A 27 Jan 2006 Initial Release

1013794B 14 July 2006 General Update

1013794C 13 July 2015 Update Format. Incorporated all outstanding RSIs, RPINs, and RSBs

1031794D 10 Jan 2018 Updates to the Error Codes, Tests, and Theory of Operation.

1031794/001E DRAFT Incorporated outstanding RSIs. Final manual update.

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 Models 5400/5500/5600 Maintenance Manual

Service Information List

Service Information List

The following Raymond Service Information (RSI) documents have been incorporated into this
manual (use the blank rows below to log Service Information documents when they are added to
this manual).

Revision
Document Number Subject
Incorporated

RPIN OPR-06-R004 Adjustment procedure rail guidance A.S.C.

RPIN OPR-06-R005 Incandescent Light Wiring Changes

RPIN OPR-06-R007 Error codes 5M & 5P

RPIN OPR-06-R008 Terminal stud movement

RPIN OPR-06-R009 Schematic Revision

RPIN OPR-06-R011 Addition to scheduled maintenance

RPIN GEN-06-R004 Servicing of Power Cables Used on AC Motors

RPIN OPR-07-R002 Center lift cylinder end-cap design change

RPIN OPR-07-R003 Steer motor on gear box replacement

RPIN OPR-07-R006 Wire guidance

Revision C
RPIN OPR-07-R008 Input test correction

RPIN OPR-08-R001 New error codes

RPIN OPR-08-R002 Enabling active maintenance tests

RPIN GEN-08-R003 New Cylinder End Cap Wrenches

RPIN GEN-08-R004 Terminal Torque on Curtis Power Amplifier (P/N 1042226/XXX)

RPIN OPR-08-R005 Steer motor test, O44

RPIN OPR-08-R008 Steer motor gear orientation

RPIN GEN-09-R002 Intermittent issues on truck with optional alarms

RPIN OPR-09-R004 Error Code AH

RPIN OPR-10-R002 Scheduled Maintenance Task Update

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Models 5400/5500/5600 Maintenance Manual

Service Information List

Revision
Document Number Subject
Incorporated

RPIN GEN-10-R004 Recommended Chain Lubrication

RSB OPR-06-006 Drive Unit Leaking

RSB OPR-06-007 This bulletin supersedes RPIN OPR-06-R005

RSB OPR-08-002 Drive Motor Pinion Nut

RSB OPR-08-003 Incandescent Light Wiring

RSB OPR-08-004 Software Update 3.5

RSB OPR-09-001 Drive Unit Leakage

RSB OPR-09-003 VM Software Version 4.6

RSI OPR-11-002 Correction to Test A34

RSI OPR-12-001 Motor Terminal Stud Torque

RSI GEN-12-002 Static Strap Resistance

RSI GEN-12-004 Shorts to Frame Test

RSI OPR-13-001 Fuse/Relay Card Troubleshooting

RSI GEN-13-002 Fuse/Relay Card Troubleshooting

RSI OPR-13-002A Carriage Control Card (CCC) Firmware Troubleshooting

RSI OPR-13-003 OPR Wire Guidance Configure Mode Settings Revision C

MM Update. Additional info. needs to be added to the symptom

RSI OPR-13-004
tables

RSI MUL-14-001 Carriage/Mast Shimming and Bearing Inspection

RSI OPR-14-001 Lift Chain and Fork Adjustment

RSI MUL-14-002 Intermittent 2T Codes

RSI OPR-14-003 Drive Unit Radial Ring Inspection

RSI MUL-14-004 Temperature Sensor Replacement

RSI OPR-14-004 Code 2M

RSI OPR-14-005A New Wire Guidance Manager Circuit Card and Code 9F

RSI OPR-14-006 Heavy Duty Drive Unit Updates

RSI OPR-14-008 New Software Release

RSI MUL-15-002 Fuse/Relay Card Troubleshooting

RSI MUL-15-001 Recommended Lift Chain Lubrication

RSI MUL-15-005 New Horn Available

RSI MUL-15-006 Updated Torque Check Procedure

RSI OPR-16-002 Update to Minimum Brush Length and Spring Tension Table Revision D

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 Models 5400/5500/5600 Maintenance Manual

Service Information List

Revision
Document Number Subject
Incorporated

RSI OPR-18-001 Updated Deadman Pedal

RSI OPR-18-002 New Guidance Manager

RSI OPR-18-003 Component Specific Service/Torque Chart Update

RSI OPR-18-004 Jacking and Blocking Procedures

Revision E
RSI MUL-18-001 Cold Storage Hydraulic Fluid Part Number Change

RSI MUL-18-002 FlashWare 7.8 Functionality and Enhancements

Code 50 on Orderpicker Lift Trucks with the Cold Storage

RSI OPR-19-004A
Option

viii Publication: 1031794, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section 1. How to Use This Manual

Section 1. How to Use This Manual

Publication: 1031794/001E, Revised: 04 Dec 2019 1-1

Section 1. How to Use This Manual Models 5400/5500/5600 Maintenance Manual

Manual Design

Manual Design • 7. Component Procedures contains

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

1-2 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section 1. How to Use This Manual

Interactive Electronic Technical Manuals

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

Blue text in the Maintenance Manual is linked

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

Publication: 1031794/001E, Revised: 04 Dec 2019 1-3

Section 1. How to Use This Manual Models 5400/5500/5600 Maintenance Manual

Abbreviations and Symbols

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

Term/Symbol Definition Term/Symbol Definition

A Ampere ESDS Electrostatic Discharge
AC Alternating Current Sensitive
Agnd analog ground
amp Ampere or amplifier FF Forks-first
approx approximately fpm feet per minute
Assy assembly FRC Fuse/Relay Card
aux auxiliary ft. foot or feet
AWG American Wire Gauge
gal. gallon or gallons
BSOC Battery State-of-Charge GM Guidance Manager
BWI brush wear indicator gm gram
Gnd ground
CAN Controller Area Network
CCC Carriage Control Card HA Heading Angle
CCW counterclockwise HD hours on deadman
CFP Contactor Fuse Panel Ht height
cm centimeter Hgt/Wgt Height/Weight
COP Computer Operating Hz Hertz
Program
CW clockwise IETM Interactive Electronic
CS cold storage Technical Manual
in. inch or inches
DC Direct Current
DFW Distance From Wire kg kilogram(s)
Dgnd digital ground kHz kilohertz
DMM Digital Multi Meter km/h kilometers per hour
DVM Digital Voltmeter kPa kilo Pascal

EE UL Electric Truck Type lb. pound or pounds

Certification Rating where LED Light Emitting Diode
electrical equipment is L/H Load Holding
completely enclosed L/L Lift/Lower
EMF ElectroMotive Force LPA Lift Power Amplifier
EOA End-of-Aisle LPC Lift Power Contactor
EPO Emergency Power Off
EPROM Erasable Programmable Read mA milliampere
Only Memory
max maximum
ESD Electrostatic Discharge
min minute or minimum

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Models 5400/5500/5600 Maintenance Manual Section 1. How to Use This Manual

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

mm millimeter TS Traction Speed
MM Maintenance Minder™ T/S troubleshoot
mph miles per hour UL Underwriters Laboratories,
mS millisecond or milliseconds Inc.
mV millivolt or millivolts
mVAC millivolts - alternating V Volt or Volts
current VDC Volts Direct Current
VM Vehicle Manager
No. number wrt with respect to
NV non-volatile Wt Weight
NVM Non-Volatile Memory
Nm Newton Meter ® registered
™ trademark
OACH Overall Collapsed Height © copyright
OD Operator Display + plus or positive
OI Operator Interface – minus or negative
OSHA Occupational Safety and ± plus or minus
Health Association ° degrees
OTM Over-The-Mast °F degrees Fahrenheit
oz. ounce °C degrees Celsius
< less than
prox proximity > greater than
pot potentiometer % percent
psi pounds per square inch = equals
PSL Power Source Limit
PWM Pulse Width Modulation
P/N Part Number

RAM Random Access Memory

RDP Raymond Data Port
rpm Revolutions per Minute

SAE Society of Automotive

Engineers
sec. second
SG specific gravity
SOL Solenoid
spec specification
SWM Supplier Wireless Module

temp Temperature
TF Tractor-first
TPA Traction Power Amplifier
TPC Traction Power Contactor

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Section 1. How to Use This Manual Models 5400/5500/5600 Maintenance Manual

Abbreviations and Symbols

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Models 5400/5500/5600 Maintenance Manual Section 2. Safety

Section 2. Safety

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Section 2. Safety Models 5400/5500/5600 Maintenance Manual

Definitions

Definitions
This manual contains two kinds of safety
reminders:

Warning means a potentially hazardous

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

Caution means a potentially hazardous

situation exists, which, if not avoided,
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.

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Models 5400/5500/5600 Maintenance Manual Section 2. Safety

General Safety

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

Do not operate or work on this lift truck unless

you are trained, qualified, and authorized to do
so, and have read the Owner and Operator
Manuals.

Before working on this lift truck, always turn

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

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

Do not wear watches, rings, or jewelry when

working on this lift truck.
Report any malfunction or unsafe condition to
your supervisor immediately. Do not operate
this lift truck if it is in any way unsafe.

Obey the scheduled lubrication, maintenance,

and inspection steps.

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Section 2. Safety Models 5400/5500/5600 Maintenance Manual

General Safety

Obey exactly the safety instructions in this Always operate and park this lift truck indoors.
manual. Obey the repair instructions in this
manual.

Do not wash this lift truck with a hose.

Do not use an open flame near the lift truck,

except when welding. See Welding Safety on
page 2-14.

Do not add to or modify this lift truck until you

contact your local Raymond Sales and Service
Center to receive written manufacturer
approval.
Do not use gasoline for cleaning parts. When
using cleaning fluids, obey manufacturer’s
Material Safety Data Sheets.

Clean up any spills, including hydraulic fluid,

oil, or grease that has leaked or spilled on the
floor.

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Models 5400/5500/5600 Maintenance Manual Section 2. Safety

Battery Safety

Battery Safety Wear personal protective equipment to protect

eyes, face, and skin when authorized to check,
handle, or fill batteries. This equipment
includes goggles or face shield, rubber gloves
(with or without arm shields), and a rubber
apron.
As a battery is being charged, an
explosive gas mixture forms within and
around each cell. If the area is not
correctly ventilated, this explosive gas
can remain in or around the battery for
several hours after charging. Make sure
there are no open flames or sparks in
the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
Make sure that a shower and eyewash station
are nearby in case of an accident.

Battery electrolyte is a solution of

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

Keep the charging area well-ventilated to avoid

explosive gas concentration.

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Section 2. Safety Models 5400/5500/5600 Maintenance Manual

Battery Safety

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

Do not lay tools or metal objects on top of the

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

Make sure the vent holes in the filler plugs are

open to permit the gas to escape from the cells.

Vent
Hole

Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.

Do not permit cleaning solution, dirt, or any

foreign matter to enter the cells.

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Models 5400/5500/5600 Maintenance Manual Section 2. Safety

Battery Safety

Make sure you install the correct size battery. A

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

Never plug a battery charger into the lift truck’s

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

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Section 2. Safety Models 5400/5500/5600 Maintenance Manual

Static Precautions

Static Precautions • If you are removing or installing ESDS

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

Whenever working on or near ESDS

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

Contact your local Raymond Sales and Service

Center for information.

ESD Ground Jack

Figure 2-1. ESD Ground Jack Location

• Handle circuit boards by the edges only.

Avoid touching the edge connectors.

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Models 5400/5500/5600 Maintenance Manual Section 2. Safety

Jacking

Jacking
When performing the jacking procedures:
• Use a 5-ton jack that meets ANSI/ASME
B30.1 or equivalent Safety Standards.
• Hoists must meet the following standards:
• ASME B30.2 (Overhead and Gantry
Cranes).
• ASME B30.16 (Overhead and
Underhung and Stationary Hoists).
Jack drive wheel no higher than 2
To determine the needed capacity of the in. (51 mm) off the floor
2

hoist, refer to the lift truck with Figure 2-3. Jacking Drive Tire Off Floor
maximum battery weight as set forth on
the specification tag.
• When required, use a support stand with a
2-ton capacity that meets ASME PALD
2009.
• Jack the lift truck high enough to
complete the task, but do not exceed the
value shown in Figure 2-3 and 2-4.

Jacking Lift Truck

When the lift truck is jacked up for any reason,
take the necessary precautions listed here to
make sure that the lift truck will not tip over.
• Lower the forks completely. Jack within this area - load wheel no
• Remove any load. higher than 2 in. (51 mm) off the floor
2

• Place all controls in neutral. Figure 2-4. Jacking Side of Lift Truck
• Block the wheels to prevent movement of
the lift truck.
• Turn the key switch OFF and disconnect
the battery connector.
Use extreme care when the lift truck is
• Place the jack under the designated jacked up. Never block the lift truck
jacking points. See Figures 2-3, Jacking between the telescopic and the floor.
Drive Tire Off Floor, and 2-4, Jacking Side Attach an appropriately rated rigging
of Lift Truck. device to the top of the mast, and an
• Always use solid blocks to support the lift overhead hoist to stabilize the mast if
truck. Never rely on jacks or chains to hold jacking higher than described in this
the lift truck. section. Keep hands and feet clear while
jacking the lift truck. After the lift truck
is jacked, place solid blocks or jack
stands beneath it to support it. Lower
the lift truck onto the blocks or jack
stands. Do not rely on the jack or jack
stand alone to support the lift truck.

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Section 2. Safety Models 5400/5500/5600 Maintenance Manual

Operator Platform

Operator Platform
Place a support stand between the carriage and
the floor when it is necessary to perform a
procedure with the operator platform elevated.
1. Use the remote lift/lower pendant and
raise the operator platform until you have
enough clearance to perform the
procedure.
2. Use a support stand with a 2-ton capacity
that meets or exceeds ASME PALD 2009
requirements. Place the support stand
under the carriage. Carefully lower the
operator platform onto the support stand.
Figure 2-5.
3. Turn the key switch OFF and disconnect
the battery connector.

Figure 2-5. Blocking Operator Platform

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Models 5400/5500/5600 Maintenance Manual Section 2. Safety

Emergency Lower Valve

Emergency Lower Valve

In the event that it is necessary to lower the
carriage from the ground, do the following:
1. Remove the tractor cover. The Emergency
Lower Valve is located on the lift/lower
manifold. See Figure 2-6.
2. Slowly turn the valve counterclockwise,
allowing the operator platform to lower by
its own weight.
NOTE: Leaving the valve open prevents the
operator platform from elevating.
3. Turn the valve clockwise to close. This
allows the operator platform to elevate
when the main lift control is operated.

Emergency
Lower Valve

21750_037.TIF

Figure 2-6. Emergency Lower Valve

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Section 2. Safety Models 5400/5500/5600 Maintenance Manual

Tie-Down for Transport

Tie-Down for Transport

Vertical Transport
Eye-Bolts
To transport this lift truck in an over-the-road
vehicle or rail car, follow these steps:
1. Lower the operator platform and locate the Block
lift truck in the center of the transport
vehicle.
2. Turn the key switch OFF and disconnect
the battery connector.
3. If guide rollers are present, place straps
through the guide rollers and secure to the
floor. Skip to step 5.
4. If guide rollers (used for rail guidance) are Chock Vehicle Strap On
not present: Block Bed Chains
2

a. Install eye-bolts (3/4 in. [19 mm] Figure 2-8. Tie-Down for Vertical Transport
thread size) in the holes in the bumper.
See Figure 2-7.
Horizontal Transport
b. Secure a chain from the eye-bolts to the
vehicle bed. See Figure 2-8. 1. Remove forks from carriage.

5. Strap the lift truck from the bumper or 2. Replace the cap and screen in the
guide roller to the floor of the transport hydraulic reservoir with shipping cap and
vehicle. screws.

6. Chock the drive wheel to prevent 3. Band down the carriage and battery
tractor-first movement. rollers.

7. Place a block between the baselegs and 4. Remove the dipstick, and plug the drive
platform, 7.5 in. (190.5 mm) from the front unit.
edge of the platform. 5. Remove the bottom two bumper plate bolts
8. Position an additional adjustable chain or (to be reinstalled after shipping).
strap perpendicular to the forks, over 6. Use two hoists in conjunction and lay the
operator platform, and attach it to the lift truck on the cradle.
vehicle bed. This prevents tip-over during 7. Install long bolts through the holes in the
transport. See Figure 2-8. bumper and secure to the cradle.
8. Band the lift truck to the cradle.
Eye-bolts 9. Secure the forks to the cradle below the
mast.

Figure 2-7. Eye-Bolts Installed for Transport

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Models 5400/5500/5600 Maintenance Manual Section 2. Safety

Towing

Towing
To tow this lift truck, follow these steps:
1. Lower the operator platform and remove
any load.
2. Turn the key switch OFF and disconnect
the battery connector. Brake Release Bolts
3. Using a suitable towing vehicle, lift the
tractor end of the lift truck until the drive
tire is no more than 1 in. (25.4 mm) off the
floor.
2

4. Tow the lift truck slowly in the tractor-first Figure 2-10. Location of Stowed Brake Release Bolts
direction.

NOTE: If you must tow the lift truck flat on the

ground, you must install the brake
release bolts provided. See Figures 2-9
and 2-10.
Steering is disabled while you are
towing, so you will need to manually
turn the drive unit to steer.

Brake Release Bolt Holes

Figure 2-9. Brake Release Bolt Installation

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Section 2. Safety Models 5400/5500/5600 Maintenance Manual

Welding Safety

Welding Safety • Test for shorts to frame. See

“Troubleshooting” on page 5-1. Correct
any shorts before you weld.
• Clean the area to be welded.
• Protect all lift truck components from
Flame cutting or welding on painted heat, weld spatter, and debris.
surfaces can produce potentially • Attach the ground cable as close to the
harmful fumes, smoke, and vapors. weld area as possible. Do not attach the
Before you do flame cutting or welding, ground cable to fasteners or other
remove the coating in the area where removable components.
the operation will occur.
• Disconnect all electrical connectors from
circuit cards before doing any type of
Coating removal can occur by
electric resistance welding.
mechanical and/or chemical methods.
Perform flame cutting and/or welding • Do not weld near electrical components.
operations only in well ventilated areas. • If you must weld near the battery
compartment, remove the battery from the
Before working on this lift truck, make sure lift truck.
that:
• Fire protection equipment is nearby.
• You know where the nearest eyewash
station is.

Disconnect the battery before you

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

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Models 5400/5500/5600 Maintenance Manual Section 3. Systems Overview

Section 3. Systems Overview

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Section 3. Systems Overview Models 5400/5500/5600 Maintenance Manual

Introduction

Introduction
This manual provides information for
maintenance and repair of Model
5400/5500/5600 Orderpicker lift trucks by
Raymond.

This manual contains the most current and

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

For the latest information on your Raymond lift

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

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Models 5400/5500/5600 Maintenance Manual Section 3. Systems Overview

Lift Truck Specifications

Lift Truck Specifications

Specification Tag
This lift truck is rated for performance by load
center and load weight. Review the specification
tag for detailed load capacity and load center
information. See Figure 3-1.
Due to continuous product improvement,
specifications are subject to change without
notice or obligation.

Raymond Model # Serial number Approximate weight

of lift truck with
battery installed,
Nominal battery minus load and
voltage operator

*Max battery
weight for this lift
truck
Approximate weight
of lift truck minus
battery, load, and
operator *Min battery
weight for this
lift truck

Max Battery
Rated Capacity

Max load capacity of

this lift truck

*Battery weight must be between the

min and max weight.

3412-645.wmf
Figure 3-1. Lift Truck Specification Tag

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Section 3. Systems Overview Models 5400/5500/5600 Maintenance Manual

General Information

General Information
Configuration
The vehicle configuration code is included in
the serial number of the lift truck. The
configuration code allows you to easily
determine performance and height.

Configuration Code Cross Reference

Code Model # Traction/Lift Configuration

5400 AC/DC 24V Hi-Pro

A 5500 AC/AC 24V High Performance

5600 AC/AC 36V High Performance

5400 AC/DC 24V Hi-Pro above 315 in.*

B 5500 AC/AC 24V High Performance above 315 in.*

5600 AC/AC 36V High Performance above 315 in.*

C 5400 AC/DC 24V

*At and below 315 in. uses the standard drive unit. Above 315 in., and in specific
customer applications, use the heavy duty unit.

Battery Specifications

UL note 583 specifies that a battery should

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

Weight Min/Max
Width (in.) lb. (kg) Amp
Min Max Hours

13 920 (418) 2000 (907) 450/1085

13.69 1600 (726) 2000 (907) 600/775

14.12 920 (418) up to 241 in. (6121 mm) El. Ht

2000 (907) 450/1085
1600 (726) above 241 in. (6121 mm) El. Ht.

16.12 2000 (907) 2300 (1043) 600/930*

18.12 2300 (1043) 2600 (1179)

600/1240
21.12 2600 (1179) 2900 (1315)

*Maximum amps 775 with UL label Type “E” or UL label Type “EE”

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Models 5400/5500/5600 Maintenance Manual Section 3. Systems Overview

Fluid Capacities

Fluid Capacities
Heavy Duty Drive Hydraulic
Standard Drive Unit
Units Reservoir

Fill to middle line

on tank. Approx.
0.5 gal. (1.9 liters) 0.75 gal. (2.9 liters)
7 to 8 gal. (26.5 to
30.3)

Refer to “Lubrication Specification Chart” on

page A-2.

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Section 3. Systems Overview Models 5400/5500/5600 Maintenance Manual

Installation

Installation
Installation must be performed by a Raymond
Certified Sales and Service Technician to
ensure warranty coverage.
During installation, a visual and functional
inspection must be performed. Refer to the OPR
Lift Truck Installation Guide (P/N 1169845).

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Models 5400/5500/5600 Maintenance Manual Section 3. Systems Overview

Operator Display

Operator Display Steering Indicator Lights

The steering indicator lights are located on the
The Operator Display (OD) displays data
OD Console. The steer indicator lights show the
received from the Carriage Control Card. See
operator the approximate position of the drive
Figure 3-2. The displayed data includes:
unit.
• Time or calendar
• BSOC (Battery State-of-Charge) Wire Guidance LEDs
• Hour meters (hours on deadman [HD],
hours spent lifting [HL], total miles [TM]) The wire guidance LEDs are located on the OD
• Status/Fault messages Console. The LEDs consist of two green
triangles and three yellow rectangles. The LEDs
• Weight of load (optional) indicate when the wire guidance system is
• Fork Height (optional) turned on and the lift truck is locked on the
• Maintenance required indicator guide wire.

• Over-temperature indicator
• Lift-limit indicator (optional)
• Steering direction indicator
• Guidance indicator (optional)

The OD is not required for Run Mode or to pass

SelfTest.

Status/Fault Message Display

Steering Indicator Lift-Limit Indicator
Lights Over-Temperature Indicator
Maintenance Required Indicator

Wire Guidance
LEDs

3
Figure 3-2. Operator Display Messages

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Section 3. Systems Overview Models 5400/5500/5600 Maintenance Manual

Modes of Operation

Modes of Operation • A shutdown in the lift system

If a problem occurs in the lift system, lift is
This vehicle can operate in one of two modes of prevented. Travel, lower, horn, and
operation: steering functions are still permitted.
• Run Mode Tone 4. A continuous tone with the deadman
pedal pressed and the Auto/Manual switch in
• Program Mode
Manual indicates the lift truck is over the guide
wire.
Run Mode
Tone 5. Tone ramps up then repeats is an
Run Mode is the normal operating mode for the indication that the lift truck is seeking and
vehicle. Run Mode is the only mode that normal aligning over the guide wire. The tone continues
vehicle travel is allowed. In this mode, the until the lift truck is locked on the guide wire or
selectable display is shown on the OD. Run the Auto/Manual switch is changed to Manual.
Mode starts automatically when Program Mode
Tone 6. Descending tone (bomb drop) that
is exited or after SelfTest passes.
indicates an incorrect Password or Electronic
Passkey was entered.
Audible Alarm Description
The tones described do not repeat continuously.
Within Run Mode, various lift truck situations A fault code and associated message scroll
are identified using different audible tones and across the OD. The message repeats
patterns. Run Mode Tones describes the six continuously until the key switch is turned
tones/patterns and possible cause for different OFF.
operating conditions.
Password Levels
Run Mode Tones
Two password levels are used with this system:
Tone 1. A single tone that indicates:
• Password
• Up/Down buttons or Enter is pressed
• SuperWord
• Maximum steer request is reached
Tone 2. Two tones (high/low) that indicate the Password
Traction Power Contactor (TPC) and Lift Power
Contactors (LPC) are disabled (opened). Travel, Password allows access to Configure Mode
steering, and lift/lower are disabled and the (Config) only. Instructions for using Config are
brake is applied until the problem is corrected. outlined on page 3-13.

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

SuperWord
indicate:
• A travel performance limitation SuperWord (Superwrd) allows access to all
program levels available. Only qualified service
A travel performance limitation allows the
technicians should have access to SuperWord.
lift truck to travel at a maximum of 1 mph
(1.6 km/h). Lift, lower, steering, and horn Instructions for entering or changing Password
functions operate normally. or SuperWord are described on page 3-9.
• A traction system shutdown It is strongly recommended that the SuperWord
A traction system shutdown does not allow be changed from the factory default to
the lift truck to travel. Lift, lower, steering, something else during installation so access to
and horn functions operate normally. programming is limited to qualified personnel.
With that in mind, it is very important to
remember the unique SuperWord code that was
entered and saved. If the code is lost or

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Models 5400/5500/5600 Maintenance Manual Section 3. Systems Overview

Program Mode

forgotten, it is necessary for a technician to In Maintenance Mode, individual circuits can

reset the lift truck to factory default settings. be energized and cycled to aid in
This requires the reconfiguration of all variable troubleshooting. Some tests can be performed
settings (Speed, Acceleration, Password, under both active and static conditions to
SuperWord, and so on). further aid in problem diagnosis.
NOTE: Password recovery can be performed via
Static Maintenance Mode
the Raymond Portal if FlashWare is not
available. Within the Raymond Portal, This mode allows one function at a time to be
select Service > Software > SuperWord tested.
Recovery Passkey Program and follow
the procedure in the SuperWord_readme Active Maintenance Mode
file.
This mode allows all input and analog tests to
be active in Run Mode. Navigate through the
Program Mode OD using the Up/Down buttons, then enter
Analog or Input by pressing the Enter button.
Program Mode is divided into three categories:
You can now scroll through all input and
• Configure (Config) output tests. There is no need to select items for
• Learn (Learn) Active Maintenance, and you are not limited to
the number of items. They are all available. To
• Maintenance (Maint) - Static or Active
return to the OD, navigate to Quit and press
Enter.
Configure Mode
To access Maint, SuperWord must be used. For
The Configure Mode (Config) is used to adjust a detailed description of Maintenance Mode,
the vehicle’s performance to specific customer refer to page 3-26.
requirements. To access Config, Password or
SuperWord must be used. For a detailed
description of Configure Mode, refer to
Entering Program Mode
page 3-13. Program Mode can be entered by one of the
following two methods.
Learn Mode
Method One
The Learn Mode is used to calibrate:
• Throttle potentiometer (VR1) (Controls) 1. With the key switch OFF, hold the horn
button in and move the lift/lower control
• Lift/lower potentiometer (VR2) (Controls)
to full lift.
• intellispeed™ sensor - height (optional)
2. Turn the key switch ON.
• Pressure transducer - weight (optional)
3. The OD will show all eight segments with a
• Wire guidance frequency and offset solid bar in each segment. See Figure 3-3.
(optional)
• Steer version lower than 3.4 or rail guided
lift trucks
A discussion of the Learn process for these
items is included in this section.
To access Learn, SuperWord must be used.

Maintenance Mode
The Maintenance Mode (Maint) is used to verify
the operation of various circuits of the lift truck.

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Section 3. Systems Overview Models 5400/5500/5600 Maintenance Manual

Entering Program Mode

NOTE: Initial factory set Password is 1.

Initial factory set SuperWord is 2.
_ _ _ _ _ _ _ _
5. When the Password or SuperWord is
displayed, press the Enter button once.
NOTE: If an invalid Password or SuperWord is
entered, the following message appears:
Invalid password...
To make a correction, repeat steps 2
through 4.

NOTE: To reset the SuperWord to factory

default, use FlashWare. See “FlashWare”
on page 3-28.
Down Button Enter Button 6. The menus that can be accessed depend
3 on whether SuperWord or Password was
Figure 3-3. Operator Keypad and Display
entered. Refer to Table 3-1.
Config is the first selection on the OD. If
Method Two
Config is the desired selection, press
1. With the key switch OFF, press and hold Enter. If Learn or Maint is desired
the Enter button and Down button at the (available only if Program Mode is entered
same time. See Figure 3-3. with SuperWord), use the Up/Down
2. Turn the key switch ON. buttons to scroll to that menu, then press
Enter.
NOTE: The OD will show all eight segments
To exit Program Mode, use the Up/Down
with a solid bar in each segment.
buttons to scroll to Quit, then press Enter.

Entering Password or SuperWord NOTE: If the output tests are selected in Maint,
the OD reminds the service technician
Refer to Figure 3-4. to jack the lift truck so the drive tire is
1. Observe the OD. The flashing bar at the off the floor and to open the emergency
bottom of the left-most segment indicates lowering valve while in Maintenance
the segment that is currently active. Mode. When Ready? appears on the OD,
press Enter to enter Maintenance Mode
2. Hold the Enter button down and press the output tests.
Up button to move the cursor to the right.
Hold the Enter button down and press the
Down button to move the cursor to the
left. Release the Enter button.
3. Once the segment that you want to change
is selected:
• Press the Up button to advance through
the numbers then letters
(0 1 2 3 4 . . . . . . . . . X Y Z ).
• Press the Down button to select letters
then numbers (Z Y X W V. . . . . . . . 4 3 2 1 0 ).
4. Repeat steps 2 and 3 for all character
positions in the Password or SuperWord.

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Entering Program Mode

Numbers and letters are displayed in each segment in the order shown below (then repeated)
when the UP button is pushed repeatedly.

-0123456789ABCDEFGHIJKLMNOPQRSTUVWXYZ

Push the DOWN button repeatedly to scroll the information in the opposite direction.

With the Enter button

pressed, press the Up
button to move the
cursor from left to
right. With the Enter button
- - - - - - - - pressed, press the
Down button to move
the cursor from right
to left.

Space
(indicated by
Number underscore)

Enter the correct letter or number

for each segment that makes up
the Password or SuperWord. 3 a 7 t - 4 9 k Letter

Password or SuperWord may be 1 - 8 characters in

length, using numbers, letters, spaces (indicated by an
underscore), or any combination of each.
3
Figure 3-4. Operator Display for Program Mode (Example)

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Entering Program Mode

Table 3-1. Program Mode Menu

PROGRAM MODE MENU

Menu Item Selection Description

Quit Exits Program Mode

Config Enters Configure Mode - Refer to Configure Mode and

Table 3-2, Configure Mode Menu on page 3-14.

Learn Learn Mode - See Learn Mode on page 3-19.

(SuperWord only) Quit Lrn Exits Learn Mode
Controls
Hgt/Wgt
Guidance Automatically steers the lift truck while traveling in an aisle.
Steer Only on rail guided vehicles equipped with auto-steer
centering. Learn Mode Menu no longer includes steer learn
with Version 3.4 or higher VM FlashWare. There is now a
category that is Guidance for Wire Guided vehicles only.

Maint Maintenance Mode - See Maintenance Mode on page 3-26.

(SuperWord only) Analog See Analog Input Tests on page 6-45.
Input See Input Tests on page 6-77.
Output See Output Tests on page 6-127.
PA Reset See Power Amplifier Reset on page 3-27.
WGReset Reset? N
Reset? Y
EvtLog See Event Log on page 3-27.
Act Maint See Active Maintenance Mode on page 3-27.
Enable
Disable
Quit Mnt Exits Maintenance Mode

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Entering Program Mode

Configure Mode The minimum number of characters is one, the

maximum is eight.
Configure Mode can be accessed with
SuperWord or Password, however some items in To change Password or Superwrd:
Config will only appear if SuperWord is entered. 1. Enter Config using the current password
Table 3-2 outlines all menus and submenus or SuperWord.
available in Config. 2. Select Password or Superwrd (as
applicable) from the Config menu and
Quit Cfg is first displayed when Config is
press Enter.
selected. Use the Up/Down buttons until the
desired selection is displayed. Press Enter. This 3. Enter the new code using the Up/Down
takes you into the submenu for that item. and Enter buttons.
4. When the new code is displayed, press
Current values of configurable items or the
Enter. The display returns to the main
ability to enable and disable an option appear
menu.
in the submenu. To change the value, press the
Up/Down button. When the desired value
appears, press Enter. This selects the item
currently displayed and returns to the main
menu.
All possible lift truck configurations and options
are listed in these instructions. Only the
options associated with that particular lift truck
are displayed on the OD.
To save changes, select Quit Cfg from the Config
menu and press Enter. Select Save? 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 are reset (Reset? Y), the
previous settings cannot be recalled.
To reinstate factory default settings:
1. Select Defaults from the main menu and
press Enter. Select Reset? Y.
2. Select Quit Cfg.

Changing Password or SuperWord

Both Password and Superwrd can be changed
to any combination of letters and/or numbers.
Blank spaces are not allowed (spaces are
represented by an underscore [_]).
If Program Mode is entered with a password,
only the Password can be changed. If Program
Mode is entered with a SuperWord, both
Password and Superwrd can be changed.

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Entering Program Mode

Table 3-2. Configure Mode Menu

CONFIGURE MODE MENU

Can be entered with Password unless SuperWord is specified

Menu Item Selection Description

Exits Configure Mode

Quit Cfg Save? Y Saves changes and leave Configure Mode
Save? N Abandons changes and leave Configure Mode

Restores Factory Defaults - See Default Settings on page 3-13.

Defaults Reset? Y Restores to Factory Defaults
Reset? N (default) Do not restore to Factory Defaults
CAUTION: The previous settings cannot be recalled once
defaults are reset (Reset? Y).

iP Lim
®
Refer to iPORT Kit and Installation and Maintenance
Instructions (P/N 1089339).

iP Spd Refer to iPORT Kit and Installation and Maintenance

Instructions (P/N 1089339).

Value range for TF travel is 0.1 to 6.5 mph (0.16 km/h to 10.4
Speed Max TF 0.1 to 6.5 km/h) and can be adjusted in increments of 0.1 mph (0.16
km/h).
Max FF 0.1 to 5.5 Value range for FF travel is 0.1 to 5.5 mph (0.16 km/h to 8.8
km/h) and can be adjusted in increments of 0.1 mph (0.16
km/h).

Sets End-of-Aisle Slowdown Speed

EOA Speed 1.0 mph (default) (0.0 to Maximum Speed)
(optional)
(SuperWord only)

Sets Travel Acceleration

Hard
Accel Medium (default)
Soft

Long Sets Coast

Coast Medium (default)
Short

Sets Lift/Lower Start/Stop Acceleration

Hard
Lift Medium (default)
Soft

Sets Lower Deceleration Speed. Set lowering speed below 24 in.

LwrDecel 0 through 9 (610 mm). Select from 0 (no lower deceleration) through 9
(SuperWord only) (default = 5) (highest amount of deceleration)

BSOC Resets Battery State-of-Charge

(SuperWord only) 75 (default) Variable from 55 to 100 in increments of 1

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Entering Program Mode

Table 3-2. Configure Mode Menu

CONFIGURE MODE MENU

Can be entered with Password unless SuperWord is specified

Menu Item Selection Description

ActMaint Enable (default) Sets Active Maintenance

(SuperWord only) Disable

Selects Battery Cutout Voltage: 0 to 50 in increments of 1

Cut Out 20 (default)
(SuperWord only)

Alt. C/O Refer to iBATTERY ™ Kit and Installation and Maintenance

Instructions (P/N 1139156).

Set the 24 in. (610 mm) mast switch speed from 0.5 to 2.5 mph
24 Speed 2.5 mph (default) (1.6 to 4 km/h)
(optional)
(SuperWord only)

Sets Lift/Lower Bypass

L Bypass Enable (default)
(optional) Disable
(SuperWord only)

Sets Lift Limit Bypass and Travel Cutout

LBPTrvCt Enable (default)
(optional) Disable
(SuperWord only)

Sets Lift Limit Bypass Alarm

LBPAlarm Enable (default)
(optional) Disable
(SuperWord only)

Cust Int Customer Interlock Input - enabled in FlashWare

(SuperWord only) CITrav
CI Speed 0.1 mph increments
CI Lift
This option can limit or disable travel and/or lift based on the
state of the input to the VM.

Selects English or Metric units of measure.

Units English (default)
Metric

Language No selections
available

Selects Wire Guidance Frequency

5.2 kHz 5.2 kHz and 6.25 kHz are for Factory use only
WireFreq 6.25 kHz Always select Other (default) with VM software 3.4 and above.
(optional) Other (default)
(SuperWord only)

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Entering Program Mode

Table 3-2. Configure Mode Menu

CONFIGURE MODE MENU

Can be entered with Password unless SuperWord is specified

Menu Item Selection Description

Selects between Wire and Rail Guidance (will only appear if

Guidance Wire both options are installed on the lift truck or if either option is
(optional) Rail installed on the lift truck.)
(SuperWord only)

Sets Heading Angle and Distance From Wire Exit GuideSet

Quit Gds
HA SLOW 0.6 to 2.0° in 0.2° increments
1.6 deg (default)
GuideSet HA STOP 2.0 to 4.0° in 0.2° increments
(optional) 3.0 deg (default)
(SuperWord only) DFW SLOW 0.6 to 1.6 in. (1.5 to 4.0 cm) in 0.2 in. (5 cm) increments
1.6 in (default)
DFW STOP 1.2 to 3.0 in. (3.5 to 4.0 cm) in 0.2 in. (5 cm) increments
3.0 in (default)

Sets Acquire Speed (tractor-first only)

Acquire 1.0 mph (default) 1.0 to full speed in 0.1 mph (0.16 km/h) increments
(optional)
(SuperWord only) Note: Forks-first acquire speed is fixed at 1.0 mph.

Sets Top Speed of lift truck when not in wire guidance mode
FreeSpd X.X mph 1.0 to full speed in 0.1 mph (0.16 km/h) increments
(optional) (default = Max
(SuperWord only) Speed)

WrSnLim Enable Sets Wire Sense Creep Speed

Disable
WrSnSpd 1.0 mph 1.0 mph when enabled.
(optional)
(SuperWord only)

Factory Use Only

WGAM Enable
Disable

Enters New Electronic Key

Elec Key 3_ _ _ _ _ _ _ Displays Current Elec Key
(optional) (factory setting)
(SuperWord only)

Enters New Password

Password 1_______ Displays Current Password
(factory setting)

Enters New SuperWord

Superwrd 2_______ Displays Current SuperWord
(SuperWord only) (factory setting)

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Entering Program Mode

Table 3-2. Configure Mode Menu

CONFIGURE MODE MENU

Can be entered with Password unless SuperWord is specified

Menu Item Selection Description

Displays Software Version

Quit Ver Exits Version
CCC XX.X Software version for Carriage Control Card
VM XX.X Software version for Vehicle Manager
VMB X.X Boot Block Software version for Vehicle Manager
Version GM XX.X Software version for Guidance Manager
PAT X.X Software version for Traction Power Amplifier
PTB X.XX Boot Block Software version for Traction Power Amplifier
PAL X.X Software version for Lift Power Amplifier
PLB X.XX Boot Block Software version for Lift Power Amplifier
APM Refer to iWAREHOUSE ™ Essential Installation and
Maintenance Instructions (P/N 1154530)
BSM Refer to iBATTERY Kit and Installation and Maintenance
Instructions (P/N 1139156)
Trac Mod Traction Amplifier model number
XXXXXXXX (press Enter to access)
Trac S/N Traction Amplifier serial number
XXXXX (press Enter to access)
Lift Mod Lift Amplifier model number
XXXXXXXX (press Enter to access)
Lift S/N Lift Amplifier serial number
XXXXX (press Enter to access)

Serial # XXXXX Display the Serial Number Assigned to the lift truck

Sets Time/Date
Time Sets Time of Day (AM or PM)
HH:MM:SS
AM
Clock PM
Date
MM/DD/YY Sets Current Date
Quit Clk Exits Clock

Sets Alarm for Travel

None
AlarmT Both (default) On in Both directions
(optional) Fork Ld Fork Lead On/Off
(SuperWord only) Fork Trl Fork Trail On/Off

Sets Alarm for Lift

None Exit
AlarmL Both (default) On in Both directions
(optional) Lift On/Off
(SuperWord only) Lower On/Off

Valve A Used with VM software versions below 3.4 to optimize lift/lower

B proportional value performance.
C

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Entering Program Mode

Table 3-2. Configure Mode Menu

CONFIGURE MODE MENU

Can be entered with Password unless SuperWord is specified

Menu Item Selection Description

Setup for Maintenance Minder ™

Quit MM Quit Maintenance Minder (MM) Menu
Enable Turn on MM
Setup
300 (default) Hours on Deadman – 50 to 500 (in 50 hr increments)
Mnt Mind Msg Only Message Only
L Cutout Lift Cut-Out and Message
Reset Update MM to the Current Interval
Disable Turn off Maintenance Minder
Setup Setup the Maintenance Minder Interval (See Maintenance
Minder™ Tool on page 4-3.)

Sets idle time for automatic shut-off

Disable (default)
10 Min
5 Min
Auto Off 4 Min
3 Min
2 Min
1 Min

Displays Height of Upper Reference Switch

UPRrefSW XXX in. [145 to 160 in. (3683 to 4064 mm)]
(optional) CAUTION: If upper reference switch height is changed on an
(SuperWord only) intellispeed lift truck, Learn height must be run.

Aux Mast XX in. Set Aux Mast height in inches from 20-50. Default = 20

Sim_Mode Simulation Mode is a mode of operation that disables all truck

movement but allows the truck to be used as a simulator when
used in conjunction with the Raymond Virtual Reality
Simulator.

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Entering Program Mode

Learn Mode The VM interprets the height and weight inputs

during Run. During Learn, the VM obtains a
Learn Mode is used to calibrate the control baseline for height and weight from where to
circuits to the operator controls and the lift calculate those parameters. The position of the
truck’s external sensors, [such as throttle upper and lower reference switches is part of
(VR1), lift/lower potentiometer (VR2), and the the information that is installed into the lift
optional flow sensor used with the advanced truck’s primary memory at the factory or as a
intellispeed system]. result of a change with a Passkey.
After entering the SuperWord, Config is When Learn Hgt/Wgt is performed, the carriage
displayed on the OD (see Table 3-1 on passes through both lower and upper reference
page 3-12). Scroll Up/Down through the menu switches. As hydraulic fluid flows through the
until Learn is displayed, then press Enter. The Flow Sensor to move the carriage, the Flow
alarm beeps, indicating that you are in Learn Module produces two quadrature phased
Mode. pulsed outputs to the VM. The VM counts and
Select the item you want to learn. Follow the stores the number of pulses between the
instructions as they appear on the OD. Learn reference switches. The VM uses this
instructions vary slightly between vehicles with information to determine the position of the
different options. Instructions repeat until they carriage as the lift truck is operated during Run
have been completed. Mode.

After the system is satisfied that the The formula for calculating weight from the
instructions on the OD have been followed, the pressure transducer voltage is programmed into
alarm beeps and the next instruction appears. the VM, but it needs to know the reference
This continues until all required components voltage from where to start the calculation. It
are learned. After all steps are satisfied, Quit Lrn monitors and stores the voltage from the
is displayed, allowing Learn to be exited. pressure transducer as the carriage is lifted
between the reference switches during Learn.
Learn Controls This value is used for the reference voltage for
lifting an empty carriage.
Learn Controls is necessary on all lift trucks.
During Learn Controls, the Vehicle Manager After the carriage is lifted between the reference
(VM) calibrates its control circuits to the output switches, the carriage elevates about
voltage from the Travel Potentiometer (VR1) and 12 in. (304mm) and pauses before lowering
the Lift Potentiometer (VR2). again. During this pause, the VM stores the
value that is produced from the pressure
The VM measures and stores the neutral transducer when an empty carriage is elevated
voltage value and the maximum forward and and stationary.
reverse voltage values from VR1. These values
are used by the VM to determine direction and
speed requested by the operator during Run
Mode.
The VM also measures and stores the neutral
and the maximum lift and lower voltage values
from VR2. These values are used by the VM to
determine if lift or lower is being requested and
the percentage of full speed that is being
requested.

Learn Hgt/Wgt
Learn Hgt/Wgt is only present if the intellispeed
option is installed on the lift truck.

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Entering Program Mode

When to Run Learn

Table 3-3. When to Run Learn

Is Learn
Component Repaired/Adjusted Portion of Learn to run
Required?

Vehicle Manager Yes — Controls, Height, Weight, Steer

Upper Mast Switch — No —

Lower Mast Switch — No —

Carriage Control Card (CCC) Yes — Controls

Carriage Control Card PROM Yes — Controls

Steer Position Proximity Home Sensor Yes — Learn Steer Zero or Learn

Deadman Switch (S2/S23) — No —

Lift Potentiometer (VR2) Yes — Controls

Guidance Manager Yes — Frequency and Offset

Pressure Transducer Yes — Height, Weight

Lift/Lower Solenoid — No —

Load Holding Solenoid — No —

Brake — No —

Throttle Potentiometer (VR1) Yes — Controls

Flow Sensor Module Yes — Height, Weight

Filter Card Yes — Frequency and Offset

Antenna Card Yes — Frequency and Offset

Home Proximity Sensor Yes — Steer

operator steps on the deadman pedal, the

carriage immediately begins to lift. The display
continuously scrolls the following message:
Before Learning height and weight, the
To abort, step off deadman
vehicle must be placed in an area where
the platform is able to lift beyond the If all the parameters measured during Learn are
upper mast reference switch (156 in. within tolerance, the following message
[396 cm] plus the height of the carriage). appears:
Done learning
When Hgt/Wgt is selected, the following
If, at any time during Learn, the operator steps
message appears:
off the deadman pedal or the measurements fall
Carriage will automatically lift/lower
outside a tolerance, the following message
between the reference switches
appears:
The operator is prompted as follows: Unable to learn...lower then press enter to
Step on deadman to start learn continue
This message scrolls continuously until the
operator steps on the deadman pedal. After the

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Entering Program Mode

If the failure is not the result of stepping off the 3. Select WireFreq from the Learn menu and
deadman, attempt to Learn again. If repeated press Enter. The following message
attempts to learn fail, run tests: appears:
• Test A13 - Pressure Sensor Voltage Center over wire, Then press enter
(optional) (Page 6-52) After enter is pressed, the following
• Test I02 - Lower Mast Reference (24 in.) message is displayed:
Switch (Page 6-80) Learning wire frequency
• Test I69 - Upper Mast Reference Switch NOTE: This process takes several seconds.
(Page 6-113)
4. When the frequency and amplitude of the
• Test I26 - Flow Sensor Count (Page 6-92) guide wire is learned, the following
(use Active Maintenance) message is displayed:
Wirefreq
Learning Wire Frequency: Software Versions
Below 3.4 5. Select Quit Lrn from the Learn menu and
press Enter to exit Learn Mode. Cycle the
Lift trucks equipped with an optional wire key switch OFF, then ON. Re-enter Learn
guidance system can be configured as follows. Mode prior to learning Wire Guidance
Three selections are available under WireFreq in Offsets.
Config.
6. If a valid frequency is not found, or if at
If 5.2 kHz or 6.25 kHz is selected, the Guidance any time during the learning process, the
Manager utilizes preset guide wire strength operator presses the Enter button, the
values and calculates only the wire guidance following message is displayed:
offsets (Wg Offset must be run). Unable to learn. Press enter to continue
NOTE: The 5.2 kHz setting requires a guide wire 7. If repeated attempts to learn wire
output of 100 mA. The 6.25 kHz setting frequency fail, run the following tests:
requires a guide wire output of 225 mA. • Test A51 - Left Tractor Guidance Coil
Other must be selected for all other Voltage (Page 6-63)
guide wire outputs.
• Test A52 - Right Tractor Guidance Coil
If Other is selected, the Guidance Manager is Voltage (Page 6-65)
calibrated to the frequency and amplitude of the • Test A53 - Left Load Guidance Coil
guide wire in order to correctly calculate wire Voltage (Page 6-67)
guidance offsets. Both scenarios are discussed
in the following paragraphs. • Test A54 - Right Load Guidance Coil
Voltage (Page 6-69)
Learn WireFreq • Test A55 - Tractor Near Wire Coil
Voltage (Page 6-71)
WireFreq is visible in the Learn menu only if
Other is selected under WireFreq in Config. • Test A56 - Load Near Wire Coil Voltage
WireFreq must be learned before Wg Offset is (Page 6-73)
attempted. When Other is selected, the
Guidance Manager (GM) must learn the Learn Wire Guidance Offsets
frequency and strength of the AC current For wire guidance to function correctly, the GM
flowing through the guide wire. This is done as must calibrate its internal guidance circuits to
follows: the voltage it receives from each guidance coil
1. Verify that the line driver is adjusted to the on the Antenna Card. The GM must also know
correct frequency and amplitude. the straight ahead position of the drive unit.
2. Center the lift truck over the guide wire to
within ±0.5 in. (±13 mm).

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Entering Program Mode

These values are obtained while learning the a position other than centered over the wire. If
wire guidance offsets as follows: the drive unit was not straight ahead, the GM
would learn an incorrect angle and the lift truck
NOTE: The Coast value in Config must be set to
may wander on the wire. Re-learn the wire
Long and the lift truck driven in the
guidance offsets as many times as necessary to
tractor-first direction.
make the lift truck track within 0.5 in. (13 mm)
1. Center the lift truck over the guide wire as of the guide wire.
closely as possible. 5. If the Learn procedure is completed
2. Set the Auto/Manual switch to Auto to correctly, the following message is
initiate Learn. displayed:
Done learning
3. Drive the lift truck tractor-first on the
guide wire for at least 60 ft. (18 meters). The lift truck should guide centered over
Allow lift truck to coast to a stop. This is the guide wire.
done to allow the lift truck to center If Enter is pressed during the Learn
correctly to its neutral position. If the process, the session is aborted and the
brake or plugging is applied, the drive unit following message is displayed:
may shift position. Unable to learn. Press enter to continue
4. After the lift truck has coasted to a stop, 6. Run Tests A51 through A56.
place the Auto/Manual switch in the
Manual position. When the Auto/Manual Learn Steer Zero
switch changes state, the GM stores the
This procedure removes the need to manually
voltage it measured from each guidance
adjust the Home Proximity Switch to make the
sensor coil. This voltage value is used to
lift truck track centered over the wire.
determine the wire guidance offsets and
establish the scale factors required to 1. Center the lift truck over the guide wire.
determine Heading Angle (HA) and 2. Select Learn Steer Zero.
Distance From Wire (DFW) when in Run
3. Place the Auto/Manual switch in Auto and
Mode.
drive the lift truck in both directions over
When the lift truck powered up, it auto centered the guide wire. Maintain a speed of greater
and reset the pulse counter for steering than 1.2 mph (1.9 km/h) for more than
position. As the lift truck was traveling on the two seconds. Once a change in speed of
wire in step 3, the Feedback Encoder was less than 1 mph (1.6 km/h) is seen for two
keeping track of the deviation of the drive unit seconds, the Steer Zero position for that
from the auto center position. When the travel direction is stored and the lift truck
Auto/Manual switch changed states in step 4, will beep.
the GM also stored the number of Feedback 4. After Learn for both travel directions is
Encoder pulses between the Auto Center complete, select Quit Lrn from the Learn
position and the position that the drive unit was menu and press Enter to exit Learn Mode.
located when the Auto/Manual switch changed Cycle the key switch OFF, then ON. Test
state. That is the value that the GM uses as the lift truck operation.
straight ahead when determining how to
position the drive unit to keep the lift truck Learning Wire Frequency: Software Version
centered over the wire (sensor coil voltages at 3.4 and Up
the learned value) as the lift truck drives on the
wire. Lift trucks equipped with an optional wire
guidance system have three selections available
If the lift truck was not centered over the wire under WireFreq in Config.
when the Auto/Manual switch changed states
in step 4, the GM would learn incorrect values If 5.2 kHz or 6.25 kHz is selected, the GM uses
(lift truck position) from the sensor coils. The preset guide wire strength values and
GM would then attempt to keep the lift truck in

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Entering Program Mode

calculates only the wire guidance offsets (Wg process. If still unable to learn the wire,
Offset must be run). verify that the output of the line driver
conforms to Raymond specifications.
NOTE: The 5.2 kHz setting requires a guide wire
Then perform Analog tests A51 through
output of 100 mA. The 6.25 kHz setting
A56. See “Analog Input Tests” on
requires a guide wire output of 225 mA.
page 6-45.
Other must be selected for all other
guide wire outputs. 7. The ODI automatically changes to guide
tractor-first. Pressing the Down arrow
If Other is selected, the GM is calibrated to the
allows the Wire Guidance Offsets Learn
frequency and amplitude of the guide wire in
process to be skipped and advance to step
order to correctly calculate wire guidance
8.
offsets. Both scenarios are discussed in the
following paragraphs. 8. After tractor-first travel is initiated, the
ODI displays:
Learn WireFreq: gently coast to a stop then press Enter
1. Center the lift truck over the guide wire. NOTE: The ODI displays “wrong direction” if
2. Enter the Program Mode via SuperWord forks-first travel is attempted.
and select Configure Mode. Scroll to Coast
After traveling more than 20 feet at a
and set it to Long. Save change and exit
constant speed of more than 0.5 mph (0.8
Configure Mode.
km/h), return the Travel Control Handle
3. Select Learn Mode, Guidance, and Enter. to neutral and allow the lift truck to gently
Pressing the Up arrow at any time aborts coast to a stop. Press Enter. The Wire
the guidance learn process. Guidance Offsets values are now written to
4. The Operator Display Indicator (ODI) the EEPROM on the GM.
displays: 9. The ODI displays:
step on deadman guide both directions until centered then
The ODI displays press auto/man switch to press Enter
auto if it is not already in that position. This is the “Learn Steer Zero” process for
5. The ODI displays: calibrating the guide Drive Unit position
relative to the Steer Center Proximity
center over wire then press Enter
Switch.
NOTE: Pressing the Down arrow allows the Travel speed must be greater than 0.5
Learn Wire process to be skipped and mph (0.8 km/h) and held constant. When
advances you to step 6. This step should these conditions are met for a period of
be performed regardless of the WireFreq two seconds, the alarm horn chirps and
selection in Configure Mode unless the the “Steer Zero Value” for the current
Learn Wire process is being intentionally direction is written.
skipped. If the lift truck was not
previously centered over the wire, do it NOTE: This chirp indicates that the test is not
now. Press Enter. complete, but is collecting data.

6. The ODI displays: Observe the lift truck’s tracking

performance in both directions relative to
busy learning wire
the guide wire. When satisfied, the lift
After approximately 30 seconds, learning
truck is tracking as centered as possible,
the frequency and field strength of the
press Enter to conclude the “Learn Steer
floor signal is accomplished. Their values
Zero” process and return to the main
are written to the EEPROM on the GM.
Learn menu.
NOTE: If the message Learn Wire Failed is 10. In the Configure Mode, return the Coast
displayed, press Enter to retry or press parameter to its original setting.
the Up arrow to abort the guidance learn

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Section 3. Systems Overview Models 5400/5500/5600 Maintenance Manual

Entering Program Mode

NOTE: Manual adjustment of the home next step. If it is less than 1 in. (25.4 mm)
proximity sensor to center the lift truck proceed to step 13.
over the guidewire is no longer required. 11. Drive the lift truck back 10 ft. (3 meters) to
NOTE: DFW Stop is now adjustable from the original position.
1.2 (30 mm) to 3 ins. (76 mm). 12. Use the Up/Down arrows to adjust the
Previously, it was 1.6 (41 mm) to value on the display. More negative
3 ins. (76 mm). numbers cause the lift truck to drive to the
right when driven tractor-first. Changing
Learn Auto Steer Center: the value by one corresponds to a
Use this procedure on lift trucks with Rail deviation of about 0.25 in. (6 mm) over
Guidance and Auto Steer Centering option. 10 ft. (3 meters)
Adjust the center position of the drive unit so 13. Repeat steps 9 through 11 until a
that the lift truck drives straight when in the deviation of 1 in. (25.4 mm) in less over 10
aisle. ft. is achieved.
1. Place the lift truck in an area where there 14. To save the value, press the Enter button.
is a straight line at least 20 ft. (6 meters) in The lift truck’s display will show Save? N.
length, with wire guidance grooves, yellow Press the Up/Down button arrows to
aisle markers, or rails. display Save? Y, then press the Enter
2. Press the rail switch and secure it to button.
simulate a rail. 15. Learn Auto Steer Center is complete.
3. Cycle the key switch OFF and then ON.
Learning Wire Frequency: Software Version
4. Enter SuperWord Mode. 9.3 and Up
5. Select Learn and then Steer. The display
The new GM no longer has the option to select
shows Str XXX where XXX is a number
wire frequency. The GM will automatically
between -50 and 50. This is the steer
detect and set the correct values. The new GM
proximity offset from dead center in 10ths
learn procedure has 3 phases. To store all of the
of degrees.
Wire Guidance values, the learn procedure
6. Step on the deadman pedal. Wait for the needs to be completed.
lift truck to self-center the drive unit.
NOTE: The Heading Angle and Distance From
7. Select “Manual” on the Auto/Manual Wire settings are temporarily set to the
switch. The lift truck is now in “seeking maximum values during the learn
mode” and can be driven with manual process. Travel slowdowns may occur
steering. when learning.
8. Position the lift truck so that it drives
The Learn Procedure is as follows:
parallel to the reference line. Make small
corrections in the steering wheel position Phase 1
until the lift truck can be driven 1. Center the lift truck over the wire with the
10 ft. (3 meters) without deviating from Auto/Manual switch in the Manual
the line more than 1/2 in. (13 mm) position.
without steering.
2. Cycle the Key Switch OFF, then follow the
9. Drive back to the original position. Stop steps on page 3-9 to enter SuperWord
the lift truck. Select “Auto” on the Mode.
Auto/Manual switch. The steer unit will
center and manual steer is disabled. 3. Enter Learn Mode and select Guidance.
The OD reads Step on deadman or
10. Drive forward 10 ft. (3 meters). Measure ENTER to Abort.
the deviation of the lift truck from the
reference line. The deviation should be less 4. Step on the deadman pedal.
than 1 in. (25.4 mm). If not, proceed to the

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Models 5400/5500/5600 Maintenance Manual Section 3. Systems Overview

Entering Program Mode

5. The OD shows Center on wire, then 12. If possible, travel the full length of the wire
ENTER. The lift truck is already centered or until the letter of your travel direction
over the wire. Select ENTER. begins to flash. The display will show a T
6. The OD shows Wait…, and may take up to for tractor first or F for forks first. See
30 seconds to gather signal samples. Figure 3-6.

You are now finished with Phase 1 of the Learn

process.
NOTE: The new wire guidance does not have a
frequency selection. Step 6 is the lift Figure 3-6. Example of Tractor First
truck learning the correct frequency.
Phase 2 13. Once all data points are captured in one
direction, or wire has run out, plug to a
stop and travel in the opposite direction.
7. The OD scrolls Must lock onto wire. Place
14. Continue to drive up and down the wire in
the Auto/Manual switch to the Auto
both directions until the display flashes
position.
OK. See Figure 3-7. This indicates that
8. The OD scrolls Guide tractor first. Drive both directions have collected sufficient
the lift truck tractor first for roughly 20 data points.
feet. Steering will be automatic during this
time. Once you have driven far enough,
the OD scrolls Gently coast to stop.
9. Return the control handle to neutral and
allow the lift truck to gently coast to a Figure 3-7. Collection of Data Points Complete
stop. Select ENTER.
You are now finished with Phase 2 of the Learn 15. Coast to a stop.
process. 16. After coming to a stop, the system will
scroll Press ENTER. Select ENTER.
NOTE: The lift truck speed will be limited to
2.5 mph (4 km/h) for the duration of You are now finished with the Phase 3 of the
this procedure. Learn process.
Phase 3
17. Exit Learn by using the Up and Down
arrows to cycle through the menu. Select
10. The system will scroll Guide both
Quit Lrn. Select ENTER. You are now
directions until centered OK.
back to the main menu.
11. Drive the lift truck through the aisle to
18. Select Quit.
start collecting data points.The lift truck
will beep each time a data point is
captured. The display will indicate how far
the lift truck is deviating from the wire.
See Figure 3-5.

Figure 3-5. Deviation From Wire

NOTE: A beep no longer means that the learn

procedure is finished.

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Section 3. Systems Overview Models 5400/5500/5600 Maintenance Manual

Entering Program Mode

Maintenance Mode
Maintenance Mode allows service technicians to
test individual circuits within the system.
During Static Maintenance Output Tests,
Maintenance Mode is accessed through
always jack the drive tire off the floor
Program Mode after the SuperWord is entered.
and open the Emergency Lowering
Refer to page 3-9 for information on procedures
Valve.
for accessing Maintenance Mode.
NOTE: If the test does not appear in the Use extreme care when the lift truck is
Maintenance Mode menu for an option jacked up. Never block the lift truck
when you think it should, either that between the telescopic and the floor.
option is not enabled (through Attach an appropriately rated rigging
FlashWare) or the lift truck does not device to the top of the mast, and an
have the latest software. overhead hoist to stabilize the mast if
jacking higher than described in the
General Jacking Safety section. Keep hands and
feet clear while jacking the lift truck.
NOTE: If you need to enter Maint several times
After the lift truck is jacked, place solid
to resolve a problem, it may save time if
blocks or jack stands beneath it to
SuperWord is temporarily changed to a
support it. Lower the lift truck onto the
single digit code. Remember to re-enter
blocks or jack stands. Do not rely on the
the correct SuperWord when you are
jack or jack stand alone to support the
done.
lift truck. See “Jacking” on page 2-9.

By entering Static Maintenance Mode,

the safety circuits associated with the
Disconnecting wires or connectors to
system are disabled. Extra precautions
integrated circuits with power on can
must be taken in Static Maintenance
result in premature failure of those or
Mode. Follow all instructions contained
other components. Always disconnect
in this manual for each test. If you are
the battery before making or breaking
unsure how to conduct a test while in
any connections.
Maintenance Mode, do not proceed with
the test. Contact a certified Raymond
When removing a connector, do not pull on the
technician.
wires to separate the connection.
All circuit cards are conformal coated. When Static Maintenance Mode
testing circuit cards, make sure a good
In Static Maintenance Mode, the lift truck is
electrical connection is made between the board
inoperative. This mode allows the technician to
test point and the probe. This eliminates false
test and operate individual circuits without
results.
operating the lift truck. All tests are available
during static testing.
If Digital Outputs are selected from Maint, the
OD displays:
Warning jack up the drive wheel, press enter
when ready
Press Enter to start Maintenance Mode. The
Up/Down buttons are used to turn the test on
and off.

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Models 5400/5500/5600 Maintenance Manual Section 3. Systems Overview

Entering Program Mode

Active Maintenance Mode Event Log

Active Maintenance Mode (Act Maint) permits The Event Log (Evtlog) stores the last twenty
testing of various systems on the lift truck. In error codes recorded on the lift truck. Entries
Active Maintenance, all Analog and Digital tests are stored in order of occurrence, with the most
can be selected with the results displayed while recent error first.
operating the lift truck in Run Mode. To enable
To access the Event Log, use the Up/Down
a test for Active Maintenance:
buttons to scroll to Evtlog and press Enter.
1. Enter Program Mode using SuperWord.
If no errors are stored, Empty is displayed.
2. Scroll to Maint and press Enter.
If errors have been logged, use the Up/Down
3. Scroll to Act Maint and press Enter.
buttons to scroll through the list.
4. Select enable. This enables all Input and
Analog tests. To clear the log, use the Up/Down buttons to
scroll to Clr log. Press Enter. Scroll to Clr yes
5. Scroll back to Act Maint, Quit Mnt, and and press Enter.
press Enter.
6. Quit Program Mode. The lift truck will go
through SelfTest.
7. When SelfTest completes, Analog and
Input are now visible when scrolling
through the display selections. Choose
either Analog or Input.
You may now choose any available Analog or
Input test to monitor while the lift truck is
operating in Run Mode.
To turn Active Maintenance off and follow steps
1 and 2 above. At step 3, scroll to Disable and
press Enter. Follow steps 4 and 5 to enter Run
mode. Tests will no longer be available when
scrolling through the display options.
All tests can be selected. Individual tests can be
turned off by going back to that test in Maint
and pressing Enter. The asterisk disappears.
The tests selected for Active Maintenance are
stored in memory even if the key switch is
turned OFF.
To select one of the Active Maintenance tests,
press the deadman pedal and use the Up/Down
buttons to select the test you want displayed
while operating the lift truck. The test selected
remains on the display until another test or
display selection is made.

Power Amplifier Reset

Power Amplifier Reset (PA Reset) returns the
power amplifier back to its default baud rate of
125K. This feature is helpful when the power
amplifier is to be returned to stock or installed
on a different model lift truck.

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Section 3. Systems Overview Models 5400/5500/5600 Maintenance Manual

FlashWare

FlashWare the PC and the J9 connector on the VM.

See Figure 3-8. Make sure that the port for
the P/N 610-809/W7P cable is set
Overview correctly.
NOTE: Refer to FlashWare Help for specific
FlashWare allows you to update software, view FlashWare related topics.
and configure options on the lift truck through
the following features:
Serial connector (J9)
• Update Vehicle Manager software
• Clear Primary Memory
• Clear Vehicle Manager
• Reset factory default settings
• Update Display software
• Update Power Amplifier Software

For more detailed FlashWare information, click

on “Help” and select “Help Topics” from the
menu bar. Figure 3-8. Lift Truck FlashWare Connections

FlashWare can be installed on any PC. The PC

communicates with the truck software via a Starting FlashWare
serial (9 pin) or USB port. 1. With the key switch ON, double-click the
FlashWare icon on the main desktop
Installing FlashWare on a screen or navigate via Start > Programs >
Windows Compatible Device FlashWare. The lift truck Opening Screen
appears. See Figure 3-9.
If you are a customer service technician, obtain
FlashWare from your Raymond Sales and
Service Center.

If you are a Raymond Sales and Service Center

technician, obtain FlashWare from the
Raymond Portal software download site.

To install FlashWare on the PC, double-click the

installation file and follow the instructions on
the screen. The software package is a
self-extracting executable file. Read the Figure 3-9. Lift Truck Opening Screen
“Readme” file in the software package for the
latest detailed installation instructions. NOTE: When entering or using FlashWare, it is
normal for a 50 Series Code to be
displayed.
Connecting Device to Lift Truck
2. From the menu bar, click
There is one method available to connect the “Communications”, then select connection
device to a manager: COMx (9-pin Serial).
• USB to Serial - this method requires the NOTE: “x” numbers vary depending on the
correct drivers to be installed on the computer configuration.
device. With the key switch OFF, connect
cable P/N 610-809/W7P to a USB port on

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Models 5400/5500/5600 Maintenance Manual Section 3. Systems Overview

Starting FlashWare

3. From the menu bar, click “Connect to

Truck”, then select “All Other Trucks”. If
the device is connected to a correctly
functioning VM, the Lift Truck Setup
screen is displayed.
NOTE: Refer to FlashWare Help for specific
FlashWare related topics.

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Section 3. Systems Overview Models 5400/5500/5600 Maintenance Manual

Wire Guidance

Wire Guidance Wire Guidance Setup

This procedure should not normally have to be
Wire guidance is a means to automatically steer performed. For the lift truck to guide correctly,
the lift truck while traveling in an aisle. It offers the following must be true:
precise steering at full-speed travel in Very
• for 5.2 kHz, the current through the guide
Narrow Aisle (VNA) applications.
wire must be 100 mA peak-to-peak ±10%
A wire guidance system consists of two • for 6.25 kHz, the current through the
sub-systems. guide wire must be 225 mA peak-to-peak
• Warehouse-installed equipment includes a ±10%
guide wire and line driver. The guide wire
NOTE: For S/W version 9.3 or higher, the
is installed in the floor and emits an
frequency is not selectable.
Alternating Current (AC) signal at a
specific frequency and amplitude If the warehouse portion of the guidance system
generated from the line driver. has a different line driver output, refer to Learn
• Lift truck-installed equipment includes: WireFreq on page 3-21.
• Two guidance sensors, tractor end and
load end
• Guidance Manager (GM)
• Steer feedback encoder
• Auto/Manual switch, on operator
console
• Associated cables and mounting
brackets
The lift truck must learn the amplitude
and frequency of the guidance signal to
correctly track the guide wire.
NOTE: This manual covers all lift
truck-installed equipment. For
information on warehouse-installed
equipment, refer to PDSS-0051,
Raymond Wire Guidance.
To operate wire guidance, refer to the operator
manual.

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Models 5400/5500/5600 Maintenance Manual Section 3. Systems Overview

Cold Storage

Cold Storage
Cold storage is an option that enables lift truck
operation in temperatures of –20°F (–28.86°C)
to 40°F (4°C).
On cold storage lift trucks, the electrical panel
on the tractor is completely enclosed to contain
heat. Components added to the lift truck for
cold storage are listed in the table below and
shown on the electrical schematic.

Heater Assemblies

Location
Components
Carriage Control Card Control Handle Deadman Pedal

Heating elements HTRC HTRH HTRDM

Thermostats S81 S91 S80

Fuses FU21 (10A) None FUDM (5A)

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Section 3. Systems Overview Models 5400/5500/5600 Maintenance Manual

Storage

Storage the reservoir is full before storing. Before

returning the lift truck to service, drain the
reservoir and change the filter. Fill the reservoir
If the lift truck is going to be stored for any
with new hydraulic fluid. Operate the hydraulic
length of time, cover the lift truck with canvas
systems slowly to allow internal components to
or plastic.
be lubricated.
If the lift truck is going to be stored for more
NOTE: If the lift truck is going to be stored for
than 30 days, jack and block the lift truck up more than six months, spray hydraulic
off the floor. components with a silicone protectant.
Do not let silicone protectant spray get
on circuit cards.

Use extreme care when the lift truck is

jacked up. Never block the lift truck
Hydraulic Cylinders
between the telescopic and the floor. Store the lift truck with the cylinder pistons
Attach an appropriately rated rigging retracted. Coat all exposed chrome surfaces of
device to the top of the mast, and an the piston with hydraulic fluid.
overhead hoist to stabilize the mast if
jacking higher than described in the
Jacking Safety section. Keep hands and Lift Chains
feet clear while jacking the lift truck. Liberally coat all chains with oil to prevent rust
After the lift truck is jacked, place solid and corrosion.
blocks or jack stands beneath it to
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the Electronics
jack or jack stand alone to support the Make sure all electronics stay dry.
lift truck. See “Jacking” on page 2-9.

Warranty
The Raymond Corporation must be contacted
by an authorized Raymond Sales and Service
Center for the correct warranty procedures.

Motors
The brushes in DC motors must be lifted away
from the commutator surface. When preparing
the lift truck for service, the surface must be
inspected and polished, if necessary, using a
rubber abrasive polish. Polishers are
specifically made for polishing commutators. Do
not use a stone.
Periodically rotate the motor shafts to coat the
bearings with lubricant, reducing the possibility
of oxidation and corrosion.

Hydraulic System
The hydraulic system will absorb moisture
when left standing for a long time. Make sure

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Models 5400/5500/5600 Maintenance Manual Section 3. Systems Overview

UL Label “EE”

UL Label “EE”
Underwriters Laboratories (UL) ratings indicate
that specific criteria have been met by the
manufacturer, and tested and documented by
UL. “EE” designated lift trucks are electrically
powered units that have, in addition to all of the
requirements for “E” and “ES” units, electric
components completely enclosed. In certain
applications, an “EE” lift truck may be used
where an “E” or “ES” lift truck may not be
considered suitable.

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Section 3. Systems Overview Models 5400/5500/5600 Maintenance Manual

UL Label “EE”

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Models 5400/5500/5600 Maintenance Manual Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance

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Section 4. Scheduled Maintenance Models 5400/5500/5600 Maintenance Manual

Maintenance Guidelines

Maintenance Guidelines
Following a regularly scheduled maintenance
program:
• Promotes maximum lift truck performance
• Prolongs maximum lift truck life
• Reduces costly down time
• Prevents unnecessary repairs

Scheduled Maintenance includes:

• Lubrication
• Cleaning
• Inspection
• Service

Perform all of the scheduled inspections and

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

When operating under severe or extreme

conditions, do these services more often as
specified in Table 4-1.

Table 4-1. Maintenance Frequency

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

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Models 5400/5500/5600 Maintenance Manual Section 4. Scheduled Maintenance

Maintenance Minder™ Tool

Maintenance Minder™ Setting Time Interval and Action

Option
Tool
The first time you enter the time interval menu,
Maintenance Minder Tool is a feature that alerts the Factory Suggested setting, followed by the
the operator when the lift truck is due for letters FS is displayed. Subsequently, when you
scheduled maintenance. enter the time interval menu, the last used
setting is displayed. Values from 50 to 500
Maintenance Minder, when configured and hours, in increments of 50, are available. Use
enabled, monitors the Hours on Deadman (HD) the Up/Down button to scroll to the desired
meter. When the time interval for scheduled time interval. With the desired value displayed,
maintenance is exceeded, the operator is press the Enter button.
informed in the following ways:
Use the Up/Down button to select the desired
• One of two messages scrolls on the OD for
action option. Then press the Enter button.
at least 30 seconds following the DAILY
CHECKLIST message: • MSG ONLY causes the OD to show
SCHEDULED MAINTENANCE DUE when the
Scheduled maintenance due
scheduled maintenance time interval is
or
exceeded.
Lift cutout, scheduled maintenance due
• L CUTOUT causes the OD to show LIFT CUT
• A wrench icon flashes OUT, SCHEDULED MAINTENANCE DUE when the
• The audible alarm sounds the high-low scheduled maintenance time interval is
tone for approximately 5 seconds exceeded. Lift is disabled the next time the
power circuits are cycled.
Lift Cutout, when active, does not disable the
lift function until power to the control circuits is Use the Up/Down button to select QUIT MM from
cycled (key switch OFF or battery the submenu. If the status has changed, you
disconnected). When control circuit power is are prompted to save changes. Press the Enter
cycled, lift is disabled until Maintenance Minder button.
is reset or disabled, or the lift cutout option is NOTE: From the Config Menu, exit by selecting
turned OFF. QUIT CFG. You will not be prompted again
to save changes, but any changes saved
Enabling when you QUIT MM are retained.

Once installed in the configuration options, Changing Time Interval or

MAINTENANCE MINDER appears in the Configure
Mode menu. The initial factory setting is Action Option
DISABLE. To enable the feature, enter Configure
Mode. When Maintenance Minder is active, and you
wish to change the time interval or action
NOTE: For instructions on selecting Modes of option, enter Configure Mode.
Operation, see Modes of Operation on
page 3-8. With Configuration Mode selected, use the
Up/Down button to display the MNT MIND item.
With Configuration Mode selected, use the Press the Enter button. When entered from an
Up/Down button to scroll to display enabled state, Maintenance Minder offers a
MAINTENANCE MINDER. Press the Enter button. submenu with the options QUIT MM, RESET,
When entered from a disabled state, DISABLE, and SETUP. Use the Up/Down button to
Maintenance Minder offers a submenu with the select SETUP, then press the Enter button. The
options QUIT MM and ENABLE. Use the Up/Down current time interval is displayed (hours).
button to select ENABLE. Press the Enter button.

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Section 4. Scheduled Maintenance Models 5400/5500/5600 Maintenance Manual

Resetting Maintenance Minder

Proceed as described under “Setting Time

Interval and Action Option” on page 4-3.

Resetting Maintenance Minder

When Maintenance Minder is active, and, after
you have performed scheduled maintenance,
you wish to reset the reminder prompt, enter
Configure Mode.

With Configuration Mode selected, use the

Up/Down button to display the MNT MIND item.
Press the Enter button. Use the Up/Down
button to select RESET, then press the Enter
button. Select QUIT MM and press the Enter
button again. Save changes, as prompted.

Disabling
When Maintenance Minder is active and you
wish to disable it, enter Configure Mode.

With Configuration Mode selected, use the

Up/Down button to display the MNT MIND item.
Press the Enter button. Use the Up/Down
button to select DISABLE, then press the Enter
button. Select QUIT MM and press the Enter
button again. Save changes, as prompted.

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Models 5400/5500/5600 Maintenance Manual Section 4. Scheduled Maintenance

Initial 90 Day/250 Deadman Hours (HD) Maintenance

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

Component What to do

Drive Unit Break mounting bolts free and reapply thread-locking compound
(P/N 990-544). Re-torque standard drive unit mounting bolts to 180 ft. lb.
(244 Nm). Re-torque heavy duty drive unit mounting bolts to 350 ft. lb.
(475 Nm).

Hydraulic Tank Change filter.

Power Amplifier(s) Torque power amplifier terminal bolts - 100 in. lb. (11.3 Nm).

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Section 4. Scheduled Maintenance Models 5400/5500/5600 Maintenance Manual

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 What to do Refer to

Battery Check the weight stamped on the battery in the lift truck against the
minimum and maximum allowable weights on the specification tag Page 3-3
for the lift truck. Report any lift trucks that are running with
batteries under the minimum or over the maximum allowable weight. Page 5-2
Inspect all battery connectors and leads for damage and cuts in
protective coatings. Make sure the battery gates are in place and not
damaged. Make sure the battery has no more than 0.5 inch (13 mm)
free play in any direction.

Brakes In an open area, measure stopping distance. Traveling to 2 to 3 mph

(3.2 to 4.8 km/hr) empty, push the EPO switch. The empty lift truck Page 7-63
should stop within 2 to 4 feet (0.6 to 1.2 m). During normal
operation, with a rated load and traveling at top speed, the lift truck
should stop within approx. one and one-half lift 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 the brake, clean the rotor and replace the pads. Check
brake gap.

Contactors Inspect contactor tips for burnt or pitted surfaces. Failure to replace
the tips may prevent the contactor from opening or closing causing Page 4-12
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 Handle Verify that travel function is smooth and responsive through full Page 7-21
range of motion. Check for play in the center position of the travel
control. Verify all handle switches function correctly.

Deadman Pedal Check for smooth operation with no binding. Check for correct Page 7-27
activation and deactivation of the deadman switch by the pedal.

Drive Unit Inspect for leaks. Check the fluid level. Make sure the O-ring is Page 7-29
present on the dipstick. Examine for radial ring wear. Apply grease to
the steer gear on the drive unit. Lubricate all grease points on the
drive unit.

Electrical Cables Inspect all power cables for nicks or cuts. Give special attention to
cables 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 pulley
cables. Set tension so the cables just stay on the pulleys. Higher
tension causes premature failure. Maximum spring tension is 5 to 7
in. lb. (0.57 to 0.79 Nm).

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Models 5400/5500/5600 Maintenance 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 What to do Refer to

Forks Examine for excessive wear, bends, cracks, welding arcs, excessive Page 7-125
heat, or unauthorized modifications and replace if found. Check fork
up tilt. It must be between level and 0.5 in. (12.7 mm) maximum.
Check fork tip height. Verify they are within 0.25 in. (6.3 mm) of each
other (31 in. and longer) or 0.125 in. (3.2 mm) of each other (under 31
in.) at the tips.

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

Hardware Check bolt torque of major components (motors, pumps, brake, drive Appendix
unit, and mast-to-tractor mounting bolts).
If the fastener was previously marked with a paint pen when torqued,
look at the markings to verify the fastener has not moved. If the
fastener has moved or is in question, remove the fastener, clean the
threads, and apply the appropriate thread-locking compound. Install
the fastener and torque to the correct value. Use a paint pen and
mark the fastener for future inspection.
If the fastener was not previously marked with a paint pen, determine
the correct torque values. Set the torque wrench to 85% of the
required torque value and check the torque of the fastener, turning it
in the tightening direction. If the fastener does not move, use a paint
pen and mark the fastener for future inspections. If the fastener
moves, remove the fastener, clean the threads, and apply the
appropriate thread-locking compound. Install the fastener and torque
to the correct value. Use a paint pen and mark the fastener for future
inspections.
Replace any broken or missing hardware.

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

Hydraulic Hoses Inspect all hydraulic hoses for leaks, nicks, cuts, chafing, and bulges.
Replace damaged hoses as soon as possible. Inspect all fittings for
leaks. Repair any leaks immediately. Inspect over-the-mast hoses for
correct tension. Make sure over-the-mast pulleys spin freely and
show no signs of wear.

Hydraulic Tank Check the fluid level.

Lift Chains Check adjustment. Page 4-11

Adjust the main lift chains so the top of the inner telescopic is even Page 7-129
with the outer telescopic ±0.125 in. (3.2 mm) and both chains have
equal tension.
Adjust the free lift chains so the top of the fork, near the platform, is
at a minimum of 2.75 in. (70 mm) and the tips are at a maximum of
3.5 in. (89 mm) from the floor. Inspect center cylinder chain anchors
and springs. Inspect for excessive stretch or wear (tool P/N
939-10606).

Lubrication Lubricate all grease points on the drive unit and load wheels. Apply Page A-2
grease to the steer gear on the drive unit. Coat all lift chains with
spray lubricant.

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Section 4. Scheduled Maintenance Models 5400/5500/5600 Maintenance Manual

Every 180 Days or 500 Deadman Hours (HD)

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

Component What to do Refer to

Mast Wipe old grease off mast uprights and apply new grease. Inspect
anti-rattle pads. Examine mast bearings. Inspect mast and carriage Page 7-117
stops for tightness and wear. Inspect rails for abnormal wear, metal
flakes, or shavings. Repair any grooves worn in the mast deeper than
1/8 in. (3 mm).

Motors AC - Check cable lugs. Make sure they are tight to the terminal
studs. The outside nut should be torqued to the value listed on
page 7-74. 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 the condition of the commutator per photos
on page 5-11. Find the shortest brush in the holder. Remove each
brush and check overall dimension per the table on page 7-76.
Inspect each 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 the brush spring tension. Blow out the inside of the motor
with compressed air. Blow out the impeller and cooling fins. Make
sure cable lugs are tight to the terminal studs. The inside and outside
nuts should be torqued to the values listed on page 7-74. Replace any
cable that shows signs of excessive heat. Check sensor wires for
sound connection and condition.

Overhead Guard Inspect the guard for physical damage. If structurally damaged,
replace the carriage.

Pallet Clamp Check the operation of the pallet clamp.

Power Amplifier(s) Torque the power amplifier terminal bolts to 100 in. lb. (11.3 Nm).

Safety Belt or Check for signs of wear, fraying, or damage.

Harness and Tether

Shorts to Frame Check for electrical shorts to frame. Page 5-2

Skid Pads To check floor clearance, park the lift truck on a level and flat floor
surface. Measure the clearance between each skid pad and the floor.
Correct clearance is 0.31 to 0.56 inches (8 to 14 mm). If clearance
exceeds 0.75 inch (19 mm), the skid pads must be replaced.

Static Straps Make sure the static straps are not worn or broken. Clean debris
from the straps. Check the resistance of the resistor in standoff. The
resistance must measure >200K and <250K. EE lift trucks require a
phosphor bronze static strap; do not use steel braided cable on EE lift
trucks.

Steering Check the steering system function is smooth and responsive,

without binding and excessive play. Inspect teeth on the steer gear
and drive unit for wear.

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Models 5400/5500/5600 Maintenance 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 What to do Refer to

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

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

Warning Decals Replace any illegible or damaged decals.

Warning Lights Check for correct operation.

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

Wire Guidance Check the sensor assemblies for damage and mounting hardware for
tightness. Verify the lift truck acquires and tracks the guide wire
correctly. Verify the brake is applied when the lift truck loses the
wire.

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Section 4. Scheduled Maintenance Models 5400/5500/5600 Maintenance Manual

Every 360 Days or 2000 Deadman Hours (HD)

Every 360 Days or 2000

Deadman Hours (HD)

Perform the following maintenance tasks every 360 days or 2000 HD, whichever comes first.

Component What to do Refer to

Drive Unit Change the fluid. Page A-2

Hydraulic Reservoir Change the fluid and filter. Page A-2

Lift Pump Separate the lift pump and motor. Apply lubricant (P/N 1223184) to Page 7-102
the spines.

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Models 5400/5500/5600 Maintenance Manual Section 4. Scheduled Maintenance

Chain Maintenance

Chain Maintenance
Lift Chain Inspection
Make sure the chains are not damaged. Check
the chain for wear using a Chain Gauge
(P/N 939-10606).

Condition Cause Maintenance Procedure

Use a chain gauge or lay the chain on a flat

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

Steam cleaning or degreasing new

Rust and Corrosion Lubricate chain frequently.
lift truck chains

Infrequent Oiling

Rust
Cracked Plates Replace the chain.
Corrosion

Chain Fatigue

Bent pins or plates Replace the chain.

Tight Joints
Rusty joints or peened plate edges Replace the chain.

Chain Side Wear Chain misalignment Replace the chain.

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Section 4. Scheduled Maintenance Models 5400/5500/5600 Maintenance Manual

Contactor Tip Inspection

Contactor Tip Inspection

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

Figure 4-1. Severely Pitted Contactor

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

Section 5. Troubleshooting

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

Electrical Troubleshooting

Electrical • Whenever measuring resistance, turn the

key switch OFF and disconnect the battery
Troubleshooting connector. Battery current can damage an
ohmmeter. Isolate the component from the
circuit.
General • Before replacing an electrical component,
disconnect and clean all jack/pin
connectors on the component(s) with
contact cleaner (P/N 990-600/CC3).
Reconnect and retest truck.
Block the lift truck so that the drive tires
are off the floor whenever a
troubleshooting procedure requires Shorts to Frame
turning the key switch ON. This prevents
accidents caused by unexpected lift “Shorts to frame” is an industry term for
truck travel. unintentional current leakage paths between
normally isolated electrical circuits and their
Unless otherwise directed, disconnect metal enclosures.
the battery connector when you check
electrical circuits or components with an Shorts to frame may be metallic connections,
ohmmeter. Electrical current can damage such as a wire conductor contacting metal
an ohmmeter. through worn insulation. More often, shorts to
frame are resistive “leakage” paths caused by
Before removing a power amplifier, contamination and/or moisture.
discharge the amplifier’s internal
capacitor by jumpering the + and – These leakage paths can result in unwanted
terminals with a 100 ohm 25W resistor. electrical noise on the metallic lift truck
structure and can cause incorrect operation.
• Many problems can be caused by a dirty
battery. Make sure the battery is clean. Shorts to frame are caused by:
• Save time and trouble by looking for • Accumulation of dirt
simple causes first. • Battery electrolyte leakage
• Use a Digital MultiMeter (DMM) such as a • Motor brush dust
Fluke meter for all measurements. Analog
• Motor brush leads touching the housing
meters can give inaccurate readings and
load down sensitive electronic circuits • Breakdown in insulation
enough to cause failure. Make sure meter • Bare wires
cables are connected to the correct meter
• Pinched wiring harness
jacks and that the correct function and
scale are selected. • Incorrect mounting of circuit cards
• Printed circuit boards are conformal
Shorts to frame can occur at numerous
coated. Make sure meter leads make a
locations on a lift truck, including:
good electrical connection with test points.
• Batteries
• When measuring voltage, connect the
positive meter lead to the connector or • Motors
probe point marked (+) in the test. • Cables, wiring, and harnesses
Connect the negative meter lead to the
• Heatsinks
connector or probe point marked (–).
• Bus bars
• Solenoids

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

Shorts to Frame

• Contactors 4. With the battery disconnected (or removed

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

Install another battery in the lift truck and • Motors

repeat this procedure from step 1. • Heatsinks
• Power cables
If the test light does not illuminate,
• Power circuit components
continue to the next step.
3. Use a DMM set on the ampere function to • Control circuit components
measure the current leakage from the c. Repair or replace the component
battery case to battery B+ and from the causing the low resistance condition.
battery case to battery B– (not lift truck B+ Repeat step 4.
and B–). Begin measuring at the highest d. Reconnect all other components
ampere scale and work toward the lowest. previously disconnected, one at a time,
A reading of more than 0.001A (1mA) measuring resistance between steps. If
indicates a serious short. Do not continue a reading is <1000 ohms when
until this condition is corrected. The meter reconnecting a component, that
may be damaged if you proceed before component or its wiring is faulty.
correcting this condition. Repair or replace as appropriate.

Install another battery in the lift truck and e. When, after all components are
repeat this procedure from step 1. reconnected, you get readings
>1000 ohms, continue with the next
If the current is <0.0002A (0.2mA), go to step.
step 4. If the current is >0.0002A (0.2mA) 5. Reconnect the battery connector and turn
and <0.001A (1mA), remove the battery the key switch ON. If the battery was
from the lift truck, then continue with previously removed, make sure the battery
step 4. Make sure the battery case does case does not touch the lift truck frame.
not touch the lift truck frame during the
remaining tests. NOTE: The functions being checked must be
energized. For example, to check for

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

Shorts to Frame

shorts to frame in the travel circuit,

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

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

Battery State-of-Charge

Battery State-of-Charge configured at 95%, plugging in a battery at

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

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

Fuses

Fuses
Test /Inspection

Examine the fuse for signs of overheating,

discoloration, cracking, or other physical
damage. Replace as necessary.

To test a fuse, remove it from the lift truck or

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

Fuse Function Location Amps

FU1 Power Fuse for Steer Power Amplifier 100

FU2 Power Fuse for Traction Power Amplifier 350

Contactor Panel
Power Fuse for Lift Power Amplifier - Model 5500, 5600 500
FU3
Power Fuse for Lift Motor - Model 5400 350/Hi-Pro - 500

FU5 Control Fuse for Vehicle Manager B+ 15

FU6 Control Fuse for Vehicle Manager B– 15

FU7 Control Fuse for Aux Power B+ 5

Fuse/Relay Card
FU7 Control Fuse for Aux Power B+ with Cold Storage Option 15

FU8 Control Fuse for Aux Power B– 5

FU8 Control Fuse for Aux Power B– with Cold Storage Option 15

FU9 Control Fuse for RF Terminal B+ Carriage Console 2

FU10 Control Fuse for RF Terminal B– Plate 2

FU21 Control Fuse for Cold Storage CCC Heater CCC Heater Plate 10

Control Fuse for Cold Storage Deadman Heater Carriage Console 5

FUDM
Plate

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

Fuses

Electrical Connector Locator Chart

Table 5-2. Connector Locator Chart

Connector Function or Routing Location

FSUP Connector on Fan Suppressor Near Fan

HTR3 Connector for Deadman Heater Near Deadman

J1 Connector for Lift/Lower Pendant Near VM in Main Harness

JP1 Connector for Lights Light Assembly

JP1L Connector from Load Wire Guidance Antenna to Filter Card Load Antenna

JP1T Connector from Tractor Wire Guidance Antenna to Filter Card Tractor Antenna

JP2 Connector for Lights Light Assembly

JP10 Connector for Warning Light Under Warning Light

JPA7 Connector for Home Sensor Hydraulic Compartment

JPB– (–) Battery Connector

Battery Connector
JPB+ (+) Battery Connector

JPB1 Connector on Lift Motor Fan (EE only) Near Lift Motor

JPBR Connector for Brake Near Brake Assembly

JPC1 Connector for Steering Encoder

JPC2 Connector for Display Card

JPC3 Connector for 60 in. Limit Switch

JPC4 Connector for Lower Inhibit

JPC5 Connector for Lights/Fans

JPC6 Connector for Lift/Lower Bypass Switch

JPC7 Connector for Deadman Switches

JPC8 Connector for 24 in. Limit Switch

JPC9 Connector for Control Handle Carriage Control Card

JPC11 Connector for Over-the-Mast Cable Number One

JPC12 Connector for Spare Power

JPC13 Connector for Sidegate Switches

JPC14 Connector for Sidegate Switches

JPC15 Connector for Light Display Card

JPC16 Connector for Over-the-Mast Cable Number Two

JPC17 Connector for Aux Card

JPC18 Connector for Aux Card

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

Fuses

Connector Function or Routing Location

JPC19 Connector for Aux Lift and Lower Switch

Aux Card
JPC20 Connector for Aux Limit Switch

JPC21 Connector for Secondary Steer Input Encoder Carriage Control Card

JPC23 Connector on Aux Card for Aux Deadman Aux Card

JPE4 Connector for Steer Motor Encoder Hydraulic Compartment

JPF1 B– Aux Power and B+ Power Amps Connector

JPF2 B+ Key Switch Relays Connector

Fuse/Relay Card
JPF3 B– Connector

JPF4 Key Switch, EPO, Battery Sense Connector

JPLA1 Lift Amp Connector Lift Amplifier

JPLA2 Lift Motor Encoder Connector

Near bottom of Lift Motor
JPLA3 Lift Motor Temperature Sensor Connector

JPLA4 Lift Motor Encoder/Temperature Sensor Connector Hydraulic Compartment

JPS1 Contactor Panel Interface Connector Contactor Panel

JPS2 Wire Guidance Power Connector

Guidance Manager Card
JPS4 Wire Guidance Communications Connector

JPS8 Connector for 120 in./150 in. Limit Switch

Behind Fuse/Relay Card
JPS10 Connector for Lift Inhibit Switch

JPS15 Connector for Travel Alarm Near Lift Amp

JPS16 Connector for Travel Cutout Switch

JPS25 Connector for Over-the-Mast Cable Number One Behind Fuse/Relay Card

JPS26 Connector for Over-the-Mast Cable Number Two

JPS27 Connector for Over-the-Mast wires for optional equipment Over-the-Mast wiring

JPS28 Connector for 180 in. Limit Switch Behind Fuse/Relay Card

JPS50 Connector for Pressure Transducer A

Hydraulic Compartment
JPS51 Connector for Flow Module

JPS52 Connector for Lift/Lower Alarm Behind Fuse/Relay Card

JPS53 Connector for Rail Sense Switch Near Horn Assembly

JPS54 Connector for Aisle Detect Sensor Number One

Hydraulic Compartment
JPS55 Connector for Aisle Detect Sensor Number Two

JPS57 Connector for Lift Cutout Behind Fuse/Relay Card

JPSC1 Splice for CAN Bus Below Battery Connector

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

Fuses

Connector Function or Routing Location

JPSC2 Splice for CAN Bus Behind Drive Motor

JPT2 USB Connector

JPT4 Connector

JPT6 Electric Steer Connector

JPT9 FlashWare Connector

JPT10 CAN Digital Inputs and Outputs Connector

JPT12 Lift Pendant Connector Vehicle Manager

JPT14 B+, B–, CAN Communications Connector

JPT18 Coil Drivers Connector

JPT20 Proportional Coil Drivers Connector

JPT22 Digital Inputs Connector

JPT24 Analog Inputs Connector

JPTA1 Traction Amp Connector Traction Amplifier

JPTA2 Traction Motor Encoder Connector Near Bottom of Drive

JPTA3 Traction Motor Temperature Sensor Connector Motor

JPTA4 Traction Motor Encoder and Temperature Connector Top of Drive Motor Power
Cables

JPW1 Connector for Load Sensor Filter Card GM P/N

1183339
JPW2 Connector for Tractor Sensor GM Card P/N
1268588/001

JPY1 Connector for Flow Module

JPY2 Connector for Flow Sensor Temperature Sensor

Flow Module
JPY6 Connector for Flow Sensor Channel One

JPY7 Connector for Flow Sensor Channel Two

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

DC Motors

DC Motors Figure 5-2. Mica Undercutting

Mica Segment
Types of DC Motors
NORMAL
There are two primary types of DC Motors (refer UNDERCUT
to Figure 5-1):
• A series-wound motor has only two
High Mica
external connections because the
armature and field windings are connected
internally.
• A permanent magnet motor has two
HIGH MICA
external connections. The field is produced
by an internal magnet.
The commutator must be smooth and clean to
NOTE: Field connections may be labeled A or S. provide maximum brush wear. When
Series wound motor field connections commutators are not correctly maintained,
may be labeled D. carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
Series-Wound Motor Permanent Magnet the armature.
S/D Motor
MS+
A2 Remove the brushes from their box. Inspect the
contact surface and brush length. If the brush
surface has groove(s) or pit marks, it indicates
MS
the presence of a burr on the commutator
surface.
MS–
A1
MP Good commutation is indicated by a dark
brown polished commutator and an evenly
A polished brush wearing surface. See
“Commutator Surfaces” on page 5-11.
Figure 5-1. Motor Circuits
If the commutator appears rough, pitted, or has
Inspection signs of burning or heavy arcing between the
commutator bars, remove the motor for
Inspect the commutator for surface condition servicing.
and high mica. Most armatures have the mica
undercut. If the armature on your motor does Servicing
not, do not attempt to cut it.
Some conditions identified in Table 5-3 may be
resolved by cleaning the commutator with a
special polishing stone. Polishing the
commutator should only be attempted for these
specified conditions. Refer to “Polishing the
Commutator” on page 7-76.

Some conditions can be resolved by recutting

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

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

DC Motors
Table 5-3. Commutator Surfaces

Condition Probable Cause Commutator Surface

Uniform coloring indicates satisfactory
BRUSHWEAR01.tif

operation of the machine and brushes.

Good Condition-Light Film Acceptable film color may vary from light to
dark due to film thickness.

This condition can appear in alternating bars as

BRUSHWEA03.tif

shown or every 3rd or 4th bar. This is caused by

Satisfactory Condition-Light imbalances in the windings or other motor
and Dark Pattern variances and is not an indication of
commutator problems. The motor should have
no issues running, however this condition may
indicate a need for more frequent inspections.
Threading or streaked film on the commutator
BRUSHWEAR04.tif

surface. May be accompanied by rattling or loud

Unsatisfactory operation. Frequently due to incorrect brush
Condition-Streaky Film with grade. Environmental conditions such as
No Commutator Wear freezer or low humidity, can be a contributing
factor. This condition may be repaired with a
polishing stone if caught soon enough. Refer to
Polishing the Commutator on page 7-76.
Patchy colors of varying densities and shape.
BRUSHWEAR05.tif

This condition is generally due to unclean

Unsatisfactory operating conditions and does not indicate
Condition-Uneven Film damage to the commutator. Clean the
commutator with a polishing stone and
compressed air (refer to Polishing the
Commutator on page 7-76). Consider more
frequent scheduled maintenance intervals.
Dark areas can be isolated or regular. Indicates
BRUSHWEAR06.tif

Unsatisfactory Condition- the commutator is out-of-round. Continued use

Film With Dark Areas may result in failure and damage to other
systems. Motor should be replaced or recut at a
qualified repair facility.
Bars are low on entry and leaving edges causing
BRUSHWEAR07.tif

Unsatisfactory brushes to rub on the middle of the bars.

Condition-Example of Continued use may result in failure and
Incorrect Commutator damage to other systems. Motor should be
Machining replaced or recut at a qualified repair facility.
Consider more frequent scheduled maintenance
intervals.
Bars are low in the middle causing brushes to
BRUSHWEAR08.tif

Unsatisfactory ride on entry and leaving bar edges. Continued

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

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

DC Motors

Condition Probable Cause Commutator Surface

This is a further development of the third
BRUSHWEAR09.tif

example. Earlier corrective action should have

Unsatisfactory been taken. Continued use may result in failure
Condition-Streaky Film With and damage to other systems. Motor should be
Commutator Wear replaced or recut at a qualified repair facility.
Consider more frequent scheduled maintenance
intervals.
Darkening of commutator in sequences two pole
BRUSHWEAR10.tif

pitches apart. May result from an armature

Unsatisfactory fault or some other fault. Continued use may
Condition-Double Pole Pitch result in failure and damage to other systems.
Motor should be replaced or recut at a qualified
repair facility.
May result from storage of machine with
BRUSHWEAR11.tif

brushes in position for long periods. May also

result from operation in prolonged stall
Unsatisfactory conditions. Storage marks are easily removed
Condition-Brush Contact with a polishing stone (refer to Polishing the
Mark Commutator on page 7-76). Stall marks should
be cleaned and inspected for damage or shorts.
Motor should be replaced if damage has
occurred.
Condition is caused by high mica in every slot
BRUSHWEAR12.tif

and can be caused by improper or excessive

Unsatisfactory Condition-Bar stoning. Same effect can occur on one bar only.
Edge Burning-Cause High May also notice chattering or loud operation.
Mica Continued operation will result in increased
brush wear and may result in commutator
damage. Motor should be replaced or recut at a
qualified repair facility.
Due to sparking under brush. This is caused by
BRUSHWEAR13.tif

overloaded machines or low brush pressure.

Check brush spring tension (refer to Motor
Brush Spring Tension on page 7-75). If not
Unsatisfactory corrected, will result in damage to commutator.
Condition-Small Bright Spots May be repaired with a polishing stone (refer to
Polishing the Commutator on page 7-76) if
caught early and no scoring has occurred. If
damaged, motor should be replaced or recut at
a qualified repair facility

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

DC Motors

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

less than 100,000 ohms, the motor is
An open circuit is an electrical circuit within the grounded. Clean, repair, or replace the
motor that is broken. This can be caused by: motor as necessary.
• bad brushes or brush springs
• a broken wire in field or armature winding Short Circuited Armature
• loose or bad connections
A short-circuit in the armature causes heating
To test a motor for an open circuit: that could result in burning of the:
1. Isolate the motor from the lift truck circuit • armature coil
by removing the power cables. Use two • brush wires
wrenches to avoid twisting the terminal • commutator segments
stud.
2. With the motor at room temperature, Short-Circuited Winding
connect leads of a digital ohmmeter to the
(+) and (–) terminals of the motor. The A short-circuited winding is one where the
meter should read less than 1 ohm of insulation on the field or armature has broken
resistance. down at two or more points. The breakdown
3. If the meter indicates high resistance, creates a low resistance path that allows
check the condition of the brushes before current to flow from one turn of the coil to
replacing the motor. another adjacent coil turn, without actually
flowing through the coil wire. The result is a
NOTE: If you find an open circuit in a decrease in total resistance of the motor
series-wound motor, the motor must be winding and an increase in the current flow.
disassembled by a motor rebuilding The severity of the short circuit depends on its
facility to isolate the problem to the field location.
or armature circuit.
A shorted motor may be indicated by:
Grounded Motor Test • slow or sluggish operation
• running faster than normal
In a grounded motor, an electrical circuit exists • overheating
between the current-carrying conductors and • blowing a power fuse
the motor housing. This can be caused either by
• severe burning or discoloration on one or
direct contact or through conductive foreign
more commutator segments every 90° of
material.
rotation
The ground may be caused by:
These symptoms can be caused by problems
• insulation breakdown
other than the motor itself, such as binding in
• brush leads touching the motor housing an attached pump, hose, or solenoid valve.
• build-up of carbon dust or other materials
Separate the pump and the motor. Inspect the
To test for a grounded motor: coupling for damage or wear. Check the
1. Isolate the motor from the lift truck circuit hydraulic system pressures. Troubleshoot
by removing the power cables. Use two hoses or valves as required.
wrenches to avoid twisting the terminal
studs. Testing a motor for short circuited windings
requires special equipment at a motor
2. Attach one lead of a megohm meter or rebuilding facility.
digital ohmmeter to a motor terminal and
the other lead to an unpainted surface of
the motor housing. Set the ohmmeter to
the highest scale.

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

AC Motors

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

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

armature) and a stator (in place of the DC field).
There is no electrical connection to the rotor;
current is induced in the rotor. The stator has
three windings staggered 120° apart, and three
external connections labeled U, V, and W. See
Figure 5-3.

AC
3φ

V W
Figure 5-3. AC Drive Motor Circuits

Open Winding

If the AC motor fails with an open winding, the

motor moves erratically, as if hunting or
searching, and there is a ticking sound.
Rotation is much slower than usual.

Use a clamping ammeter to measure current in

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

Shorted Winding

If the AC motor fails with a shorted winding, the

motor moves erratically, as if
hunting/searching, and there is a high-pitched
sound.

Use a clamping ammeter to measure current in

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

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

AC Motors

Carriage Control Card Connectors (Original Card)

TP2 PC11 PC1 PC12

TP3

IL3

TP5
IL1 PC9

TP1
PC8

PC15

PC2
M11
PC6

IL2

PC5
M10

TP4

PC1

PC7

PC21 PC4

PC10

PC3 PC14 PC13 PC18 PC17

5
Figure 5-4. Carriage Control Card Connectors (Original Card)

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

AC Motors

Carriage Control Card Connectors (Replacement Card)

PC26 PC11 PC16 PC12

PC9

PC8

PC15 PC2

PC6

PC5

PC1

PC7

PC4

PC22 PC20
PC3 PC14 PC13

PC23 PC24 PC19 PC10

Figure 5-5. Carriage Control Card Connectors (Replacement Card)

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

AC Motors

Vehicle Manager Connectors

5MOTOR_AC3PHASEA.EPS
MOTOR_AC3PHASEB.EPS

Figure 5-6. Vehicle Manager Connectors

Guidance Card Connectors (Original Card)

DSP1 P1 P2 P3 P4 P5

5MOTOR_AC3PHASEA.EPS
MOTOR_AC3PHASEB.EPS

Figure 5-7. Guidance Card Connectors (Original Card)

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

AC Motors

Guidance Card Connectors (Replacement Card)

D1
JW2
J2
Q9

J1
L1

D5

JW1

L2

F1
P6

P1 P2 P4 P5

Figure 5-8. Guidance Card Connectors (Replacement

Card)

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

AC Motors

Filter Card Connectors

JW2

JW1

5MOTOR_AC3PHASEA.EPS
MOTOR_AC3PHASEB.EPS

Figure 5-9. Filter Card Connectors

NOTE: Filter Cards are not present on lift

trucks that have had a Guidance Card
Replacement (P/N 1268588/001).

Fuse Relay Cards

PF1 PF1
15A 15A

1 4

FU8 FU6
FU7
FU8

FU5

FU6

FU7 FU5
K2 K4

K3 K1

K3 K2 K4 K1

13 1 7 1 10 1

PF4 PF2 PF3

PF4 PF3
PF2

Original Fuse Relay Card Replacement Fuse Relay Card

5MOTOR_AC3PHASEA.EPS
MOTOR_AC3PHASEB.EPS

Figure 5-10. Fuse Relay Card Connectors

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

AC Motors

Auxiliary Card Assembly

Figure 5-11. Auxiliary Card Connectors

NOTE: Auxiliary Card Assemblies are not

present on lift trucks that have had a
Carriage Card Replacement (P/N
1275051/003).

5-20 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

Fuse/Relay Card Troubleshooting

Fuse/Relay Card Test for Original Fuse/Relay Card

Troubleshooting 1. Perform Test O32 - Toggle Relay Enable
(Page 6-139).
Refer to “Fuse Relay Card Connectors” for 2. Turn the key switch OFF and remove the
Fuse/Relay Card component and connector relay (refer to Removal and Replacement).
location information.
3. Measure the resistance across pins 1-A
and 1-B. Resistance should measure
Determine which Fuse/Relay Card is installed
approximately 1100 ohms. Replace as
on the lift truck by the part number on the
necessary.
card. The original Fuse/Relay Card P/N is
1022159. The replacement Fuse/Relay Card
P/N is 1262467

Fuses
4. Measure the resistance between circuits 2
Fuses for system power (FU5 and 6) and Aux and 3. Welded tips will have a resistance
power (FU7 and 8) are present on the <0.5 ohm. Otherwise, there should be an
Fuse/Relay Card. Refer to page 5-6 for open circuit. Replace as necessary.
inspection and testing of fuses.
Test for Replacement Fuse/Relay Card
Relays 1. Perform Test O32 - Toggle Relay Enable
(Page 6-139). Replace the Fuse/Relay Card if
Relays should be checked when indicated by a necessary.
test or when troubleshooting any of the
symptoms listed in the following table. Relay Removal and Replacement of Original
Fuse/Relay Card Only
Relay Circuit Possible Symptoms
Key-ON Key-ON options do not
Remove relays by carefully cutting the strap
K1 securing them to the socket. Pull the relay out
Aux Power power up with the lift truck.
straight to avoid bending or damaging the pins.
Subsystem Contactors, solenoids,
Install the relay by aligning the pins with the
K2 Power brake, horn, or fans do not
operate.
corresponding sockets. Firmly press the relay
straight into the socket until it is fully seated.
Amp Amps do not power up or Secure the relay with a new strap.
K3 Power have stopped
communicating.
The relays on the replacement Fuse/Relay Card
Keep-Alive Keep-alive accessories for are not removable.
K4 Power Cold Storage do not
function.
Capacitor and FGND
Inspection on Original Fuse/Relay Card Problems with the filter capacitors (C1, C2, or
C3 on original Fuse/Relay Card, and C3 on
Visually inspect the relay and socket for replacement Fuse/Relay Card) are most
discoloration, melting, or other signs of heating. frequently observed on lift trucks equipped with
Replace as necessary. If the socket is melted or an RF scanner unit. Visually inspect the
damaged, replace the Fuse/Relay Card. capacitors for any sign of damage. The
capacitors may be physically different from the
Inspection on Replacement Fuse/Relay Card one pictured. Inspect the mounting screw in the
Visually inspect each relay for discoloration, upper left mounting hole of the Fuse/Relay
melting, or other signs of overheating. If found, Card (marked FGND). See Figure 5-12. If
replace the Fuse/Relay Card.

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

Fuse/Relay Card Troubleshooting

necessary, clean or replace this screw to make Fuse/Relay Card as necessary.

sure there is a solid connection to the frame.

To test, measure the resistance from the FGND

screw to any piece of bare metal on the frame
with a DMM. Resistance should be <0.5 ohm.

Figure 5-13: Early version

CR5

Figure 5-12: Fuse/Relay Card Ground Screw examples

Input Diodes on Original Fuse/Relay

Card
NOTE: Remove connectors JP1 through JP4
before performing this test.

To test the relay coil input diodes, locate CR5

and CR6 on the Fuse/Relay Card for your card CR6
version. See Figure 5-13 and Figure 5-14. Using
a DMM set to the “diode” function, measure the
voltage by putting the black probe on the
banded (right) side of the diode and the red
probe on the non-banded (left) side. Voltage
should be approximately 0.5V across each
diode. An open circuit is displayed if the diodes
are tested in the reverse direction. Replace the

Figure 5-14: Current version

Input Diodes on Replacement

Fuse/Relay Card
NOTE: Remove connectors JP1 through JP4
before performing this test.

To test the relay coil input diodes:

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

Fuse/Relay Card Troubleshooting

1. Locate CR5 and CR6 on the Fuse/Relay 3. Replace the Fuse/Relay Card as
Card. necessary.
2. Measure the voltage using a DMM set to
the “diode” function.
3. Put the black probe on the banded (right)
side of the diode and the red probe on the
non-banded (left) side.
Voltage should be approximately 0.5V
across each diode. An open circuit is
displayed if the diodes are tested in the
reverse direction.

4. Replace the Fuse/Relay Card as

necessary.

Figure 5-15. Fuse Relay Card Diodes (Replacement Card)

Inrush Protection

A resettable fuse protects the VM battery sense

circuit and can be reset by turning the lift truck
off momentarily. Opening of the fuse frequently
manifests as an FH code along with other
F-series codes.
NOTE: This test should be performed after the
lift truck has had a chance to come to
room temperature.

To test the original Fuse/Relay Card, remove

JPF4 from the card. Measure the resistance
from PF4-1 to PF4-7. Resistance should rise
slowly from near zero to approximately 1.3
ohms. Replace the Fuse/Relay Card as
necessary.

To test the replacement Fuse/Relay Card:

1. Remove JPF4 from the Fuse/Relay Card.
2. Measure the resistance from PF4-1 to
PF4-7. Resistance should be
approximately 1.3 ohms.

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

Drive Unit Troubleshooting

Drive Unit
Troubleshooting
Refer to page 7-31 for standard drive unit repair
procedures and page 7-51 for heavy duty drive
unit repair procedures.

Table 5-4.

Symptom Probable Cause Required Action

Oil leaks Damaged sealing rings Replace sealing rings, bearing shims, and
drive shaft bearings.

Worn or damaged drive shaft Replace sealing rings, bearing shims, drive
shaft bearings, and drive shaft.

Housing/cover joint Reseal

Worn or damaged housing Replace drive unit.

Drive wheel Worn or damaged drive shaft bearings Replace sealing rings, bearing shims, and
wobbles drive shaft bearings.

Worn or damaged drive shaft Replace sealing rings, bearing shims, drive
shaft bearings, and drive shaft.

Loose wheel mounting hardware Inspect housing and drive shaft for damage.
Re-torque mounting hardware.

Noise Worn or damaged drive shaft bearing Replace sealing rings, bearing shims, and
drive shaft bearings.

Worn or damaged pinion bearings Replace pinion bearing and pinion shaft nut.

Worn or damaged gear set (drive shaft is Replace sealing rings, bearing shims, drive
in good condition) shaft bearings, pinion bearings, pinion shaft
nut, and gear set.

Worn or damaged gear set (drive shaft is Replace sealing rings, bearing shims, drive
worn or damaged) shaft bearings, pinion bearings, pinion shaft
nut, gear set, and drive shaft.

Worn or damaged helical gear and pinion Replace helical gear and pinion.

Steering Inadequate bearing lubrication Grease steering bearing.

binds
Worn or damaged steering bearing Replace radial rings and ball bearings.

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

Communication Error Code (50 Series) Troubleshooting

Communication Error Test and clean the static straps.

Code (50 Series) Test for shorts to frame. See Shorts to Frame on
page 5-2.
Troubleshooting
Communication Code Every Time Key
Fault codes numbered in the 50 series indicate Is Turned ON
communication problems.
Troubleshoot the code on the display using
Intermittent Communication Codes Input Test 23 (I23).

If possible, determine what the operator was Enter Input Test 23 (I23). The display shows the
doing when the codes were generated such as devices that are communicating with the CCC.
driving, plugging, lifting, or sounding the horn. The CCC requests version information from the
devices on the CAN Bus, then sends this
Focus on these circuits for shorts to frame and information to the display.
external noise being generated that can • If no versions are displayed, the CCC is not
interfere with the communication circuits. communicating.
Determine where in the SelfTest Cycle the code • Check the key switch input at
is generated (for instance, when the drive motor JPT14-12.
is energized or when the horn is sounded).
• The VM LED status should be blinking.
Intermittent Codes During SelfTest • If any versions are displayed, then the
CCC and the devices showing a version are
Make sure the key switch is turned OFF for at working correctly.
least five seconds before turning it back to the • If all versions are present, then
ON position. Test the key switch for high communication is being affected by
resistance. If nothing is found in the following loading, noise, terminations, and/or
steps, replace the key switch. excessive errors causing re-send.
1. Test for shorts to frame. See Shorts to • If the fault code is intermittent, the cause
Frame on page 5-2. could be a faulty cable, cable connection,
2. If equipped with an optional light/fan card, or socket.
package, disconnect PC5. If the code goes • If the fault code cannot be reset, and other
away, troubleshoot the light/fan circuitry. version information is present, then the
NOTE: The condition of the light/fan receiving manager defined under the code
suppressor module cannot be checked title, may need to be replaced.
with a DMM. If the suppressor module is
suspected to be bad, replace it. Before any device is replaced for a
communication error code, check the
During Travel and/or Plugging following:
1. Check the Over-the-Mast Cable’s
If the lift truck is equipped with an optional connection and sockets.
travel alarm, disconnect the wires to the relay.
2. Check the condition of the static straps.
If the code goes away, troubleshoot the travel
alarm circuitry. 3. Verify the condition of all bus+/bus– cables
and connections.
NOTE: The condition of the travel alarm
suppressor module cannot be checked 4. Check for shorts to frame. Make sure the
with a DMM. If the suppressor module is battery is clean. See “Shorts to Frame” on
suspected to be bad, replace it. page 5-2.

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

Communication Error Code (50 Series) Troubleshooting

5. Check for loose, worn, or chipped motor

brushes or rough motor commutator.
6. Check the condition of all motor cables,
crimps, terminals, and connections.
7. Make sure unapproved electrical devices
have not been connected to the lift truck
electrical system.
8. Make sure that the horn or light and fan
package is not shorted to the truck frame.

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Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting

Troubleshooting Aisle Exit Error Code J2

Troubleshooting Aisle
Exit Error Code J2
Refer to the “sub-codes” in Table 5-5 when
troubleshooting Code J2 - Aisle Exit Error
(VM S/W V4.6 and up).
NOTE: Subcodes are viewed in the error log.
They will be listed next to the J2 code in
place of BSOC.

Table 5-5. Code J2 Sub-Codes

Sub-Code Description

01 The second member of an End-Of-Aisle (EOA) magnet pair has not been detected after more than
40 in. (102 cm) of travel. Aisle status indicated “In-Aisle” at the time the initial magnet was
encountered.

02 Same as Sub-code 01, except aisle status indicated “Out-of-Aisle” at the time the initial magnet
was encountered.

03 Guidance switch was not switched to AUTO while aisle status indicated “In-Aisle” and the lift
truck has traveled more than 30 ft. (9.1 m) down the aisle in MANUAL guidance mode.

04 Same as Sub-code 03. This is a redundant check.

05 Shorted sensor. The lift truck has traveled more than 5 ft. (1.5 m) with the sensor continuously
indicating the presence of a magnet.

06 Deadman was released (hard plug mode) as it passed over a magnet and speed is >1 mph
(1.6 km/h).

07 Lift truck powered up while parked directly over a magnet. The lift truck must be keyed ON in a
position where it is away from any magnets.

08 Same as Sub-code 05. This is a redundant check.

11 Same as Sub-code 01, except it was recorded when the Guidance Switch was in Manual,
indicating the lift truck passed over a magnet while lift truck was free roaming.

12 Same as Sub-code 02, except it was recorded when the Guidance Switch was in Manual,
indicating the lift truck passed over a magnet while lift truck was free roaming.

98 “In-Aisle” or “Out-of-Aisle” is stored and remembered when the key switch is turned OFF.
Non-volatile RAM expects to see “In-Aisle” or “Out-of-Aisle” during key ON. This event is logged if
the information that is seen is neither of the two at power-Up.

99 J2 code is remembered at key ON. If a J2 is detected in non-volatile RAM at power-Up, the error
is displayed again. This creates a duplicate entry in the error log. Event 99 is logged to indicate
this code was not cleared prior to the key switch being turned OFF so it is not assumed to be
another J2 occurrence.

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Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual

Troubleshooting Aisle Exit Error Code J2

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Models 5400/5500/5600 Maintenance Manual

Symptom Tables: Hydraulic Functions

Symptom Tables:
Hydraulic Functions
NOTE: If it is determined that a component
failed as a result of hydraulic fluid
contamination, replace the failed
component and flush, fill, and bleed the
hydraulic system.
NOTE: Use these symptom tables in
conjunction with the electrical and
hydraulic schematics.

Intermittent Lift/Lower

Possible Cause Action

Bad wiring Check wiring harnesses between valves and VM.
Hydraulic contamination (can cause binding Replace damaged component and flush, fill, and
proportional valve or load holding solenoid) bleed the hydraulic system.

Lift Function
No Lift - Carriage: Lift motor does not run

Possible Cause Action

Bad battery Adjust lift cutout as necessary. Replace the battery
with a fully-charged battery.
Bad optional lift limit switch Run Test I05 - Lift Inhibit Switch (optional)
(Page 6-83) and Test I04 - Lift/Lower Inhibit
Bypass (optional) (Page 6-82).
12 Volts to the encoder is open. The motor will Run Test I20 - Lift Motor RPM (AC lift only)
turn very slow and the amperage will go high. (Page 6-86).

Slow Lift - Carriage: Lift motor runs

Possible Cause Action

Bad battery Adjust lift cutout as necessary. Replace the battery
with a fully-charged battery. Test the battery for
bad cells. See Battery Procedures on page 7-70.
Emergency lowering valve not seated correctly Make sure the emergency lowering valve is closed.
Check for contamination. If contamination is
present, clean the valve, flush, fill, and bleed the
hydraulic system.
Bad proportional lift/lower valve Inspect for binding. Run Test O12 - Proportional
Solenoid PWM Ramp (Page 6-131).
Relief valve REL1 stuck open Test system pressure. Check for contamination. If
contamination is present, replace the valve, flush,
fill, and bleed the hydraulic system.

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 Models 5400/5500/5600 Maintenance Manual

Lower Function

Possible Cause Action

Plugged or malfunctioning flow control valve Check for contamination in the hydraulic fluid. If
in lift cylinder contamination is present, inspect and clean the
relief valve, replace the flow control valves, flush,
fill, and bleed the hydraulic system.
Bad lift pump Test system pressure.
Binding in the mast Inspect the mast and bearings for signs of binding.
Bad lift motor DC Lift Trucks: Test the lift motor. Check amp
draw.
AC Lift Trucks: Run Test O28 - Ramp Lift Motor
(AC lift only) (Page 6-136).
Bad lift motor encoder Run Test I20 - Lift Motor RPM (AC lift only)
(Page 6-86).

Unable to Pick Up a Load

Possible Cause Action

Battery problems Adjust lift cutout as necessary.
Replace the battery with a fully-charged battery.
Test battery for bad cells. See Battery Procedures
on page 7-70.
Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Bad lift pump Test system pressure.
Bad lift motor DC Lift Trucks: Test the lift motor. See DC Motors
on page 5-10. Check amp draw.
AC Lift Trucks: Run Test O28 - Ramp Lift Motor
(AC lift only) (Page 6-136).
Optional Pressure Switch and/or 2 stage See “Test I70 - Pressure Switch (optional)” on
Solenoid not functioning correctly. page 6-114. and Test O25 - Toggle 2 Stage Select
Note: This may not be seen until you Solenoid (optional) on page 6-135
transition out of Free Lift; then the lift motor
may stall.

Lower Function
Slow Lower

Possible Cause Action

Binding proportional valve Check the proportional valve operation. Run Test
O12 - Proportional Solenoid PWM Ramp
(Page 6-131).
Mechanical binding in bearings or telescopic Adjust or replace the bearings. If still slow, check
the mast shimming.
Plugged or malfunctioning flow control valve Open the emergency lower valve. If still slow,
remove and inspect the flow control valves. Check
for contamination in the hydraulic fluid. If
contamination is present, inspect and clean the
relief valve, flush, fill, and bleed the hydraulic
system. If no contamination is found, replace the
flow control valves in the main lift cylinders.

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Models 5400/5500/5600 Maintenance Manual

Lower Function

Intermittent Lower

Possible Cause Action

Bad load holding solenoid Run Test O11 - Toggle Load Holding Solenoid
(Page 6-130).
Binding proportional valve Check the proportional valve operation. Run Test
O12 - Proportional Solenoid PWM Ramp
(Page 6-131).
Plugged or malfunctioning flow control valve Open the emergency lower valve. If still slow,
remove and inspect. Check for contamination in
the hydraulic fluid. If contamination is present,
inspect and clean the relief valve, flush, fill, and
bleed the hydraulic system. If no contamination is
found, replace the flow control valves in the main
lift cylinders.

Load Drifting/Settling

Possible Cause Action

Incorrect lift pressure adjustment Check and adjust the lift pressure setting.
Load holding solenoid Run Test O11 - Toggle Load Holding Solenoid
(Page 6-130). Check for contamination in the
hydraulic fluid. If contamination is present,
inspect and clean the relief valve, flush, fill, and
bleed the hydraulic system.
Load too large for lift truck capacity Check load weight. Check lift pressure setting.
Emergency lower valve leaking Replace the emergency lower valve.

Publication: 1031794/001E, Revised: 04 Dec 2019 5-31

 Models 5400/5500/5600 Maintenance Manual

Symptom Tables: Travel Functions

Symptom Tables: Travel

Functions
Slow or Sluggish Acceleration

Possible Cause Action

Dragging the brake Adjust the brake.
Worn wheel bearings Replace the wheel bearings.
Debris in the wheel axle Remove debris.
Binding the drive unit Remove the drive motor and check drive unit
movement.

Slow Travel

Possible Cause Action

Note: Determine if problem is mechanical or electrical.
Mechanical:
Dragging the brake Adjust the brake.
Debris in the wheel axle Remove debris.
Binding the drive unit Remove the drive motor and check drive unit
movement.
Binding in the control handle Run Test A22 - Traction Throttle Request
(Page 6-57) to determine if the controller is still
seeing a 100% request.
Electrical:
Bad mast speed limit switch (S10 or S11) or Run Test I02 - Lower Mast Reference (24 in.)
associated wiring Switch (Page 6-80), Test I69 - Upper Mast
Reference Switch (Page 6-113), or Test I03 - 60 in.
Limit Switch (Page 6-81).
Incorrect configuration Reconfigure the lift truck.
Drive motor or power amplifier temperature Run Test A08 - Traction Motor Temperature
(temperature icon illuminated) (Page 6-48) or Test A10 - Traction Power Amplifier
Temperature (Page 6-50)
Bad encoder pulses from the drive motor Run Test I19 - Traction Motor RPM (Page 6-85).
encoder

5-32 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual

Symptom Tables: Electrical Symptoms

Symptom Tables:
Electrical Symptoms
NOTE: Use these symptom tables in
conjunction with the electrical and
hydraulic schematics.
NOTE: For intermittent issues with optional
devices such as RF units, check the
Fuse/Relay Card Capacitor and FGND.
Refer to Troubleshooting Aisle Exit Error
Code J2 on page 5-27.

Electrical Motors

Motor Arcing

Possible Cause Action

Worn brushes or incorrect brush tension Replace the brushes and brush springs.
Partially shorted motor armature or field Clean the motor.
Rough or pitted motor commutator Replace the motor.

Motor Overheating

Possible Cause Action

Dragging brake Adjust the brake. See Brake on page 7-63.
Application exceeds designed workload -- Check with Raymond Sales and Service Center
short runs with plugging/acceleration or Service Manager to verify this is a correct
heavy duty lifting cycles application.
Using deadman pedal to stop all the time
Bad battery Check the battery voltage, both open circuit and
under load. Replace if necessary with a
fully-charged good battery.
Incorrect BSOC Cutout value Check the battery specific gravity at cutout, after
the battery has stabilized. Compare to the battery
manufacturer specifications for discharged
battery. Adjust the BSOC Cutout as needed.
Cable, terminal, or wiring problems Replace the wiring or cables as necessary. See
Look for discolored terminals, loose or Power Cables on page 7-72.
damaged crimps Check the cable connection torque. See
Component Specific Service/Torque Chart on
page A-4.
Worn, damaged, or bad brushes or springs Inspect the motor brushes.
Check the brush spring tension.
Binding gearbox or pump Check the gearbox or pump for binding. Clean,
repair, or replace as necessary.
Hydraulic fluid viscosity too high or too low Replace the hydraulic fluid with the correct fluid.
See Lubrication Specification Chart on page A-2.
Pressure relief set too high Adjust the pressure relief.

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 Models 5400/5500/5600 Maintenance Manual

Symptom Tables: Electrical Symptoms

Operator Display Problems

Scrambled or Intermittent Display

Possible Cause Action

Loose JPC15 harness or Re-seat cards and harness connections.
card connectors
Intermittent wires or Test for continuity while flexing the harness. If discontinuity is found,
connectors in harness replace the wiring harness.
Electrical noise in Check the tightness of motor power cable connections (see page 7-72).
motors Check the motor brushes for arcing. Replace if necessary.
Bad key switch Replace the key switch.
Worn or missing static Replace as necessary.
straps

Dead Lift Truck

Display is Dark - No functions operate

Possible Cause Action

No LEDs illuminated Refer to Pin-Out Matrix on page 8-19 and the Electrical Schematics. Check
on circuit cards for B+ at the following locations wrt TP4:
• FU5
• JPF4-10
• JPC16-8
• JPC6-1
• JPC6-2
• JPC16-6
• JPF4-8
• JPF4-11
• JPT14-12
Check for B– at the following locations wrt TP1:
• FU6
• JPF3-3, 4, 5, 6, 7, 8 and 12
• JPT14-1, 2, 8, 9 and 10
• JPC16-4
• JPT14-3
• JPC11-6
If all of the above locations have the correct voltages, refer to the Diagnosis
and Repair table in Test A14 - VM +12V Power Supply (Page 6-53).

5-34 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual

Symptom Tables: Electrical Symptoms

Auto Steer Center Problem

Intermittent Lift Truck Error Codes

Possible Cause Action

Noise, shorts to frame See “Shorts to Frame” on page 5-2.
Calculated position of Error Code G2 displayed, see CODE G2 Inform service on page 6-41.
the drive unit bad Check the adjustment of the home prox sensor.
Large correction to Steer motor encoder, steering amp, or VM may be bad. Check the home
steering prior to braking prox sensor adjustment.
Mechanical issue, worn Repair or replace as necessary.
radial ring

Lift Truck Codes After Deadman Pedal Pressed

Possible Cause Action

Steering will move in See “Test I25 - Steer Motor Encoder” on page 6-91.
both directions during
auto center
Steering only in one Check the home proximity sensor adjustment. See “Test I24 - Home
direction Position Proximity Sensor” on page 6-90. Run Test O44 - Steer Motor
(Page 6-145).
No movement in Run Test O44 - Steer Motor (Page 6-145). Repair or replace as
steering. Mechanical necessary.
issue, worn radial ring

Lift Truck Codes Before Deadman Pedal Pressed

Possible Cause Action

Low voltage measured Replace the VM.
between JPT6-6 and
JPT6-4
Fuse FU1 open Replace fuse FU1.
High resistance Check the brushes, replace the steer motor.
measured between Steer
Motor terminals.
Bad Steer Amplifier Replace the steer amplifier.
Bad VM Replace the VM.

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 Models 5400/5500/5600 Maintenance Manual

Symptom Tables: Electrical Symptoms

5-36 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes, and Tests

Section 6. Messages, Codes, and Tests

Publication: 1031794/001E, Revised: 04 Dec 2019 6-1

Section 6. Messages, Codes, and Tests Models 5400/5500/5600 Maintenance Manual

Power Amp LED Diagnostics

Power Amp LED

Diagnostics
Most error conditions are displayed as a
message or fault code on the OD.

The power amps also contain a Light Emitting

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

Power amp blink codes consist of a red LED

flash followed by a number of quick orange LED
flashes. The two-digit code flashed by the yellow
LED identifies the specific fault code. One red
LED blink will be followed by the first digit of
the code. Two red LED blinks will be followed by
the second digit of the code.

Specific codes:
• Code 12: Motor phase detected shorted.
• Code 37: Motor phase detected open.
• Code 72: Amp has not received CAN
messages from the VM.

6-2 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes, and Tests

Summary List

Summary List
Messages
LPA Approaching Overtemperature (temp icon only). . . . . . . . . . . . . . . . . . . . . . 6-9
TPA Approaching Overtemperature (temp icon only) . . . . . . . . . . . . . . . . . . . . . 6-9
Truck Travel Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Aligning: Wire Is Sensed Truck Is Now Aligning . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Battery State-of-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
The height tracking system needs to recalibrate position. . . . . . . . . . . . . . . . . 6-10
Deadman?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
End of Aisle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
EPO Pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
EPO has been pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
ERG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Incorrect FlashWare Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Guidance Not Learned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
24 in. Limit Switch Not Sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Interlock activated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Truck will not pass SelfTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Scheduled Maintenance Reminder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Installed battery is too light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Truck Lift Speed Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Truck is disabled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
RDP has timed out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Load Coil Pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Tractor coil pair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Lost wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Lower Side Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Truck Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Platform Hung... Lift Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Press auto/manual switch to auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Switch (S24) Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Truck Lowering Inhibited. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Aux Buttons Pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Both Pendant Buttons Pressed Before Time-out. . . . . . . . . . . . . . . . . . . . . . . . 6-16
Truck Lift/Lower Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Control Handle Moved Before Deadman Pressed . . . . . . . . . . . . . . . . . . . . . . . 6-16
Release lift to resume operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Scheduled Maintenance Reminder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Seeking: AUTO/MAN Switch Is In Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
TPA not receiving Motor RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Speed Limited Due To Steer Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Truck Speed Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Truck Stalled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Truck Steering Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Truck Travel Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Truck Travel Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
View SWM Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 10: SelfTest Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

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Section 6. Messages, Codes, and Tests Models 5400/5500/5600 Maintenance Manual

Messages

Code 1H: TPA Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Code 1K: Platform Hung Lift Slowly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 2A: Traction Motor Approaching Overtemperature . . . . . . . . . . . . . . . . . . 6-20
Code 2E: Traction Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . 6-21
Code 2G: Phase Open on Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 2H: Failure Detected in Traction Motor Speed Feedback Encoder . . . . . . . 6-21
Code 2M: TPA Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 2T: TPA Current Calibration Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 2U: TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 2V: High DC BUS Voltage – TPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 2W: TPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 2X: TPA Power Supply Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 2Y: Incorrect Traction Power Amplifier Installed . . . . . . . . . . . . . . . . . . . . 6-23
Code 42: LPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . . . . 6-23
Code 43: LPC Detected Open When Commanded Closed . . . . . . . . . . . . . . . . . . 6-23
Code 4C: FU1 Sense Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 4F: TPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . . . . 6-24
Code 4G: TPC Detected Open After Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code 4H: TPA, TPC Contactor Coil or Coil Driver Open or Shorted. . . . . . . . . . . 6-24
Code 4K: LPA, LPC Contactor Coil or Coil Driver Open or Shorted . . . . . . . . . . . 6-24
Code 50: No VM Communications Received by CCC . . . . . . . . . . . . . . . . . . . . . 6-25
Code 51: No CCC Communications Received by VM . . . . . . . . . . . . . . . . . . . . . 6-25
Code 56: Platform Hung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code 59: CAN Transmission Buffer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 5A: CAN BUS Error Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 5B: Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 5E: No Guidance Manager CAN Communications Received by the VM . . . 6-26
Code 5G: No Communications Received by VM from TPA. . . . . . . . . . . . . . . . . . 6-27
Code 5J: No communications Received by VM from LPA . . . . . . . . . . . . . . . . . . 6-27
Code 5M: No communications received by TPA from VM.. . . . . . . . . . . . . . . . . . 6-27
Code 5P: No communications received by LPA from VM. . . . . . . . . . . . . . . . . . . 6-27
Code 61: 24 in. Limit Switch Not Sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code 63: Upper and Lower Reference Switches Do Not Agree. . . . . . . . . . . . . . . 6-28
Code 64: No Flow Sensor Pulses When Lift/Lower Requested . . . . . . . . . . . . . . 6-28
Code 66: Calculated Height Does Not Match at
Upper Reference Switch (150 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code 67: Calculated Height Does Not Match at
Lower Reference Switch (24 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code 6D: Lift Pressure Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code 6F: Lift Motor Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code 6K: 60 in. Switch Does Not Agree with Lower Mast Reference . . . . . . . . . . 6-29
Code 6M: 60 in. and/or 24 in. Switch Disconnected . . . . . . . . . . . . . . . . . . . . . 6-29
Code 6N: Flow Sensor Temperature Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code 6P: 60 in. Limit Switch Out-of-Sequence with Upper
Reference Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code 7E: Lift Motor Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . 6-30
Code 7F: LPA Temp Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code 7G: LPA Motor Phase Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code 7H: Failure Detected in Lift Motor Feedback Encoder . . . . . . . . . . . . . . . . 6-31
Code 7M: LPA Failed to Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Code 7T: LPA Current Sensor Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Code 7U: LPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

6-4 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes, and Tests

Messages

Code 7V: LPA High Voltage on DC BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Code 7W: LPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Code 7X: LPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Code 7Y: Incorrect Lift Power Amplifier Installed . . . . . . . . . . . . . . . . . . . . . . . 6-32
Code 80: Throttle Potentiometer (VR1) Voltage Out-of-Range . . . . . . . . . . . . . . 6-32
Code 81: Lift/Lower Potentiometer (VR2) Voltage Out-of-Range . . . . . . . . . . . . 6-32
Code 83: Throttle Potentiometer (VR1) Out-of-Neutral . . . . . . . . . . . . . . . . . . . 6-33
Code 84: Brake Inoperable; Not Applied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Code 88: Lift and/or Travel Potentiometer Voltage Out-of-Range . . . . . . . . . . . 6-33
Code 8C: Deadman Switches Do Not Agree . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Code 8F: Lift/Lower Potentiometer Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . 6-33
Code 8L: Electric Brake Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Code 91: Drive Unit Turned >10° while Guiding on Wire . . . . . . . . . . . . . . . . . 6-34
Code 92: Tracking Limits Exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Code 93: Not Near Wire; Tractor Coil Pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Code 94: Not Near Wire; Load Coil Pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Code 9A: Bad Wire Guidance Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Code 9B: Bad SDO (CAN - Service Data Object) Data Received. . . . . . . . . . . . . 6-35
Code 9E: Track And Hold Signal Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Code 9F: Filter Card Not Connected to Guidance Manager. . . . . . . . . . . . . . . . 6-36
Code 9G: No Input; Load Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Code 9H: No Input; Tractor Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Code 9J: Load Antenna Input Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Code 9K: Tractor Antenna Input Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Code 9M: Tractor Antenna Input Too High. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Code A0: Incorrect Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Code A2: Software Compatibility Issue with VM and TPA . . . . . . . . . . . . . . . . . 6-38
Code A4: Software Compatibility Issue with VM and LPA . . . . . . . . . . . . . . . . . 6-38
Code AH: Bad CCC Checksum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Code AL: VM Battery Backed Up RAM Failed . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Code AP: TPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Code AT: LPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Code F8: Microcontroller COP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Code FE: Internal VM Circuit for BSOC Not Calibrated . . . . . . . . . . . . . . . . . . 6-39
Code FG: +5V Reference Voltage and +12V Power Supply Failure. . . . . . . . . . . 6-39
Code FH: Battery Voltage Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Code FN: Relays Did Not Open at Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Code FP: VM In-Circuit Hardware Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Code FT: VM Internal Software Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Code G0: Steer Tiller Encoder 1 is Intermittent or Failed . . . . . . . . . . . . . . . . . 6-41
Code G2: Auto Steer Center Failed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Code G3: Home Prox Switch Not Functioning Correctly . . . . . . . . . . . . . . . . . . 6-41
Code G4: Open Detected in Steer Control Circuit . . . . . . . . . . . . . . . . . . . . . . . 6-41
Code G5: Short Detected in Steer Power Circuit. . . . . . . . . . . . . . . . . . . . . . . . 6-42
Code G7: Steer Tiller Encoder 2 is Intermittent or Failed . . . . . . . . . . . . . . . . . 6-42
Code GD: No Steer Motor Encoder Pulses Seen . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Code GE: Both Steer Tiller Encoders Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Code GF: Wire Guidance Position Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . 6-43
Code J2: Aisle Exit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Code J4: Aisle Sensor Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Code VC: The CAN Chip will not Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Code X3: 180 in. Limit Switch Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

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Section 6. Messages, Codes, and Tests Models 5400/5500/5600 Maintenance Manual

Messages

Code X4: Lift Cutout Switch Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-44

Code X5: Lift Inhibit Switch Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-44
Test A04 - Throttle Potentiometer Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-46
Test A05 - Lift/Lower Potentiometer Voltage . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-47
Test A08 - Traction Motor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-48
Test A09 - Lift Motor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-49
Test A10 - Traction Power Amplifier Temperature . . . . . . . . . . . . . . . . . . . . .. . 6-50
Test A11 - Traction Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-51
Test A13 - Pressure Sensor Voltage (optional) . . . . . . . . . . . . . . . . . . . . . . . .. . 6-52
Test A14 - VM +12V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-53
Test A15 - Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-54
Test A19 - Lift Power Amplifier Temperature (AC lift only) . . . . . . . . . . . . . . .. . 6-55
Test A20 - Lift Motor Current (AC lift only) . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-56
Test A22 - Traction Throttle Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-57
Test A23 - Lift Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-58
Test A34 - Lift/Lower Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-59
Test A35 - Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-60
Test A37 - Steer Power Amplifier Current . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-61
Test A51 - Left Tractor Guidance Coil Voltage . . . . . . . . . . . . . . . . . . . . . . . .. . 6-63
Test A52 - Right Tractor Guidance Coil Voltage . . . . . . . . . . . . . . . . . . . . . .. . 6-65
Test A53 - Left Load Guidance Coil Voltage . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-67
Test A54 - Right Load Guidance Coil Voltage . . . . . . . . . . . . . . . . . . . . . . . .. . 6-69
Test A55 - Tractor Near Wire Coil Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-71
Test A56 - Load Near Wire Coil Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-73
Tests A96 through A100 - iBATTERY Tests . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-75
Test A101 - Guidance Manager 12V Power Supply Out of Range . . . . . . . . .. . 6-76
Test I00 - Carriage Deadman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-78
Test I01 - Brake Deadman Switch (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-79
Test I02 - Lower Mast Reference (24 in.) Switch . . . . . . . . . . . . . . . . . . . . . .. . 6-80
Test I03 - 60 in. Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-81
Test I04 - Lift/Lower Inhibit Bypass (optional) . . . . . . . . . . . . . . . . . . . . . . .. . 6-82
Test I05 - Lift Inhibit Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-83
Test I15 - Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-84
Test I19 - Traction Motor RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-85
Test I20 - Lift Motor RPM (AC lift only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-86
Test I23 - CAN Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-87
Test I24 - Home Position Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-90
Test I25 - Steer Motor Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-91
Test I26 - Flow Sensor Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-92
Test I35 - Steer Tiller Encoder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-93
Test I36 - Steer Tiller Encoder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-94
Test I38 - EPO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-95
Test I39 - Neutral Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-96
Test I41 - Aux Mast Lift Switch S32
(CCC 1107833/101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
Test I41 - Aux Mast Lift Switch S32
(CCC 1275051/003) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
Test I42 - Aux Mast Lower Switch S33
(CCC 1107833/101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99
Test I42 - Aux Mast Lower Switch S33
(CCC 1275051/003) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100
Test I43 - Slack Chain Switch

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes, and Tests

Messages

(CCC1107833/101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
Test I43 - Slack Chain Switch
(CCC 1275051/003) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
Test I44 - Aux Mast Lift Ref Switch S34
(CCC 1107833/101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-105
Test I44 - Aux Mast Lift Ref Switch S34
(CCC 1275051/003) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106
Test I45 - Slk S29 [Slack Chain 1 Switch (S29)] . . . . . . . . . . . . . . . . . . . . . . . 6-107
Test I46 - Slk Ch S30 [Slack Chain 2 Switch (S30)] . . . . . . . . . . . . . . . . . . . . . 6-108
Test I65 - Rail Guidance Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109
Test I66 - Auto/Manual Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-110
Test I67 - Sidegate Switches (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111
Test I68 - Travel Cutout/Battery Gate and PSL Switch (optional) . . . . . . . . . . 6-112
Test I69 - Upper Mast Reference Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
Test I70 - Pressure Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114
Test I72 - End-of-Aisle Sensor 2 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-115
Test I73 - End-of-Aisle Sensor 1 (optional) - Software versions 5.7 and below . 6-117
Test I73 - EOA2, Left - Software versions 5.8 and above . . . . . . . . . . . . . . . . . 6-119
Test I74 - Lower Inhibit Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121
Test I75 - 180 in. Limit Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Test I76 - Lift Cutout Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
Test I91 - iPORT Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124
Test I92 - iPORT Error Bitmap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-125
Test I93 - End Of Aisle EOA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126
Test O00 - Toggle the Traction Power Contactor . . . . . . . . . . . . . . . . . . . . . . . 6-128
Test O02 - Toggle the Lift Power Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-129
Test O11 - Toggle Load Holding Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-130
Test O12 - Proportional Solenoid PWM Ramp . . . . . . . . . . . . . . . . . . . . . . . . . 6-131
Test O18 - Toggle Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-132
Test O19 - Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-133
Test O20 - Travel Alarm (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134
Test O25 - Toggle 2 Stage Select Solenoid (optional) . . . . . . . . . . . . . . . . . . . . 6-135
Test O28 - Ramp Lift Motor (AC lift only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-136
Test O29 - Ramp Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-137
Test O30 - Toggle Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138
Test O32 - Toggle Relay Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-139
Test O39 - Display Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-140
Test O40 - Lift/Lower Alarm (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-141
Test O41 - Aux Select Solenoid (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-142
Test O42 - Main Select Solenoid (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-143
Test O43 - Aux Load Hold Solenoid (optional) . . . . . . . . . . . . . . . . . . . . . . . . . 6-144
Test O44 - Steer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-145

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Section 6. Messages, Codes, and Tests Models 5400/5500/5600 Maintenance Manual

Messages

6-8 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Messages and Codes

Messages and Codes

Section 6. Messages, Codes and Tests

NOTE: All “M” Series codes are iBATTERY

related error codes. Refer to iBATTERY
Battery Monitoring System Installation
and Maintenance Instructions.

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

None
LPA Approaching Overtemperature Test A19 - Lift Power Cycle the key switch
(temp icon only) Amplifier Temperature OFF/ON to clear after the lift
The VM senses the lift power amplifier (AC lift only) (Page 6-55) power amplifier has cooled.
temperature is approaching 185°F
(85°C). Lift performance is limited.

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

None
TPA Approaching Overtemperature Test A10 - Traction Power Cycle the key switch
(temp icon only) Amplifier Temperature OFF/ON to clear after the
The VM senses the traction power (Page 6-50) traction power amplifier has
amplifier temperature is approaching cooled.
185°F (85°C). Traction performance is
limited.

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

ADF, PDF, AHA, PHA

Truck Travel Inhibited None Turn off WGAM in Configure
WGAM has been left turned on in Mode.
Configure Mode.

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

Aligning
Aligning: Wire Is Sensed Truck Is None None
Now Aligning
The Auto/Manual switch is in the
Auto position. The guide wire is
sensed. The lift truck is trying to
acquire the wire.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Battery low, no lift

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

Battery low, no lift

Battery State-of-Charge If charging or changing the Lift is disabled. The battery
Lift interrupt has occurred due to the battery does not clear the needs to be charged or
battery state-of-charge. message, run Test A15 - changed.
Battery Voltage
(Page 6-54)

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

Cross upper or lower limit switch

The height tracking system needs Test I02 - Lower Mast Move the forks past either
to recalibrate position. Reference (24 in.) Switch the 24 in. or 150 in. switch.
The 24 in. switch is open, indicating (Page 6-80)
the forks are elevated, and the system Test O12 - Proportional
has counted over 1024 in. of Solenoid PWM Ramp
accumulated fork up and down (Page 6-131)
movement without detection either Test I69 - Upper Mast
24 in. of 150 in. switches. Reference Switch
(Page 6-113)

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

Deadman?
Deadman? Test I00 - Carriage Message displayed during
Deadman switch(es) activated Deadman (Page 6-78) SelfTest - release deadman,
while truck is attempting to Test I01 - Brake Deadman resume operation. If
perform SelfTest or control handle Switch (S2) (Page 6-79) message does not clear, refer
inputs detected and deadman to the Inputs listed. Message
pedal(s) not pressed. displayed after SelfTest -
depress deadman pedal(s). If
message does not go away,
refer to the Inputs listed.

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

End of aisle
End of Aisle Test I93 - End Of Aisle Not an error.
The message is displayed until the EOA (Page 6-126)
truck slows down or stops as it exits Test I72 - End-of-Aisle
the end of the aisle and the operator Sensor 2 (optional)
releases the travel control. (Page 6-115)
Test I73 - End-of-Aisle
Sensor 1 (optional) -
Software versions 5.7 and
below (Page 6-117)

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

EPO Pressed

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

EPO Pressed
EPO Pressed Test I38 - EPO Switch Lift the EPO switch and cycle
CCC or VM senses the EPO switch is (Page 6-95) the key switch OFF/ON to
open (IN). clear.

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

EPO Rekey
EPO has been pressed Test I38 - EPO Switch Make sure the EPO switch is
CCC or VM senses the EPO switch was (Page 6-95) lifted and cycle the key
pressed, then lifted, without key switch OFF/ON to clear.
switch being cycled.

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

ERG
ERG None Check shorts to frame.
CCC startup error Replace CCC.
The CCC micro-controller has been
started in Bootstrap mode

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

FlashWare options incorrectly configured

Incorrect FlashWare Options Use FlashWare to set a Cycle the key switch
FlashWare options incorrectly valid configuration. OFF/ON to clear.
configured/ verify options are
configured correctly in FlashWare.

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

Guidance not learned

Guidance Not Learned None Learn Guidance to clear.
When the Auto/Manual switch was
placed in the Auto position, the wire
guidance parameters were
out-of-range.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Initialize to allow full speed travel

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

Initialize to allow full speed travel

24 in. Limit Switch Not Sensed Test O12 - Proportional Travel is limited to
Too much time has passed without Solenoid PWM Ramp 2.5 mph (4 km/h). Make
crossing the 24 in. limit switch while (Page 6-131) sure the Emergency Lower
the lift request is above a certain Test I02 - Lower Mast Valve is closed. Cycle the key
threshold. Reference (24 in.) Switch switch OFF/ON to clear.
(Page 6-80)

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

Interlock activated, clear to resume

Interlock activated None Cycle the key switch
OFF/ON to clear.

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

Invalid password
Truck will not pass SelfTest None Enter the correct password
Incorrect password has been entered. or default using FlashWare.

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

Lift cut-out pending ... low battey

Battery Low None Message is displayed for five
minutes, then lift is
disabled. Change the
battery.

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

Lift cutout, Scheduled maintenance due

Scheduled Maintenance Reminder None Lift is disabled. Reset Mnt
This code occurs when configure mode Mind in Configure mode.
Maintenance Minder has been set to
request it be activated.

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

Lift limited...Installed battery is too light

Installed battery is too light None Replace the battery with a
The battery in the truck is below correct size battery. Refer to
minimum allowable battery weight. the specification tag for
battery minimum.

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Lift speed Limited

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

Lift speed Limited

Truck Lift Speed Inhibited Test I20 - Lift Motor RPM Cycle the key switch
This code is generated by the Lift (AC lift only) (Page 6-86) OFF/ON to clear.
Power Amplifier after not receiving
encoder pulses.

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

Log in to enable truck

Truck is disabled None Refer to iPORT Kit
RDP has the initial speed set to zero. Installation and
Maintenance
Instructions.

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

Loss of connection to the SWM

RDP has timed out None Refer to iPORT Kit
RDP has a problem with the local Installation and
communications. Maintenance
Instructions.

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

Lost LCP
Load Coil Pair Test A53 - Left Load Check that the truck did not
Not near wire. This is the antennae on Guidance Coil Voltage run off the wire. Re-run the
the fork end of the truck. (Page 6-67) Learn procedure. Travel is
Test A54 - Right Load not allowed while
Guidance Coil Voltage Auto/Manual switch is in
(Page 6-69) Auto. Set the Auto/Manual
Test A56 - Load Near Wire switch to Manual. Check the
Coil Voltage (Page 6-73) wiring between the Guidance
Manager and the VM.
Replace the Guidance
Manager. Cycle the key
switch OFF/ON to clear.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Lost TCP

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

Lost TCP
Tractor coil pair Test A51 - Left Tractor Check truck did not run off
Not near wire. This is the antennae on Guidance Coil Voltage the wire. Re-run the Learn
the tractor end of the truck. (Page 6-63) procedure. Travel is not
Test A52 - Right Tractor allowed while Auto/Manual
Guidance Coil Voltage switch is in Auto. Set the
(Page 6-65) Auto/Manual switch to
Test A55 - Tractor Near Manual. Check the wiring
Wire Coil Voltage between the Guidance
(Page 6-71) Manager and the VM.
Replace the Guidance
Manager. Cycle the key
switch OFF/ON to clear.

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

Lost wire
Lost wire Check the line driver Travel is not allowed while
The electronics on the truck can no output per W. G. Manual. the Auto/Manual switch is
longer detect a signal from the wire Check truck did not run in Auto. Set the
that is buried just below the surface of off wire. Re-run Learn the Auto/Manual switch to
a floor. procedure. Manual. Check the wiring
between the Guidance
Manager and the VM.
Replace the Guidance
Manager. Cycle the key
switch OFF/ON to clear.

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

Lower sidegates to resume operation

Lower Side Gate Test I67 - Sidegate Lower Sidegates to clear.
While standing on the deadman pedal, Switches (optional)
a sidegate is detected up when you (Page 6-111)
attempt to travel or lift.

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

Overheated, allow time to cool

Truck Overheated This is the actual Allow time for the lift truck
The system has detected that an over message: depending on to cool. Check the lift truck
temperature condition exists. what motor is over heated Event Log to determine what
will determine if the motor or amp is causing the
Traction or Lift speed is code.
reduced.

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Platform hung... lift slowly

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

Platform hung... lift slowly

Platform Hung... Lift Slowly Test I45 - Slk S29 [Slack Lift the platform slowly to
Slack chain switch has transitioned Chain 1 Switch (S29)] clear. Code 56 is logged. If
during operation. (Page 6-107), Test I46 - lifted for too long, this
Slk Ch S30 [Slack Chain 2 message will transition to
Switch (S30)] (Page 6-108) 1K.

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

Press auto/manual switch to auto

Press auto/manual switch to auto Test I66 - Auto/Manual The near coil has detected
This appears on wire guidance Switch (optional) the presence of the wire
equipped trucks when the system (Page 6-110) guidance floor signal, or the
senses the wire. It occurs on rail Test I65 - Rail Guidance guide rail switch input.
guidance system based on switch Switch (optional)
input. (Page 6-109)

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

Press bypass switch to continue lifting

Switch (S24) Activated Test I05 - Lift Inhibit Lift is disabled unless the
Lift Inhibit Switch (S24) has been Switch (optional) bypass switch is activated.
crossed or open. (Page 6-83) Lower the vehicle below the
lift inhibit switch.

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

Press bypass switch to continue lowering

Truck Lowering Inhibited Test I74 - Lower Inhibit Lower is disabled unless the
Lower Inhibit Switch (S25) has been Switch (optional) bypass switch is activated.
crossed. (Page 6-121) Lift above the lower inhibit
switch.

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

Release aux buttons to resume operation

Aux Buttons Pressed Test I41 - Aux Mast Lift Cycle the key switch
Auxiliary deadman and auxiliary lift or Switch S32 (CCC OFF/ON to clear.
lower switches are activated at 1107833/101) (Page 6-97)
start-up. Test I42 - Aux Mast Lower
Switch S33 (CCC
1107833/101) (Page 6-99)

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Release buttons

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

Release buttons
Both Pendant Buttons Pressed None Allow more time between
Before Time-out pressing the buttons.
Both buttons are pressed at the same
time. Must have at least a two second
delay between pressing the first and
second.

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

Release bypass switch

Truck Lift/Lower Inhibited Test I04 - Lift/Lower Release the switch.
Will happen with either lift or lower Inhibit Bypass (optional)
bypass switch (S7) activated for an (Page 6-82)
extended period of time.

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

Release control handle to resume operation

Control Handle Moved Before Test A04 - Throttle Release the throttle, step on
Deadman Pressed Potentiometer Voltage the deadman, and resume
(Page 6-46) travel.

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

Release lift to resume operation

Release lift to resume operation Test A05 - Lift/Lower Check for excessive
Control handle was moved before the Potentiometer Voltage mechanical play in the lift
deadman pedal was pressed at (Page 6-47) control knob. Release the lift
start-up. control knob, step on the
deadman, and resume
operation.

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

Scheduled maintenance due

Scheduled Maintenance Reminder None Reset Mnt Mind in Configure
This code occurs when configure mode mode.
Maintenance Minder has been set to
request it be activated.

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Seeking

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

Seeking
Seeking: AUTO/MAN Switch Is In None None
Auto
The guide wire has not been sensed.
The lift truck is trying to find the wire.

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

Speed limited
TPA not receiving Motor RPM Test I19 - Traction Motor Travel speed is limited. Cycle
This code is generated by the Traction RPM (Page 6-85) the key switch OFF/ON to
Power Amplifier after not receiving clear.
encoder pulses.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Speed limited due to steer angle

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

Speed limited due to steer angle

Speed Limited Due To Steer Angle Test I02 - Lower Mast Straighten the drive unit to
A speed limiting condition due to a Reference (24 in.) Switch within 10° of straight ahead
combination of steering angle and (Page 6-80) or lower the carriage below
height is in effect. Test I03 - 60 in. Limit the 24 in. lower mast
Switch (Page 6-81) reference switch.
Test I69 - Upper Mast 1. If the operator platform
Reference Switch height is between 24 in.
(Page 6-113) (610 mm) and 60 in.
Test I75 - 180 in. Limit (1520 mm) and the
Switch (optional) steering angle is >10°,
(Page 6-122) max travel speed is
limited to 2.5 mph
(4 km/h).
2. If the operator platform
height is between 60 in.
(1520 mm) and 150 in.
(3810 mm) (with
intellispeed) or the
upper reference switch
(S10) (without
intellispeed) and the
steering angle is >10°
then max travel speed
is limited to 1 mph
(1.6 km/h).
3. If the height of the
operator platform is
greater than or equal to
50 in. (3810 mm) (with
intellispeed) or the
Upper Mast Reference
Switch (S10) (without
intellispeed) and
steering is greater than
10°, then travel is not
permitted.

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

Speed limited due to unknown height... lower to reference switch

Truck Speed Limited Test I02 - Lower Mast Lower the lift truck below the
Lift truck powered on when above 24 Reference (24 in.) Switch 24 in. limit switch.
inch limit switch. (Page 6-80)

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Stalled, release control handle to resume operation

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

Stalled, release control handle to resume operation

Truck Stalled Travel speed limited. Test Travel speed or lift speed is
No encoder pulses are received by the I19 - Traction Motor RPM limited depending on which
Power Amplifier. (Page 6-85). Lift speed amplifier is not receiving
limited. Test I20 - Lift encoder pulses. Cycle the
Motor RPM (AC lift only) key switch OFF/ON to clear.
(Page 6-86)

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

Steer limited due to height

Truck Steering Inhibited None Lower the lift truck below the
Lift truck is elevated above the upper upper reference switch.
reference switch and a steering
request of more than 10 degrees has
been requested.

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

Travel cutout
Truck Travel Inhibited Test I68 - Travel Travel is disabled. Lower the
Lift truck has been elevated above Cutout/Battery Gate and lift truck below the travel
travel cutout switch, or a battery gate PSL Switch (optional) cutout switch, or make sure
is not correctly installed (optional). (Page 6-112) the battery gates are
correctly installed.
Travel cutout is also used for
trucks with fuel cell and the
Power Source Limit (PLS).

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

Travel Interlock Activated

Truck Travel Inhibited None Lower the lift truck below the
This occurs when the lift truck is limit switch.
configured with lift limit with bypass
and configure mode is choosing to not
allow travel when above the lift limit
switch.

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

View SWM Display

View SWM Display None View display. Refer to SWM
The SWM has instructed the RDP to documents.
throw a message to tell the operator to
look at it.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE 10 Inform Service

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

CODE 10 Inform Service

Code 10: SelfTest Failed Test A35 - Brake All functions are disabled.
The brake test did not pass SelfTest. (Page 6-60) Make sure the EPO is not
Test O00 - Toggle the pressed. The TPC must close
Traction Power Contactor during SelfTest.
(Page 6-128) Check the battery voltage.
Check the brake wires.
Cycle the key switch
OFF/ON to clear.

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

CODE 1H Inform service

Code 1H: TPA Out-of-Range Test A10 - Traction Power Cycle the key switch
The Traction Power Amplifier has Amplifier Temperature OFF/ON to clear after the
reported its internal temperature is (Page 6-50) traction power amplifier has
less than –40°F (–40°C) or greater than returned to ambient
+203°F (+95°C). temperature.

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

CODE 1K Inform service

Code 1K: Platform Hung Lift Slowly Test I45 - Slk S29 [Slack Lift platform if it is hung up
Slack chain switch has transitioned Chain 1 Switch (S29)] to clear.
during operation. (Page 6-107), Test I46 -
Slk Ch S30 [Slack Chain 2
Switch (S30)] (Page 6-108)

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

CODE 2A Overheated Allow time to cool

Code 2A: Traction Motor Test A08 - Traction Motor Travel speed is linearly
Approaching Overtemperature Temperature (Page 6-48) derated starting at 266°F
The traction amplifier senses the (130°C). Travel speed is
traction motor is approaching limited to 1 mph (1.6 km/h)
overtemperature. Traction at 300°F (149°C). Cycle the
performance is limited. key switch OFF/ON to clear
after the traction motor has
cooled.
Version 4.6 corrects this
intermittent code.

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 2E Inform service

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

CODE 2E Inform service

Code 2E: Traction Motor Temp Test A08 - Traction Motor Travel is limited to 2.5 mph
Sensor Out-of-Range Temperature (Page 6-48) (4.0 km/h). Clears when the
The traction motor temperature sensor reason for the fault is
is open or shorted. corrected.

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

CODE 2G Inform service

Code 2G: Phase Open on Traction Test O29 - Ramp Traction Travel is disabled. Cycle the
Motor Motor (Page 6-137) key switch OFF/ON to clear.
The traction power amplifier has
detected no current draw in one of the
three phases of the motor.

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

CODE 2H Inform service

Code 2H: Failure Detected in Test I19 - Traction Motor Travel is limited to
Traction Motor Speed Feedback RPM (Page 6-85) 1 mph (1.6 km/h). If a single
Encoder channel is bad, this code is
displayed during Run. If one
or both channels are bad at
SelfTest, STALLED is
displayed. Cycle the key
switch OFF/ON to clear.

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

CODE 2M Inform service

Code 2M: TPA Pre-Charge Failed None Travel is disabled. Check for
Traction power amplifier failed to B+ at TPA+. Cycle the key
pre-charge correctly. switch OFF/ON to clear. If
the code will not clear,
replace the traction power
amplifier. The VM cannot
cause this code. Remove the
power fuse for the Steer Amp
(FU1) and turn the key
switch ON. If Code 2M is no
longer displayed, replace the
Steer Amp. The lift contactor
can also cause this code.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE 2T Inform service

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

CODE 2T Inform service

Code 2T: TPA Current Calibration None Travel is limited to 2.5 mph
Error (4.0 km/h). Cycle the key
The traction power amplifier has switch OFF/ON to clear. If
sensed a current calibration error. the code will not clear,
replace traction power
amplifier. The VM cannot
cause this code.
Load VM S/W 5.1 before
updating the Curtis Amp
with OS S/W 12.87. Failure
to do so will result in an AP
or AT code.

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

CODE 2U Inform service

Code 2U: TPA Overcurrent or Short None Travel is disabled. Cycle the
Circuit key switch OFF/ON to clear.
The traction power amplifier has Check for shorted traction
sensed current in excess of 400A. motor power cables. If the
code will not clear, replace
the traction power amplifier.
The VM cannot cause this
code.

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

CODE 2V Inform service

Code 2V: High DC BUS Voltage – TPA Test A15 - Battery Voltage If the voltage is OK, replace
The traction power amplifier has (Page 6-54) the TPA. Cycle the key
detected an overvoltage condition at switch OFF/ON to clear. The
the (+) terminal. VM cannot cause this code.
Version 4.6 solves this
intermittent code.

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

CODE 2W Inform service

Code 2W: TPA Internal Fault None Cycle the key switch
Traction power amplifier internal OFF/ON to clear. Replace
circuitry has malfunctioned. the traction power amplifier.

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 2X Inform service

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

CODE 2X Inform service

Code 2X: TPA Power Supply None Cycle the key switch
Out-of-Range OFF/ON to clear. Disconnect
The power supply output in the the (+) wire to the temp and
traction power amplifier is less than speed sensors. If OK,
4.5V, greater than 5.5V, or too much troubleshoot the wires and
current is being drawn by an external sensors. If not OK, replace
component. the TPA. The VM cannot
cause this code.

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

CODE 2Y Inform service

Code 2Y: Incorrect Traction Power None Replace with a correct power
Amplifier Installed amp. Travel is limited to 2.5
mph (4.0 km/h).

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

CODE 42 Inform service

Code 42: LPC Detected Closed When Test O02 - Toggle the Lift Cycle the key switch
Commanded Open Power Contactor OFF/ON to clear.
AC Lift - the lift power amplifier has (Page 6-129)
detected an incorrect voltage at the B+
terminal on the amplifier.
DC Lift - the VM has detected an
incorrect voltage at JPT18-9.

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

CODE 43 Inform service

Code 43: LPC Detected Open When Test O02 - Toggle the Lift Cycle the key switch
Commanded Closed Power Contactor OFF/ON to clear.
AC Lift - the lift power amplifier has (Page 6-129)
detected an incorrect voltage at the B+
terminal on the amplifier.
DC Lift - the VM has detected an
incorrect voltage at JPT18-9.

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

CODE 4C Inform service

Code 4C: FU1 Sense Validation None Check FU1 and FU1 Sense
FU1 detected open by the VM. This is line (JPT22-19). If FU1 opens
a sense lead validation. If the fuse is during Run, Code G4 is
bad during Run mode, another error displayed. Cycle the key
code will detect it. switch OFF/ON to clear.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE 4F Inform service

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

CODE 4F Inform service

Code 4F: TPC Detected Closed When Test O00 - Toggle the Travel is disabled.
Commanded Open Traction Power DC Lift - lift is also disabled.
The traction power amplifier has Contactor (Page 6-128) Cycle the key switch
detected an incorrect voltage at the B+ OFF/ON to clear.
terminal on the amplifier.

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

CODE 4G Inform service

Code 4G: TPC Detected Open After Test O00 - Toggle the Travel is disabled.
Power-Up Traction Power DC Lift - lift is also disabled.
The traction power amplifier has Contactor (Page 6-128) Cycle the key switch
detected the TPC open after power-up. OFF/ON to clear.

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

CODE 4H Inform service

Code 4H: TPA, TPC Contactor Coil Test O00 - Toggle the Cycle the key switch
or Coil Driver Open or Shorted Traction Power OFF/ON to clear.
Contactor (Page 6-128)

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

CODE 4K Inform service

Code 4K: LPA, LPC Contactor Coil or Test O02 - Toggle the Lift Lift is disabled. Cycle the key
Coil Driver Open or Shorted Power Contactor switch OFF/ON to clear.
AC lift only. (Page 6-129)

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 50 Inform service

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

CODE 50 Inform service

Code 50: No VM Communications Test I23 - CAN Bus All functions are disabled.
Received by CCC (Page 6-87) See Communication Error
The Carriage Control Card has not Code (50 Series)
received correct communications from Troubleshooting on
the VM. page 5-25.
Note: This code is displayed during Possible bad connection
FlashWare procedure. between CCC cold storage
mounting plate and lift truck
frame. Check the resistance.
Replace the flat and lock
washers on the mounting
hardware with a star washer
if more than 1 ohm.
Cycle the key switch
OFF/ON to clear.

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

CODE 51 Inform service

Code 51: No CCC Communications Test I23 - CAN Bus All functions are disabled.
Received by VM (Page 6-87) See Communication Error
The VM has not received correct Code (50 Series)
communications from the CCC. Troubleshooting on
page 5-25. Cycle the key
switch OFF/ON to clear.

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

CODE 56 Inform service

Code 56: Platform Hung Test I43 - Slack Chain Lift platform slowly. Inspect
No switch input was seen during Switch wiring to slack chain
lower. (CCC1107833/101) switches.
(Page 6-101), Test I45 -
Slk S29 [Slack Chain 1
Switch (S29)]
(Page 6-107), Test I46 -
Slk Ch S30 [Slack Chain
2 Switch (S30)]
(Page 6-108)

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE 59 Inform Service

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

CODE 59 Inform Service

Code 59: CAN Transmission Buffer Test I23 - CAN Bus All functions are disabled.
Error (Page 6-87) See Communication Error
The VM has detected a CAN Code (50 Series)
transmission buffer error. Troubleshooting on
page 5-25..

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

CODE 5A Inform service

Code 5A: CAN BUS Error Overflow Test I23 - CAN Bus All functions are disabled.
CAN bus error overflow detected by (Page 6-87) See Communication Error
VM. Code (50 Series)
Troubleshooting on
page 5-25. Cycle the key
switch OFF/ON to clear.

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

CODE 5B Inform service

Code 5B: Communication Error Test I23 - CAN Bus All functions are disabled.
There is no space in the CAN queue for (Page 6-87) Check for a short to frame or
the current message to be received. a bad connection in the bus
wiring. See Communication
Error Code (50 Series)
Troubleshooting on
page 5-25.
Replace the VM, then the
CCC. Cycle the key switch
OFF/ON to clear.

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

CODE 5E Inform service

Code 5E: No Guidance Manager CAN Test I23 - CAN Bus Travel is disabled in AUTO
Communications Received by the (Page 6-87) mode. Travel is allowed in
VM MANUAL mode. Check to see
if something is dragging the
GM down, for example,
antenna card. Cycle the key
switch OFF/ON to clear.

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 5G Inform service

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

CODE 5G Inform service

Code 5G: No Communications Test I23 - CAN Bus Travel is disabled. Cycle the
Received by VM from TPA (Page 6-87) key switch OFF/ON to clear.
The VM has not received CAN
communications from the traction
power amplifier.

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

CODE 5J Inform service

Code 5J: No communications Test I23 - CAN Bus Lift is disabled. Cycle the key
Received by VM from LPA (Page 6-87) switch OFF/ON to clear.
AC Lift only - The VM has not
received CAN communications from
the lift power amplifier.

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

CODE 5M Inform service

Code 5M: No communications Check wiring, Replace the required part
received by TPA from VM. Maintenance Mode Test and cycle the key switch
The TPA has not received CAN I23 - CAN Bus OFF/ON to clear.
communications from the VM for over (Page 6-87)
one minute after power was applied to If the VM is not working,
pin 1 at the amp. you cannot get into
history. Troubleshoot
per general
communications
methods. If the lift truck
displays a code after
checking the wires,
replace the VM.

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

CODE 5P Inform service

Code 5P: No communications Check wiring, Test I23 - Replace the required part
received by LPA from VM. CAN Bus (Page 6-87) and cycle the key switch
The LPA has not received CAN If the VM is not working, OFF/ON to clear.
communications from the VM for over the code cannot get into
1 minute after power was applied to listing. Troubleshoot per
pin 1 at the amp. general communications
methods. If the lift truck
displays a code after
checking the wires,
replace the VM.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE 61 Inform service

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

CODE 61 Inform service

Code 61: 24 in. Limit Switch Not Test I02 - Lower Mast Travel is limited to 2.5 mph
Sensed Reference (24 in.) Switch (4.0 km/h). Make sure the
Too much time has passed without (Page 6-80) Emergency Lower Valve is
crossing the 24 in. limit switch while Test O12 - Proportional closed. Cycle the key switch
lift request is above a certain Solenoid PWM Ramp OFF/ON to clear.
threshold. (Page 6-131)

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

CODE 63 Inform service

Code 63: Upper and Lower Test I02 - Lower Mast Travel is limited to
Reference Switches Do Not Agree Reference (24 in.) Switch 1 mph (1.6 km/h). Cycle the
The VM has sensed that the positions (Page 6-80) key switch OFF/ON to clear.
of the upper (S10) and the lower (S11) Test I69 - Upper Mast
reference switches were out of Reference Switch
sequence. (Page 6-113)

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

CODE 64 Inform service

Code 64: No Flow Sensor Pulses Test I02 - Lower Mast Travel is limited to
When Lift/Lower Requested Reference (24 in.) Switch 1 mph (1.6 km/h). Lift or
No pulses were seen from the flow (Page 6-80) lower past one of the mast
sensor when lifting past one of the two Test I26 - Flow Sensor reference switches. Cycle the
mast reference switches (24 and 150 Count (Page 6-92) key switch OFF/ON to clear.
in.). (intellispeed only) Test I69 - Upper Mast Check the strain relief at
Reference Switch connector JPY-1.
(Page 6-113)

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

CODE 66 Inform service

Code 66: Calculated Height Does Test I26 - Flow Sensor Travel is limited to
Not Match at Upper Reference Count (Page 6-92) 1 mph (1.6 km/h). Cycle the
Switch (150 in.) Test I69 - Upper Mast key switch OFF/ON to clear.
intellispeed count and calculated Reference Switch Extended periods of slow lift
height of the upper reference switch (Page 6-113) requests can cause this
(S10) are out of tolerance. (intellispeed code. Repeat test I26 and
only) I69.

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 67 Inform service

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

CODE 67 Inform service

Code 67: Calculated Height Does Test I02 - Lower Mast Travel is limited to
Not Match at Lower Reference Reference (24 in.) Switch 1 mph (1.6 km/h). Cycle the
Switch (24 in.) (Page 6-80) key switch OFF/ON to clear.
intellispeed count and calculated Test I26 - Flow Sensor Extended periods of slow lift
height of the lower reference switch Count (Page 6-92) requests can cause this
(S11) are out of tolerance. (intellispeed code. Repeat test I02 and
only). I26.

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

CODE 6D Inform service

Code 6D: Lift Pressure Sensor Test A13 - Pressure The code is displayed for five
Out-of-Range Sensor Voltage (optional) seconds. Display will then
The VM has determined that the (Page 6-52) change to “----”. Cycle the
pressure sensor voltage has exceeded key switch OFF/ON to clear.
the programmed limits.
(intellispeed only)

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

CODE 6F Overheated Allow time to cool

Code 6F: Lift Motor Overheated Test A09 - Lift Motor Lift is disabled. Allow time to
AC Lift only - Lift motor temperature Temperature (Page 6-49) cool. Cycle the key switch
has exceeded 300°F (149°C). OFF/ON to clear.

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

CODE 6K Inform service

Code 6K: 60 in. Switch Does Not Test I02 - Lower Mast Travel is limited to 2.5 mph
Agree with Lower Mast Reference Reference (24 in.) Switch (4.0 km/h). Lower, then lift
The 60 in. switch (S28) is out of (Page 6-80) past the first mast limit
sequence with the lower reference Test I03 - 60 in. Limit switch (S11). Cycle the key
switch (S11). Switch (Page 6-81) switch OFF/ON to clear.
(non-intellispeed only)

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

CODE 6M Inform service

Code 6M: 60 in. and/or 24 in. Test I02 - Lower Mast Lower, then lift past the
Switch Disconnected Reference (24 in.) Switch lower reference switch (S11).
The system detected that the 60 in. (Page 6-80) Cycle the key switch
(S28) and/or the 24 in. (S11) switch is Test I03 - 60 in. Limit OFF/ON to clear.
disconnected. Switch (Page 6-81)

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE 6N Inform service

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

CODE 6N Inform service

Code 6N: Flow Sensor Temperature None Cycle the key switch
Out-of-Range OFF/ON to clear. Only
The VM has sensed that the voltage is shown during Learn. Learn
out-of-range. (intellispeed only) values will still be stored.

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

CODE 6P Inform service

Code 6P: 60 in. Limit Switch Test I03 - 60 in. Limit Travel is limited to 1 mph
Out-of-Sequence with Upper Switch (Page 6-81) (1.6 km/h). Cycle the key
Reference Switch Test I69 - Upper Mast switch OFF/ON to clear.
The system senses that the 60 in. limit Reference Switch
switch and the upper reference switch (Page 6-113)
are out of sequence.
(non-intellispeed only)

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

CODE 7E Inform service

Code 7E: Lift Motor Temperature Test A09 - Lift Motor Lift performance is disabled
Sensor Out-of-Range Temperature (Page 6-49) by the power amplifier. Cycle
Lift motor temperature sensor voltage the key switch OFF/ON to
is out-of-range. clear.

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

CODE 7F Inform service

Code 7F: LPA Temp Out-of-Range Test A19 - Lift Power Lift is disabled. Cycle the key
The lift power amplifier has reported Amplifier Temperature switch OFF/ON to clear.
its internal temperature is less than (AC lift only) (Page 6-55)
–40°F (–40°C) or greater than +203°F
(+95°C).

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

CODE 7G Inform service

Code 7G: LPA Motor Phase Open Test O28 - Ramp Lift Lift is disabled. Cycle the key
The lift power amplifier has detected Motor (AC lift only) switch OFF/ON to clear.
no current draw in one of the three (Page 6-136)
phases of the motor.

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 7H Inform service

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

CODE 7H Inform service

Code 7H: Failure Detected in Lift Test A20 - Lift Motor Lift is limited to approx. 10
Motor Feedback Encoder Current (AC lift only) feet per minute (approx. 3
The lift power amplifier has detected (Page 6-56) meters per minute). Cycle
incorrect pulses from the lift motor the key switch OFF/ON to
encoder. clear.

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

CODE 7M Inform service

Code 7M: LPA Failed to Precharge None Lift is disabled. If cycling the
The lift power amplifier failed to key switch does not clear
precharge. this code, the amplifier must
be replaced. The VM cannot
cause this code.

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

CODE 7T Inform service

Code 7T: LPA Current Sensor Fault None. Lift is limited to 60% of
Internal lift power amplifier circuitry maximum request. If cycling
that measures current has detected a the key switch does not clear
fault. this code, the amplifier must
be replaced. The VM cannot
cause this code.

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

CODE 7U Inform service

Code 7U: LPA Overcurrent or Short None Lift is disabled. Cycle the key
Circuit switch OFF/ON to clear. The
The lift power amplifier has sensed VM cannot cause this code.
current in excess of 500A.

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

CODE 7V Inform service

Code 7V: LPA High Voltage on DC None Lift is disabled. Test the
BUS voltage at the LPA+. If OK,
The lift power amplifier has detected replace the LPA. Cycle the
that the voltage at the (+) terminal is key switch OFF/ON to clear.
overvoltage. The VM cannot cause this
code.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE 7W Inform service

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

CODE 7W Inform service

Code 7W: LPA Internal Fault None Cycle the key switch
Internal coil driver sensed open or OFF/ON to clear. If the code
shorted. will not clear, replace the lift
power amplifier. The VM
cannot cause this code.

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

CODE 7X Inform service

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

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

CODE 7Y Inform service

Code 7Y: Incorrect Lift Power None Replace with a correct power
Amplifier Installed amp.
(AC lift only)

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

CODE 80 Inform service

Code 80: Throttle Potentiometer Test A04 - Throttle Travel is disabled. Cycle the
(VR1) Voltage Out-of-Range Potentiometer Voltage key switch OFF/ON to clear.
(Page 6-46)

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

CODE 81 Inform service

Code 81: Lift/Lower Potentiometer Test A05 - Lift/Lower Lift is disabled. Cycle the key
(VR2) Voltage Out-of-Range Potentiometer Voltage switch OFF/ON to clear.
(Page 6-47)

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 83 Inform service

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

CODE 83 Inform service

Code 83: Throttle Potentiometer Test A04 - Throttle Travel is disabled. Cycle the
(VR1) Out-of-Neutral Potentiometer Voltage key switch OFF/ON to clear.
Throttle potentiometer (VR1) out of (Page 6-46)
learned neutral value.

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

CODE 84 Inform service

Code 84: Brake Inoperable; Not Test O30 - Toggle Brake Travel is disabled at
Applied Solenoid (Page 6-138) start-up. Make sure the
The drive motor bearing encoder brake release bolts are
indicated movement during SelfTest. removed from the brake
assembly. Cycle the key
switch OFF/ON to clear.
Version 4.6 solves this
intermittent code.

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

CODE 88 Inform service

Code 88: Lift and/or Travel Test A04 - Throttle Lift and Travel are disabled.
Potentiometer Voltage Potentiometer Voltage Relearn the handle. Cycle
Out-of-Range (Page 6-46) the key switch OFF/ON to
Out-of-range based on the learned Test A05 - Lift/Lower clear.
neutral value. Potentiometer Voltage
(Page 6-47)

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

CODE 8C Inform service

Code 8C: Deadman Switches Do Not Test I00 - Carriage Travel, lift, lower, and brake
Agree Deadman (Page 6-78) are disabled. Cycle the key
Deadman switches S2 and S23 do not Test I01 - Brake Deadman switch OFF/ON to clear.
agree or the steering encoder is Switch (S2) (Page 6-79)
disconnected.

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

CODE 8F Inform service

Code 8F: Lift/Lower Potentiometer Test A05 - Lift/Lower Lift and lower are disabled.
Out-of-Neutral Potentiometer Voltage Cycle the key switch
Lift/Lower potentiometer (VR2) out of (Page 6-47) OFF/ON to clear.
learned neutral value.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE 8L Inform service

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

CODE 8L Inform service

Code 8L: Electric Brake Feedback Test A35 - Brake Travel is limited to 1 mph
The VM senses the brake coil current (Page 6-60) (1.6 km/h). Cycle the key
is incorrect. switch OFF/ON to clear.

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

CODE 91 Inform service

Code 91: Drive Unit Turned >10° Test I25 - Steer Motor Lift truck plugs to 0 mph.
while Guiding on Wire Encoder (Page 6-91) Set the Auto/Manual switch
to Manual. Cycle the key
switch OFF/ON to clear.

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

CODE 92 Inform service

Code 92: Tracking Limits Exceeded Test A51 - Left Tractor Lift truck plugs to 0 mph.
Guidance Coil Voltage Set the Auto/Manual switch
(Page 6-63) to Manual. Cycle the key
Test A52 - Right Tractor switch OFF/ON to clear.
Guidance Coil Voltage
(Page 6-65)
Test A53 - Left Load
Guidance Coil Voltage
(Page 6-67)
Test A54 - Right Load
Guidance Coil Voltage
(Page 6-69)

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

CODE 93 Lost TCP Lost Wire

Code 93: Not Near Wire; Tractor Coil Test A51 - Left Tractor Lift truck plugs to 0 mph.
Pair Guidance Coil Voltage Set the Auto/Manual switch
(Page 6-63) to Manual. Cycle the key
Test A52 - Right Tractor switch OFF/ON to clear.
Guidance Coil Voltage
(Page 6-65)
Test A55 - Tractor Near
Wire Coil Voltage
(Page 6-71)

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 94 Lost LCP Lost Wire

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

CODE 94 Lost LCP Lost Wire

Code 94: Not Near Wire; Load Coil Test A53 - Left Load Truck plugs to 0 mph. Set
Pair Guidance Coil Voltage the Auto/Manual switch to
(Page 6-67) Manual. Cycle the key
Test A54 - Right Load switch OFF/ON to clear.
Guidance Coil Voltage
(Page 6-69)
Test A56 - Load Near Wire
Coil Voltage (Page 6-73)

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

CODE 9A Inform Service

Code 9A: Bad Wire Guidance Learn None Re-run the Learn procedure.
The Learn procedure did not complete Travel is limited to 1 mph
successfully. (1.6 km/h). Set the
Auto/Manual switch to
Manual. Check the wiring
between the Guidance
Manager and the VM.
Replace the Guidance
Manager. Cycle the key
switch OFF/ON to clear.

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

CODE 9B Inform Service

Code 9B: Bad SDO (CAN - Service If the error occurred while Travel is limited to 1 mph
Data Object) Data Received learning Wire Guidance, (1.6 km/h). Set the
VM received bad data from the re-run the Learn Auto/Manual switch to
Guidance Manager. procedure. Manual. Check the wiring
For lift truck software version 6.0 and If the error occurred when between the Guidance
newer, code 9B could also indicate switch changed to AUTO Manager and the VM.
that lift truck software needs to be mode for wire guidance, Re-learn Guidance. Replace
updated. update lift truck the Guidance Manager.
software Update the VM software to
the latest released software.
Cycle the key switch
OFF/ON to clear.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE 9E Inform service

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

CODE 9E Inform service

Code 9E: Track And Hold Signal Test A51 - Left Tractor Lift truck plugs to 0 mph.
Failed Guidance Coil Voltage Set the Auto/Manual switch
The lift truck is moving on the wire (Page 6-63) to Manual. Cycle the key
and the guidance signals are not Test A52 - Right Tractor switch OFF/ON to clear.
fluctuating at all. Guidance Coil Voltage
(Page 6-65)
Test A53 - Left Load
Guidance Coil Voltage
(Page 6-67)
Test A54 - Right Load
Guidance Coil Voltage
(Page 6-69)

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

CODE 9F Inform service

Code 9F: Filter Card Not Connected Check the connection Hard plug to 0 mph. Cycle
to Guidance Manager between the filter card the key switch OFF/ON to
When the Auto/Manual switch is and the Guidance clear.
switched to AUTO and the Guidance Manager. Replace the The Guidance Manager
Manager does not sense the filter card. filter card first then the circuit card
This code is not applicable with the Guidance Manager. (P/N 1181302/002)
new Guidance Manager 1268588/001. requires compatible
Code 9F should only occur with firmware
previous wire guidance systems with a (073-802-083/040).
filter card.

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

CODE 9G Inform service

Code 9G: No Input; Load Antenna Test A53 - Left Load Lift truck plugs to 0 mph.
The signal from the load antenna is Guidance Coil Voltage Set the Auto/Manual switch
not being received by the Guidance (Page 6-67) to Manual. Cycle the key
Manager. Test A54 - Right Load switch OFF/ON to clear.
Guidance Coil Voltage
(Page 6-69)

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

CODE 9H Inform service

Code 9H: No Input; Tractor Antenna Test A51 - Left Tractor Lift truck plugs to 0 mph.
The signal from the tractor antenna is Guidance Coil Voltage Set the Auto/Manual switch
not being received by the Guidance (Page 6-63) to Manual. Cycle the key
Manager. Test A52 - Right Tractor switch OFF/ON to clear.
Guidance Coil Voltage
(Page 6-65)

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 9J Inform service

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

CODE 9J Inform service

Code 9J: Load Antenna Input Too Test A53 - Left Load Lift truck plugs to 0 mph.
High Guidance Coil Voltage Set the Auto/Manual
Can be triggered by a checksum error (Page 6-67) switch to Manual. Cycle
calculated by the Guidance Manager. Test A54 - Right Load the key switch OFF/ON to
Guidance Coil Voltage clear.
(Page 6-69) Complete Tests A53 and
A54, then re-run the Learn
Procedure.

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

CODE 9K Inform service

Code 9K: Tractor Antenna Input Too Test A51 - Left Tractor Lift truck plugs to 0 mph.
High Guidance Coil Voltage Set the Auto/Manual switch
Can be triggered by a checksum error (Page 6-63) to Manual. Cycle the key
calculated by the Guidance Manager. Test A52 - Right Tractor switch OFF/ON to clear.
Guidance Coil Voltage Complete Tests A53 and
(Page 6-65) A54, then re-run the Learn
Procedure.

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

CODE 9M Inform service

Code 9M: Guidance Manager Voltage Test A101 - Guidance Wire guidance will not
is Out of Range Manager 12V Power function. Measure power
Guidance Manager Voltage is Out of Supply Out of Range being supplied to antenna
Range (Page 6-76) boards. Acceptable range is
11-13 volts.

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

CODE A0 Inform service

Code A0: Incorrect Software None Travel, lift, and lower are
Incorrect VM installed in lift truck or disabled. Cycle the key
Flashed with incorrect software. switch OFF/ON to clear. If
this code appears, upgrade
the software in the lift truck
using FlashWare. If you have
recently replaced the truck’s
VM, turn a truck option ON
and then OFF again in
FlashWare and reset factory
default.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE A2 Inform service

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

CODE A2 Inform service

Code A2: Software Compatibility None Travel is disabled. Cycle the
Issue with VM and TPA key switch OFF/ON to clear.
If this code appears, upgrade
the software in the lift truck
using FlashWare.

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

CODE A4 Inform service

Code A4: Software Compatibility None Lift is disabled. Cycle the key
Issue with VM and LPA switch OFF/ON to clear. If
AC lift only. this code appears, upgrade
the software in the lift truck
using FlashWare.

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

CODE AH Inform service

Code AH: Bad CCC Checksum None Lift and Travel are disabled.
Replace the CCC.

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

CODE AL Inform service

Code AL: VM Battery Backed Up None Travel, lift, and lower are
RAM Failed disabled. Cycle the key
switch OFF/ON to clear. If
the code will not clear,
replace the VM.

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

CODE AP Inform service

Code AP: TPA Software Fault None Travel is disabled. Cycle the
key switch OFF/ON to clear.
If the code will not clear,
Flash the traction power
amplifier with the latest
software. Also see “Code 2T:
TPA Current Calibration
Error”

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE AT Inform service

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

CODE AT Inform service

Code AT: LPA Software Fault None Lift is disabled. Cycle the key
AC lift only. switch OFF/ON to clear. If
the code will not clear, Flash
the lift power amplifier with
the latest software. Also see
“Code 2T: TPA Current
Calibration Error”

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

CODE F8 Inform service

Code F8: Microcontroller COP None Lift and Travel are disabled.
Timer is not functioning correctly. Re-install the VM software.
Replace the VM. Cycle the
key switch OFF/ON to clear.

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

CODE FE Inform service

Code FE: Internal VM Circuit for None Code is displayed for 30
BSOC Not Calibrated seconds. Replace the VM.
If intermittent, test the
Inrush Protection circuit.
See “Inrush Protection” on
page 5-23.

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

CODE FG Inform service

Code FG: +5V Reference Voltage and Test A14 - VM +12V Power Travel, lift, and lower are
+12V Power Supply Failure Supply (Page 6-53) disabled. Brake will engage.
Cycle the key switch
OFF/ON to clear.
If intermittent, test the
Inrush Protection circuit.
See “Inrush Protection” on
page 5-23.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE FH Inform service

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

CODE FH Inform service

Code FH: Battery Voltage Test A15 - Battery Voltage Travel, lift, and lower are
Out-of-Range (Page 6-54) disabled. Brake will remain
Wrong voltage battery or voltage engaged. Cycle the key
out-of-range. switch OFF/ON to clear.
If intermittent, test the
Inrush Protection circuit.
See “Inrush Protection” on
page 5-23.

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

CODE FN Inform service

Code FN: Relays Did Not Open at Test O32 - Toggle Relay Travel, lift, and lower are
Power Off Enable (Page 6-139) disabled. Brake remains
engaged. Cycle the key
switch OFF/ON to clear.

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

CODE FP Inform service

Code FP: VM In-Circuit Hardware None Travel, lift, and lower are
Failure disabled. Brake remains
engaged. Cycle the key
switch OFF/ON to clear.
Replace the VM.
If intermittent, test the
Inrush Protection circuit.
See “Troubleshooting” on
page 5-1.

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

CODE FT Inform service

Code FT: VM Internal Software Error None Travel, lift, and lower are
disabled. Brake will remain
engaged. Cycle the key
switch OFF/ON to clear. If
the code will not clear, Flash
the VM with the latest
software.
If intermittent, test the
Inrush Protection circuit.
See “Troubleshooting” on
page 5-1.

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE G0 Inform service

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

CODE G0 Inform service

Code G0: Steer Tiller Encoder 1 is See “Test I35 - Steer Tiller Coasts to 2.5 mph (4.0
Intermittent or Failed Encoder 1” on km/h). Travel is limited to
Determined by channel A and/or B page 6-93. 2.5 mph (4.0 km/h). Cycle
not functioning correctly when the key switch OFF/ON to
compared with Steer Tiller Encoder 2. clear.

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

CODE G2 Inform service

Code G2: Auto Steer Center Failed See “Test O44 - Steer Moderate plug to 0.0 mph.
1. Home switch is more than 10° from Motor” on page 6-145. Step off, then back on the
the initial value saved during a See “Auto Steer Center deadman pedal to allow
successful auto steer center. Problem” on page 5-35. travel again. Max travel
2. Auto steer center time-out is speed is limited to 1.0 mph
greater than two seconds. (1.6 km/h). Cycle the key
3. No encoder pulses sensed during switch OFF/ON to clear.
auto steer center.

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

CODE G3 Inform service

Code G3: Home Prox Switch Not See “Test O44 - Steer All steer indicator lights will
Functioning Correctly Motor” on page 6-145. flash. Travel speed is limited
See “Auto Steer Center to 1.0 mph (1.6 km/h). Cycle
Problem” on page 5-35. the key switch OFF/ON to
clear.

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

CODE G4 Inform service

Code G4: Open Detected in Steer See “Test O44 - Steer Aggressive plug to 0.0 mph.
Control Circuit Motor” on page 6-145. Step off, then back on the
No neutral pulses detected when the See “Auto Steer Center deadman pedal to allow
lift truck is not moving and the Problem” on page 5-35. travel again. Max travel
operator is on the deadman pedal. speed is set to 1.0 mph (1.6
km/h).
Cycle the key switch
OFF/ON to clear.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE G5 Inform service

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

CODE G5 Inform service

Code G5: Short Detected in Steer Test A37 - Steer Power Moderate plug to 0.0 mph.
Power Circuit Amplifier Current Step off, then back on the
Steer motor encoder pulses or (Page 6-61) deadman pedal to allow
command detected and no steer tiller See “Test O44 - Steer travel again. Max travel
encoder pulses detected. Motor” on page 6-145. speed is set to 1.0 mph (1.6
Test I25 - Steer Motor km/h).
Encoder (Page 6-91) Cycle the key switch
OFF/ON to clear.

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

CODE G7 Inform service

Code G7: Steer Tiller Encoder 2 is Test I36 - Steer Tiller Coasts to 2.5 mph (4.0
Intermittent or Failed Encoder 2 (Page 6-94) km/h). Travel is limited to
Determined by the connect detect 2.5 mph (4.0 km/h). Cycle
circuit for the CD Supply and Gnd the key switch OFF/ON to
connections or by channel A and/or B clear.
not functioning correctly when
compared with Steer Tiller Encoder
One.

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

CODE GD Inform service

Code GD: No Steer Motor Encoder Test I25 - Steer Motor Lift truck plugs to 0 mph.
Pulses Seen Encoder (Page 6-91) Travel is limited to 1 mph
No steer motor encoder pulses seen See “Test O44 - Steer (1.6 km/h). More steer tiller
when requesting a steer correction, Motor” on page 6-145. rotations are required to
travel is >0.1 mph or during auto steer turn the drive unit. Cycle the
center. key switch OFF/ON to clear.

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

CODE GE Inform service

Code GE: Both Steer Tiller Encoders Test I35 - Steer Tiller Lift truck plugs to 0 mph.
Failed Encoder 1 (Page 6-93) Travel is limited to 1 mph
Determined by the connect detect Test I36 - Steer Tiller (1.6 km/h). Cycle the key
circuit. Encoder 2 (Page 6-94) switch OFF/ON to clear.

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE GF Inform service

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

CODE GF Inform service

Code GF: Wire Guidance Position Re-run Learn Procedure. Lift and Travel are disabled.
Out-of-Range Set the Auto/Manual switch
A steer request received from the GM to Manual. Replace the Wire
was out-of-range. From the center, any Guidance Manager. Cycle
request over -90° out-of-range. the key switch OFF/ON to
clear.

Icon Code Title/Reason Tests to RunPage -27 Notes/Corrective Action

CODE J2 Inform service

Code J2: Aisle Exit Error Test I72 - End-of-Aisle Plugs to stop, speed is
Only one magnet was sensed when the Sensor 2 (optional) limited to 1 mph (1.6 km/h).
guided aisle was exited. (Page 6-115) While out of the aisle, switch
Test I73 - End-of-Aisle the Auto/Manual switch to
Sensor 1 (optional) - Manual. Turn the drive unit
Software versions 5.7 >10° and travel until the
and below (Page 6-117) code clears.
Go into lift truck history and
see what subcode was
thrown. See Table 5-5 on
page 5-27

Icon Code Title/Reason Tests to RunPage -27 Notes/Corrective Action

CODE J4 Inform service

Code J4: Aisle Sensor Error Test I72 - End-of-Aisle Travel is limited to 1 mph
Sensor 2 (optional) (1.6 km/h).
(Page 6-115)
Test I73 - End-of-Aisle
Sensor 1 (optional) -
Software versions 5.7
and below (Page 6-117)

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

CODE VC Inform service

Code VC: The CAN Chip will not Test I23 - CAN Bus All functions are disabled.
Reset (Page 6-87) See Communication Error
Most likely this is due to an internal Code (50 Series)
fault in the VM. Troubleshooting on
page 5-25.
Replace the VM. Cycle the
key switch OFF/ON to clear.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

CODE X3 Inform service

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

CODE X3 Inform service

Code X3: 180 in. Limit Switch Test I75 - 180 in. Limit Travel is limited to 1 mph
Mismatch Switch (optional) (1.6 km/h). Cycle the key
The 180 in. Switch (S100) is out of (Page 6-122) switch OFF/ON to clear.
sequence with a standard mast
switch.

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

CODE X4 Inform service

Code X4: Lift Cutout Switch Test I76 - Lift Cutout Cycle the key switch
Mismatch Switch (optional) OFF/ON to clear.
Lift Cutout Switch (S124) mismatch (Page 6-123) Up arrow icon flashes and
with standard mast switch. message lift cutout - max ht
reached.

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

CODE X5 Inform service

Code X5: Lift Inhibit Switch Test I05 - Lift Inhibit Cycle the key switch
Mismatch Switch (optional) OFF/ON to clear.
Lift Inhibit Switch (S24) mismatch (Page 6-83)
with standard mast switch.

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Models 5400/5500/5600 Maintenance Manual

Analog Input Tests

Analog Input Tests

A Diagnosis and Repair table is provided for
most tests. If a test fails, refer to the Diagnosis
and Repair table. Through the process of
elimination, these tables provide the technician
with a step-by-step approach to diagnosing a
problem and the necessary corrective action.
See the table below.
Example Diagnosis and Repair Table
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

This column
identifies the
action(s) required
(if any) before
testing the
circuit. If no
instructions are
given, all circuits
must be
The next
connected. The next
This is the Connection Connection action to be
Note: If action to be
order that point for point for The reading performed if
something was performed if
the testing the Positive the required to consider the
disconnected in the Expected
must be (+) meter Negative (–) the step a success. Expected
the prior step, Results are
performed. lead. meter lead. Results are
reconnect it met.
not met.
before
performing the
next step.

This column also

identifies the
required setting
on the meter for
this step.

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 Models 5400/5500/5600 Maintenance Manual

Test A04 - Throttle Potentiometer Voltage

Test A04 - Throttle Run Test:

Potentiometer Voltage The test is a success if the voltage displayed is
within these limits:
This test displays the voltage the CCC produces Throttle Position Voltage Displayed
based on input from the throttle potentiometer
(VR1). Full forward position
0.60 to 1.30V
Tractor-first (TF)
NOTE: Learn must be run whenever the throttle
assembly is replaced, repaired, or Neutral position 1.36 to 1.74V
adjusted. See Learn Controls on
Full reverse position
page 3-19. 1.80 to 2.50V
Forks-first (FF)

For information on using Maintenance Mode,

refer to page 3-26. If the voltage reading is outside these limits or
does not change in a smooth linear fashion, the
test has failed. Any voltage fluctuation indicates
a bad cable or VR1.

The voltage reading should decrease when the

throttle is moved from the reverse to the
forward position. If these results are not
observed, the test has failed. Perform diagnosis
and repair.

Diagnosis and Repair

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

1 JPC9 PC9-7 Perform step 2

disconnected/ PC9-8 5.3V Replace CCC
2 DCV PC9-9 Perform step 3

Neutral: 1.23-1.83V
Replace pot
3 DCV JPC9-9 JPC9-7 FF: increase Replace CCC
(VR1)
TF: decrease

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Test A05 - Lift/Lower Potentiometer Voltage

Test A05 - Lift/Lower Run Test:

Potentiometer Voltage The test is a success if the voltage displayed is
within these limits:
This test displays the voltage the CCC produces Lift/Lower
based on input from the lift/lower pot (VR2). Voltage Displayed
Control Position
NOTE: Run this test if the voltage output by the Full lift position 0.45 to 1.00V
lift/lower potentiometer (pot) exhibits
problems. Neutral position 0.96 to 1.44V

NOTE: Learn must be run when the lift/lower Full lower position 1.40 to 2.20V
pot is replaced, repaired, or adjusted.
See Learn Controls on page 3-19. If the voltage reading is outside these limits or
does not change in a smooth linear fashion, the
For information on using Maintenance Mode, test has failed. Any voltage fluctuation indicates
refer to page 3-26. a bad cable or VR2.

The voltage reading should decrease when the

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

Diagnosis and Repair

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

1 JPC9 PC9-4 Perform step 2

PC9-5 5.3V Replace CCC
2 disconnected/DCV PC9-6 Perform step 3

Neutral: 0.97-1.46V
Replace pot
3 DCV JPC9-6 JPC9-4 Lower: increase Replace CCC
(VR2)
Lift: decrease

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 Models 5400/5500/5600 Maintenance Manual

Test A08 - Traction Motor Temperature

Test A08 - Traction Motor the lift truck up by driving it hard for
approximately 30 minutes. As the motor heats,
Temperature the temperature will increase.

For information on how to use Maintenance

This test displays the temperature of the Mode, refer to page 3-26.
traction motor.

Limits Run Test:

• Normal operation: ambient to 258°F 1. With the lift truck at rest and at ambient
(125°C) temperature, compare the temperatures
• Between 266°F (130°C) and 300°F (149°C), obtained from those obtained using
speed is linearly reduced to 1.0 mph Maintenance Mode to the ambient
(1.6 km/h). temperature.
• Temperature icon lights at 275°F (135°C) 2. If the temperatures are not within several
degrees, the test has failed.
• Fault Code 2A and travel disabled at 300°F
(149°C) 3. If the lift truck is not at ambient
temperature, use the diagnosis and repair
While operating, the VM continually monitors chart to isolate the cause.
the temperature of the traction motor. If the
temperature gets too high, performance is
reduced until the motor cools down.

Use Active Maintenance to see the actual

temperature from the temperature sensor. Heat
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPTA1
1 disconnected/ JTA1-8 JTA1-7 <1200 ohms if Replace TPA Perform step 2
ohms motor is cool
JPTA3 >1200 ohms if T/S traction
motor is hot Replace traction
2 disconnected/ JTA3-2 JTA3-1 motor temp
motor temp sensor
ohms sensor

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Test A09 - Lift Motor Temperature

Test A09 - Lift Motor

Temperature
This test displays the temperature of the AC lift
motor.

Limits
• Normal operation: ambient to 294°F
(145°C)
• Temperature icon lights at 295°F (146°C)
• Fault Code 6F and lift shutdown at 300°F
(149°C)

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
As lift is operated, the readings should increase
evenly over time. If not, the test has failed.
Perform diagnosis and repair.

Diagnosis and Repair

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

JPLA1
1 disconnected/ JLA1-8 JLA1-7 <1200 ohms if Replace LPA Perform step 2
ohms motor is cool
JPLA3 >1200 ohms if
motor is hot T/S lift motor Replace lift motor
2 disconnected/ JLA3-2 JLA3-1
temp sensor temp sensor
ohms

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 Models 5400/5500/5600 Maintenance Manual

Test A10 - Traction Power Amplifier Temperature

Test A10 - Traction

Power Amplifier
Temperature
This test displays the temperature of the
Traction Power Amplifier (TPA).

Limits
• Normal operation: ambient to 175°F (79°C)
• Starting at 176°F (80°C), speed is linearly
reduced by the Traction Power Amplifier to
0.0 mph at 239°F (115°C), when traction is
disabled.
• Temperature icon lights at 185°F (85°C)
• Fault Code 1H at 203°F (95°C)

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
The OD shows the heatsink temperature that
the traction power amplifier reads.

As drive is operated, the readings should

increase evenly over time. If not, the test has
failed. Perform diagnosis and repair.

Diagnosis and Repair

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

Is TPA heatsink If not hot, replace

1 Hot to touch Perform step 2
hot to touch? TPA
N/A N/A
Allow time to Not hot to touch, no Return to
2 Replace TPA
cool. code service

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Models 5400/5500/5600 Maintenance Manual

Test A11 - Traction Motor Current

Test A11 - Traction Motor Diagnosis and Repair

NOTE: Check all motor and power amplifier
Current connections for tightness and corrosion.

This test displays the current in the traction Check individual phase currents with a
motor power circuits. clamping ammeter. The current should ramp
evenly as the lift truck accelerates and
Limits: decelerates. Phase currents must be
approximately equal. Gross differences indicate
• Above 266°F (130°C) current is reduced
a problem.
linearly
• Maximum current up to 540A when If readings are not within reference limits, the
deadman pedal is released, unaffected and test has failed.
unreduced by temperature
1. If any one phase differs significantly from
the other two, check power cable
For information on using Maintenance Mode,
continuity. Replace cables as necessary.
refer to page 3-26.
See Power Cables on page 7-72.
NOTE: This test shows best results in Active • If power cable continuity is OK,
Maintenance. troubleshoot the traction motor. See AC
Motors on page 5-14.
Run Test: • If all phases give high readings, the
drive unit may be binding. Check the
The OD shows the current that the traction drive unit.
power amplifier reads from the traction motor.
2. The power amplifier may be bad. Run Test
O29 - Ramp Traction Motor (Page 6-137).
System Condition Current Displayed

Static at Rest <20A

Travel at Full Speed <150A

Because Test A11 measures only one phase, the

test may not always reveal a problem.

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 Models 5400/5500/5600 Maintenance Manual

Test A13 - Pressure Sensor Voltage (optional)

Test A13 - Pressure

Sensor Voltage
(optional)
This test displays the voltage from the pressure
sensor used for load weight sensing.

For information on using Maintenance Mode,

refer to page 3-26.

Limits

The OD shows the voltage present with various

load weights.

Load Weight Voltage

0 (no load) Approx. 1.0V

3000 lbs. Approx. 3.0V

If the weight sensor is disconnected at the VM,

the OD shows 0V.

Run Test:
The voltage shown on the OD should increase
and decrease in a linear fashion as the load
weight is either increased or decreased. If it
does not, the test has failed. If the weight
display is inaccurate, the test has failed.
Perform diagnosis and repair.

Diagnosis and Repair

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

1 JPT20-5 JPT24-10 Step 2 Replace VM

DCV 10.5 to 13V
2 JPS50-1 Step 3 T/S harness

JPS50-3 Replace
3 Attach pressure JPS50-2 1V at 0 psi: 1V Step 4 Pressure
gauge to G1/DCV increase per 1000 psi Transducer

4 JPT24-18 JPT24-10 Replace VM T/S harness

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Models 5400/5500/5600 Maintenance Manual

Test A14 - VM +12V Power Supply

Test A14 - VM +12V

Power Supply
This test displays the output of the internal
+12V power supply of the VM.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
The display should read 10.8-13V. If the voltage
fluctuates more than 0.8V in 10 seconds, the
test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

Remove wire from PT14-5

1 Step 2 Step 4
JPT14-5/DCV (VM side)

JPC11 Replace mast

2 Step 3
disconnected/DCV cable

Disconnect all wires

supplying 12 or
5.3V from the Plug in wires
3 connectors at the TP4 10.5 to 13V Replace CCC
and connectors
CCC. Disconnect JPT14-5 one at a time.
JPC15 and Troubleshoot
JPC2/DCV the circuit that
Disconnect all wires pulls down the
supplying 12V from 12V.
4 Replace the VM
the connectors at
the VM/DCV

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 Models 5400/5500/5600 Maintenance Manual

Test A15 - Battery Voltage

Test A15 - Battery Run Test:

Voltage The test is a success if the voltage displayed is
within these limits:
This test displays the voltage the VM is reading PC must be closed.
from the battery sense line.
Nominal Battery
Voltage Displayed
A successful test proves the VM is correctly Voltage
reading BATTERY_SENSE_IN at JPT24-24.
24V 22.0 to 26.0V
NOTE: This voltage is used by the VM to
36V 33.0 to 39.0V
calculate the battery state-of-charge.

For information on using Maintenance Mode, If the reading fluctuates by more than 0.8V in
refer to page 3-26. 10 seconds with the lift truck not moving or
lifting, the test has failed. Perform diagnosis
and repair.
NOTE: If FH Code occurs, verify that the model
number viewed in FlashWare matches
the vehicle model before replacing the
VM.

Diagnosis and Repair

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

Check battery
voltage/ specific
1 TP1 Perform step 2
gravity. T/S battery
cables.

24V truck: 16 to 32V T/S harness TP1 to

2 DCV JPF4-1 TP4 Perform step 3
36V truck: 28 to 44V TP4.

3 JPF4-7 Perform step 4 T/S Fuse Relay Card.

T/S harness from

4 JPT24-24 Replace VM Fuse Relay Card to
VM.

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Test A19 - Lift Power Amplifier Temperature (AC lift only)

Test A19 - Lift Power

Amplifier Temperature
(AC lift only)
This test displays the temperature of the Lift
Power Amplifier (LPA) heatsink.

Limits
• Normal operation: ambient to 175°F (79°C)
• Starting at 176°F (80°C), speed is linearly
reduced to 0 fpm at 239°F (115°C), when
lift is disabled
• Temperature icon illuminates at 185°F
(85°C)
• Fault Code 7F at 203°F (95°C)

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
The OD shows the heatsink temperature that
the lift power amplifier reads.

As the lift is operated, the readings should

increase evenly over time. If not, the test has
failed. Perform diagnosis and repair.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

Is LPA heatsink If not hot, replace

1 Hot to touch Perform step 2
hot to touch? LPA
N/A N/A
Allow time to Not hot to touch, no Return to
2 Replace LPA
cool. code service

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 Models 5400/5500/5600 Maintenance Manual

Test A20 - Lift Motor Current (AC lift only)

Test A20 - Lift Motor 1. If any one phase differs significantly from
the other two, check power cable
Current (AC lift only) continuity. Replace cables as necessary.
See Power Cables on page 7-72.

This test displays the lift motor current through • If power cable continuity is OK,
the lift power amplifier. troubleshoot the lift motor. See AC
Motors on page 5-14.
• If all phases give high readings, the lift
pump may be binding.
The lift carriage and forks will move 2. The power amplifier may be bad. Run Test
during this test. O28 - Ramp Lift Motor (AC lift only)
(Page 6-136).

The area around the forks must be clear.

The ceiling clearance should allow for
the highest lift.

Limits
• 0 to 500A lifting
• Maximum current 675A

Test requires the use of Active Maintenance to

see correct test results.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
The OD shows the current that the lift power
amplifier reads from one phase of the lift motor.
NOTE: Because only one phase is measured, a
current problem may not be revealed.

Diagnosis and Repair

NOTE: Check all motor and power amplifier
connections for tightness and corrosion.

Check individual phase currents with a

clamping ammeter. The current should ramp
evenly as the lift truck accelerates and
decelerates. Phase currents must be
approximately equal. Gross differences indicate
a problem.

If readings are not within reference limits, the

test has failed.

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Test A22 - Traction Throttle Request

Test A22 - Traction

Throttle Request
This test displays the percentage of traction
throttle request from VR1 being read by the VM.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
NOTE: Run Learn after you replace, repair, or
adjust the throttle assembly. See Learn
Controls on page 3-19.

The OD shows the percentage of throttle

request that the VM reads from the control
handle throttle potentiometer (VR1) and sends
to the traction power amplifier.

Acceptable values are:

Throttle Position Percentage Displayed

Full Tractor-First 0 to +100

Neutral 0

Full Forks-First 0 to –100

The values must change smoothly and evenly

as the handle moves from full tractor-first to
full forks-first.

If percentages are not within reference limits,

the test has failed. Perform diagnosis and
repair.
NOTE: Any speed limiting conditions will result
in less than 100 shown on the display.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

Test should pass. Check traction

Run Test A04 -
Compare Test A04 system for speed
Throttle
results with the limits due to motor
1 Potentiometer N/A N/A Replace the TPA
results from A22. temperature, limit
Voltage
Max throw should switches, or
(Page 6-46)
show max values. configured speed.

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 Models 5400/5500/5600 Maintenance Manual

Test A23 - Lift Request

Test A23 - Lift Request

This test displays the percentage of lift throttle
request from VR2 being read by the VM.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
NOTE: Run Learn after you replace, repair, or
adjust the Lift/Lower potentiometer
(VR2). See Learn Controls on page 3-19.

The OD shows the percentage of lift request

that the VM reads from the lift potentiometer
(VR2).

Acceptable values are:

Throttle Position Percentage Displayed

Full Lower 0 to –100

Neutral 0

Full Lift 0 to +100

The values must change smoothly and evenly

as the handle moves from full lower to full lift.

If percentages are not within reference limits,

the test has failed. Perform diagnosis and
repair.
NOTE: Any lift limiting conditions will result in
less than 100% shown on display.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

Test should pass.

Run Test A05 -
Compare Test A05 Check lift system
Lift/Lower
results with the for limits due to
1 Potentiometer N/A N/A Replace the LPA
results from A23. motor temperature
Voltage
Max throw should or switches.
(Page 6-47)
show max values.

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Test A34 - Lift/Lower Current

Test A34 - Lift/Lower

Current
This test displays the current the proportional
lift/lower solenoid coil is drawing.

Test requires the use of Active Maintenance to

see correct test results.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
Acceptable values are:

State Current

Neutral Approx. 0.0A

Full Lower Approx. 0.75A

If results do not match the preceding table. the

test has failed. Perform diagnosis and repair.

Diagnosis and Repair

Perform Test O12 - Proportional Solenoid PWM

Ramp (Page 6-131).

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 Models 5400/5500/5600 Maintenance Manual

Test A35 - Brake

Test A35 - Brake

The brake coil is activated by a coil driver
located inside the VM. This test displays the
voltage measured across that coil driver.

For information on using Maintenance Mode,

refer to page 3-26.
NOTE: This test can only be run in Active
Maintenance.

Run Test:
When the test is run, observe the following
results:

State of Brake Display

Brake deactivated B+

Deadman Pedal
Approx. 12V (36V trucks)
Pressed/Travel
Approx. 0V (24V trucks)
Requested

If results do not match the preceding table, the

test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPT20 and
JPF2 T/S wires and
1 JT20-14 JF2-2 Approx. 13 ohms Perform step 2
disconnected/ coil
ohms

If no B+, T/S
Brake de-energized: B+ Fuse Relay Card.
Inspect brake
Brake energized: If voltage does
2 DCV JP20-14 TP4 assembly for
36V truck = approx. 12V not drop when
binding
24V truck = 0V energized,
replace the VM

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Test A37 - Steer Power Amplifier Current

Test A37 - Steer Power report something higher than zero

current in Maintenance Mode.
Amplifier Current If the results do not match the preceding table,
the test has failed. Perform diagnosis and
This test displays the current that the steer repair.
motor is drawing.

Test requires the use of Active Maintenance to

see correct test results.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
You should see:

State of Motor Display

At rest <2A

Clockwise (CW) Steering –30 to –50A

Counterclockwise (CCW) Steering 30 to 50A

NOTE: CW and CCW is drive unit direction.

NOTE: On a fully functional truck, this test

reports OA in Maintenance Mode
because the steer is not being moved in
Maintenance Mode. If the steer amp is
unplugged or other errors in steer
current feedback occur, the test will

Diagnosis and Repair

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

At rest: approx. 2.5V

Replace Steer
1 DCV JPT6-3 TP4 Steering CCW: <V at rest Replace VM
Amplifier
Steering CW: >V at rest

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Tractor Near Wire -

Test A55 - Tractor
Tractor Left - Test A51 Near Wire Coil
- Left Tractor Voltage (Page 6-71)
Guidance Coil Voltage Tractor Right - Test
(Page 6-63) A52 - Right Tractor
Guidance Coil Voltage
(Page 6-65)

Load Near Wire - Test

A56 - Load Near Wire
Coil Voltage
(Page 6-73)

Load Left - Test A53 - Load Right - Test A54

Left Load Guidance - Right Load Guidance
Coil Voltage Coil Voltage
(Page 6-67) (Page 6-69)

6
Figure 6-1. Location of Wire Guidance Coils and Related Tests

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Test A51 - Left Tractor Guidance Coil Voltage

Test A51 - Left Tractor Test line driver output. Refer to the applicable
Raymond Wire Guidance Maintenance Manual.
Guidance Coil Voltage For information on using Maintenance Mode,
refer to page 3-26.
This test displays the percentage of the left
tractor guidance coil voltage sensed by the
Guidance Manager. Run Test:
NOTE: Center the lift truck over the wire prior
Refer to Figure 6-1 on page 6-62 to determine
to running the test. If it will not track, it
what coil this test checks.
may not be centered and voltages will
fail the test.
Make sure the lift truck has been through the
learn process before testing. Make sure the
The test is a success if the percentage displayed
software is up to date. Inspect all motor cables.
is between 40 and 80%. If the reading is outside
Test for shorts to frame. See “Shorts to Frame”
these limits, the test has failed. Perform
on page 5-2.
diagnosis and repair.
Make sure the lift truck is set to the correct
frequency. If the frequency used is not
standard, it must first be Learned. See Learn
WireFreq on page 3-21.
Diagnosis and Repair (Use this table if you have GM 1268588/001 or newer that is not equipped with a
Filter Card)
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

J1T-1, 2,
JPW2 and PW2-1, 2, 3,
3, 4, 5, 6,
1 JP1T cables 4, 5, 6, 7, 8, 0 ohms Perform step 2 Replace cable
7, 8, 14,
disconnected 14, 15
15

JPW2
2 disconnected/ JW2-15 JW2-14 Perform step 3 Replace GM
DCV
Approx 11.5V
JP1T
3 disconnected/ J1T-15 J1T-14 Replace sensor Replace cable
DCV

NOTE: Steps 2 and 3 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair (Use this table if you have GM 1183339 or earlier equipped with a filter card)
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

Cable JW2-1, 2, 3, J1T-1, 2,

1 disconnected/ 5, 6, 7, 8, 14, 3, 5, 6, 7, 0 ohms Perform step 2 Replace cable
Ohms 15 8, 14, 15

JPW2
2 disconnected/ JW2-15 JW2-14 Perform step 4 Perform step 3
DCV

JP1-A13
JP1-B1 (Filter Approx 11.5V
(Filter
Filter Card Card Replace Steer
Card Replace Filter
3 removed/ connection Controller
connection Card
DCV on Steer Card
on Steer
Card)
Card)

Bumper Centered: 32mV

Replace
4 removed/ JPW2-3 1.5 in. left: 15mV Perform step 5
Antenna Card
mVAC 1.5 in. right: 76mV
B–
Bumper Centered: 1.1V
Replace Steer Replace Filter
5 removed/ JP1-A15 1.5 in. left: 0.6V
Controller Card Card
DCV 1.5 in. right: 2.8V

NOTE: Steps 4 and 5 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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Test A52 - Right Tractor Guidance Coil Voltage

Test A52 - Right Tractor Test line driver output. Refer to the applicable
Raymond Wire Guidance Maintenance Manual.
Guidance Coil Voltage For information on using Maintenance Mode,
refer to page 3-26.
This test displays the percentage of the right
tractor guidance coil voltage sensed by the
Guidance Manager. Run Test:
NOTE: Center the lift truck over the wire prior
Refer to Figure 6-1 on page 6-62 to determine
to running the test. If it will not track, it
what coil this test checks.
may not be centered and voltages will
fail the test.
Make sure the lift truck has been through the
learn process before testing. Make sure the
The test is a success if the voltage percentage
software is up to date. Inspect all motor cables.
displayed is between 40 and 80%.
Test for shorts to frame. See “Shorts to Frame”
on page 5-2.
If the reading is outside these limits, the test
has failed. Perform diagnosis and repair.
Make sure the lift truck is set to the correct
frequency. If the frequency used is not
standard, it must first be Learned. See Learn
WireFreq on page 3-21.

Diagnosis and Repair (Use this table if you have GM 1268588/001 or newer that is not equipped with a
Filter Card)
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

J1T-1, 2,
JPW2 and PW2-1, 2, 3,
3, 4, 5, 6,
1 JP1T cables 4, 5, 6, 7, 8, 0 ohms Perform step 2 Replace cable
7, 8, 14,
disconnected 14, 15
15

JPW2
2 disconnected/ JW2-15 JW2-14 Perform step 3 Replace GM
DCV
Approx 11.5V
JP1T
3 disconnected/ J1T-15 J1T-14 Replace sensor Replace cable
DCV

NOTE: Steps 2 and 3 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair (Use this table if you have GM 1183339 or earlier equipped with a filter card)
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

Cable dis- JW2-1, 2, 3, J1T-1, 2,

1 connected/ 5, 6, 7, 8, 14, 3, 5, 6, 7, 0 ohms Perform step 2 Replace cable
ohms 15 8, 14, 15

JPW2 dis- Perform step

2 PW2-15 PW2-14 Perform step 4
connected/DCV 3

JP1-A13
JP1-B1 (Filter
(Filter Approx 11.5V
Filter Card Card Replace Steer
Card Replace Filter
3 removed/ connection Controller
connection Card
DCV on Steer Card
on Steer
Card)
Card)

Bumper Centered: 32mV

Replace
4 removed/ JPW2-1 1.5 in. left: 15mV Perform step 5
Antenna Card
mVAC 1.5 in. right: 76mV
B–
Bumper Centered: 1.1V
JP1-A16 Replace Steer Replace Filter
5 removed/ 1.5 in. left: 0.6V
(Filter Card) Controller Card Card
DCV 1.5 in. right: 2.8V

NOTE: Steps 4 and 5 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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Models 5400/5500/5600 Maintenance Manual

Test A53 - Left Load Guidance Coil Voltage

Test A53 - Left Load Test line driver output. Refer to the applicable
Raymond Wire Guidance Maintenance Manual.
Guidance Coil Voltage For information on using Maintenance Mode,
refer to page 3-26.
This test displays the percentage of the left load
guidance coil voltage sensed by the Guidance
Manager. Run Test:
NOTE: Center the lift truck over the wire prior
Refer to Figure 6-1 on page 6-62 to determine
to running the test. If it will not track, it
what coil this test checks.
may not be centered and voltages will
fail the test.
Make sure the lift truck has been through the
learn process before testing. Make sure the
The test is a success if the voltage percentage
software is up to date. Inspect all motor cables.
displayed is between 40 and 80%.
Test for shorts to frame. See “Shorts to Frame”
on page 5-2.
If the reading is outside these limits, the test
has failed. Perform diagnosis and repair.
Make sure the lift truck is set to the correct
frequency. If the frequency used is not
standard, it must first be Learned. See Learn
WireFreq on page 3-21.

Diagnosis and Repair (Use this table if you have GM 1268588/001 or newer that is not equipped with a
Filter Card)
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

J1L-1, 2,
JPW1 and PW1-1, 2, 3,
3, 4, 5, 6,
1 JP1L cables 4, 5, 6, 7, 8, 0 ohms Perform step 2 Replace cable
7, 8, 14,
disconnected 14, 15
15

JPW1
2 disconnected/ JW1-15 JW1-14 Perform step 3 Replace GM
DCV
Approx 11.5V
JP1L
3 disconnected/ J1L-15 J1L-14 Replace sensor Replace cable
DCV

NOTE: Steps 2 and 3 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair (Use this table if you have GM 1183339 or earlier equipped with a filter card)
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

Cable dis- JW2-1, 2, 3, J1L-1, 2,

1 connected/ 5, 6, 7, 8, 14, 3, 5, 6, 7, 0 ohms Perform step 2 Replace cable
ohms 15 8, 14, 15

JPW1
2 disconnected/ PW1-15 PW1-14 Perform step 4 Perform step 3
DCV

JP1-A13
JP1-B1 (Filter Approx 11.5V
(Filter
Filter Card Card Replace Steer
Card Replace Filter
3 removed/ connection Controller
connection Card
DCV on Steer Card
on Steer
Card)
Card)

Bumper Centered: 32mV

Replace
4 removed/ JPW1-3 1.5 in. left: 15mV Perform step 5
Antenna Card
mVAC 1.5 in. right: 76mV
B–
Bumper Centered: 1.1V
JP1-A7 (Filter Replace Steer Replace Filter
5 removed/ 1.5 in. left: 0.6V
Card) Controller Card Card
DCV 1.5 in. right: 2.8V

NOTE: Steps 4 and 5 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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Models 5400/5500/5600 Maintenance Manual

Test A54 - Right Load Guidance Coil Voltage

Test A54 - Right Load Test line driver output. Refer to the applicable
Raymond Wire Guidance Maintenance Manual.
Guidance Coil Voltage For information on using Maintenance Mode,
refer to page 3-26.
This test displays the percentage of the right
load guidance coil voltage sensed by the
Guidance Manager. Run Test:
NOTE: Center the lift truck over the wire prior
Refer to Figure 6-1 on page 6-62 to determine
to running the test. If it will not track, it
what coil this test checks.
may not be centered and voltages will
fail the test.
Make sure the lift truck has been through the
learn process before testing. Make sure the
The test is a success if the voltage percentage
software is up to date. Inspect all motor cables.
displayed is between 40 and 80%.
Test for shorts to frame. See “Shorts to Frame”
on page 5-2.
If the reading is outside these limits, the test
has failed. Perform diagnosis and repair.
Make sure the lift truck is set to the correct
frequency. If the frequency used is not
standard, it must first be Learned. See Learn
WireFreq on page 3-21.

Diagnosis and Repair (Use this table if you have GM 1268588/001 or newer that is not equipped with a
Filter Card)
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

J1L-1, 2,
JPW1 and PW1-1, 2, 3,
3, 4, 5, 6,
1 JP1L cables 4, 5, 6, 7, 8, 0 ohms Perform step 2 Replace cable
7, 8, 14,
disconnected 14, 15
15

JPW1
2 disconnected/ JW1-15 JW1-14 Perform step 3 Replace GM
DCV
Approx 11.5V
JP1L
3 disconnected/ J1L-15 J1L-14 Replace sensor Replace cable
DCV

NOTE: Steps 2 and 3 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair (Use this table if you have GM 1183339 or earlier equipped with a filter card)
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

Cable JW1-1, 2, 3, J1L-1, 2,

1 disconnected/ 5, 6, 7, 8, 14, 3, 5, 6, 7, 0 ohms Perform step 2 Replace cable
ohms 15 8, 14, 15

JPW1
2 disconnected/ PW1-15 PW1-14 Perform step 4 Perform step 3
DCV
Approx 11.5V
Filter Card JP1-A13
JP1-B1 (Filter Replace Filter Replace Steer
3 removed/ (Filter
Card) Card Controller Card
DCV Card)

Bumper Centered: 32mV

Replace
4 removed/ JPW1-1 1.5 in. left: 15mV Perform step 5
Antenna Card
mVAC 1.5 in. right: 76mV
B–
Bumper Centered: 1.1V
Replace Steer Replace Filter
5 removed/ JP1-A15 1.5 in. left: 0.6V
Controller Card Card
DCV 1.5 in. right: 100mV

NOTE: Steps 4 and 5 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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Models 5400/5500/5600 Maintenance Manual

Test A55 - Tractor Near Wire Coil Voltage

Test A55 - Tractor Near Test line driver output. Refer to the applicable
Raymond Wire Guidance Maintenance Manual.
Wire Coil Voltage For information on using Maintenance Mode,
refer to page 3-26.
This test displays the percentage of the tractor
near wire guidance coil voltage sensed by the
Guidance Manager. Run Test:
NOTE: Center the lift truck over the wire prior
Refer to Figure 6-1 on page 6-62 to determine
to running the test. If it will not track, it
what coil this test checks.
may not be centered and voltages will
fail the test.
Make sure the lift truck has been through the
learn process before testing. Make sure the
The test is a success if the percentage displayed
software is up to date. Inspect all motor cables.
is between 80 and 120%.
Test for shorts to frame. See “Shorts to Frame”
on page 5-2.
If the reading is outside these limits, the test
has failed. Perform diagnosis and repair.
Make sure the lift truck is set to the correct
frequency. If the frequency used is not
standard, it must first be Learned. See Learn
WireFreq on page 3-21.

Diagnosis and Repair (Use this table if you have GM 1268588/001 or newer that is not equipped with a
Filter Card)
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

J1T-1, 2,
JPW2 and PW2-1, 2, 3,
3, 4, 5, 6,
1 JP1T cables 4, 5, 6, 7, 8, 0 ohms Perform step 2 Replace cable
7, 8, 14,
disconnected 14, 15
15

JPW2
2 disconnected/ JW2-15 JW2-14 Perform step 3 Replace GM
DCV
Approx 11.5V
JP1T
3 disconnected/ J1T-15 J1T-14 Replace sensor Replace cable
DCV

NOTE: Steps 2 and 3 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair (Use this table if you have GM 1183339 or earlier equipped with a filter card)
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPW2 and
JW2-1, 2, 3, J1T-1, 2,
JP1T
1 5, 6, 7, 8, 14, 3, 5, 6, 7, 0 ohms Perform step 2 Replace cable
disconnected/
15 8, 14, 15
ohms

JPW2
2 disconnected/ PW2-15 PW2-14 Perform step 4 Perform step 3
DCV

JP1-A13
JP1-B1 (Filter Approx 11.5V
(Filter
Filter Card Card
Card Replace Filter Replace Steer
3 removed/ connection
connection Card Controller Card
DCV on Steer
on Steer
Card)
Card)

Bumper Centered: 70mV

Replace
4 removed/ JPW2-2 1.5 in. left: 100mV Perform step 5
Antenna Card
mVAC 1.5 in. right: 100mV
B–
Bumper Centered: 2.5V
JP1-A15 Replace Steer Replace Filter
5 removed/ 1.5 in. left: 3.7V
(Filter Card) Controller Card Card
DCV 1.5 in. right: 3.7V

NOTE: Steps 4 and 5 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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Models 5400/5500/5600 Maintenance Manual

Test A56 - Load Near Wire Coil Voltage

Test A56 - Load Near Test line driver output. Refer to the applicable
Raymond Wire Guidance Maintenance Manual.
Wire Coil Voltage For information on using Maintenance Mode,
refer to page 3-26.
This test displays the percentage of the load
near wire guidance coil voltage sensed by the
Guidance Manager. Run Test:
NOTE: Center the lift truck over the wire prior
Refer to Figure 6-1 on page 6-62 to determine
to running the test. If it will not track, it
what coil this test checks.
may not be centered and voltages will
fail the test.
Make sure the lift truck has been through the
learn process before testing. Make sure the
The test is a success if the voltage percentage
software is up to date. Inspect all motor cables.
displayed is between 80 and 120%.
Test for shorts to frame. See “Shorts to Frame”
on page 5-2.
If the reading is outside these limits, the test
has failed. Perform diagnosis and repair.
Make sure the lift truck is set to the correct
frequency. If the frequency used is not
standard, it must first be Learned. See Learn
WireFreq on page 3-21.

Diagnosis and Repair (Use this table if you have GM 1268588/001 or newer that is not equipped with a
Filter Card)
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

J1L-1, 2,
JPW1 and PW1-1, 2, 3,
3, 4, 5, 6,
1 JP1L cables 4, 5, 6, 7, 8, 0 ohms Perform step 2 Replace cable
7, 8, 14,
disconnected 14, 15
15

JPW1
2 disconnected/ JW1-15 JW1-14 Perform step 3 Replace GM
DCV
Approx 11.5V
JP1L
3 disconnected/ J1L-15 J1L-14 Replace sensor Replace cable
DCV

NOTE: Steps 2 and 3 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair (Use this table if you have GM 1183339 or earlier equipped with a filter card)
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPW1 and
JW1-1, 2, 3, J1L-1, 2,
JP1L
1 5, 6, 7, 8, 14, 3, 5, 6, 7, 0 ohms Perform step 2 Replace cable
disconnected/
15 8, 14, 15
ohms

JPW1
2 disconnected/ PW1-15 PW1-14 Perform step 4 Perform step 3
DCV

JP1-A13
JP1-B1 (Filter Approx 11.5V
(Filter
Filter Card Card Replace Steer
Card Replace Filter
3 removed/ connection Controller
connection Card
DCV on Steer Card
on Steer
Card)
Card)

Bumper Centered: 70mV

Replace
4 removed/ JPW1-2 1.5 in. left: 100mV Perform step 5
Antenna Card
mVAC 1.5 in. right: 100mV
B–
Bumper Centered: 2.5V
JP1-A6 (Filter Replace Steer Replace Filter
5 removed/ 1.5 in. left: 3.7V
Card) Controller Card Card
DCV 1.5 in. right: 3.7V

NOTE: Steps 4 and 5 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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Models 5400/5500/5600 Maintenance Manual

Tests A96 through A100 - iBATTERY Tests

Tests A96 through A100

- iBATTERY Tests
Tests A96 through A100 are iBATTERY related
tests. Refer to iBATTERY Monitoring System
Installation and Maintenance Instructions
(P/N 1139156).

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 Models 5400/5500/5600 Maintenance Manual

Test A101 - Guidance Manager 12V Power Supply Out of Range

Test A101 - Guidance Run Test:

Manager 12V Power The Guidance Manager is equipped with a 2
amp fuse (F1). It is located internal to the fuse
Supply Out of Range holder on the bottom left corner. Cover removal
is required in order to remove and check the
This test displays the 12v power supply from fuse. Check the fuse prior to proceeding with
the Guidance Manager to the antenna card. the testing below.
The display should read between 11 and 13
For information on using Maintenance Mode, volts. If the voltage is outside this range the test
refer to page 3-26. has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPW2
Guidance Replace
1 Manager JW2-15 JW2-14 Perform step 2 Guidance
disconnected/ Manager
DCV

JPW1
Guidance Replace
2 Manager JW1-15 JW1-14 Perform step 3 Guidance
disconnected/ Manager
DCV 11-13V
JP1T Tractor Perform step 4
TS wiring from
Sensor before you
3 P1T-15 P1T-14 Guidance
disconnected/ replace the
Manager
DCV Tractor Sensor

Perform step 3
JP1L Load
before you TS wiring from
Sensor
4 P1L-15 P1L-14 replace the Guidance
disconnected/
Load Sensor Manager
DCV

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Models 5400/5500/5600 Maintenance Manual

Input Tests

Input Tests
A Diagnosis and Repair table is provided for
most tests. If a test fails, refer to the Diagnosis
and Repair table. Through the process of
elimination, these tables provide the technician
with a step-by-step approach to diagnosing a
problem and the necessary corrective action.
See the table below.
Example Diagnosis and Repair Table
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

This column
identifies the
action(s) required
(if any) before
testing the
circuit. If no
instructions are
given, all circuits
must be
The next
connected. The next
This is the Connection Connection action to be
Note: If action to be
order that point for point for The reading performed if
something was performed if
the testing the Positive the required to consider the
disconnected in the Expected
must be (+) meter Negative (–) the step a success. Expected
the prior step, Results are
performed. lead. meter lead. Results are
reconnect it met.
not met.
before
performing the
next step.

This column also

identifies the
required setting
on the meter for
this step.

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 Models 5400/5500/5600 Maintenance Manual

Test I00 - Carriage Deadman

Test I00 - Carriage

Deadman
This test shows what the VM is reading from
S23. The switch is hard wired through the CCC
to the VM.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
The state of the switch is displayed:

Deadman Pedal Operator Display

Up Up

Down Down

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPC7
1 disconnected PC7-5 PC7-6 Perform Step 2 Replace CCC
/DCV
10.7 to 13V
2 JPC7-5 Perform Step 3
S23-3 Repair/replace wire
3 Perform Step 4
S23-1
4 S23-2 Pedal down: Perform Step 5 Adjust/replace S23
10.7 to 13V
5 JPC7-5 JPC7-4 Pedal up: 0V Perform Step 6 Repair/replace wires
DCV
6 JPC11-6 Perform Step 7 Replace CCC

Pedal down: B+ Repair/replace

7 B+ JPS25-5 Perform Step 8
Pedal up: 0V over-the-mast cable

8 JPT22-8 Replace VM Repair/replace cable

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Models 5400/5500/5600 Maintenance Manual

Test I01 - Brake Deadman Switch (S2)

Test I01 - Brake

Deadman Switch (S2)
This test shows what the VM is reading from
S2. The switch is hard wired through the CCC
to the VM.
NOTE: Make sure jumper from JPC1-8 to
JPC1-9 is in place before running the
test.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
The state of the switch is displayed:

Deadman Pedal Operator Display

Up Up

Down Down

If these results are not observed, the test has

failed. Perform diagnosis and repair.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPC7
1 disconnected/ PC7-2 PC7-3 Perform Step 2 Replace CCC
DCV
10.7 to 13V
2 JPC7-2 Perform Step 3 Repair/replace
S2-3
3 Perform Step 4 wire
S2-1
4 S2-2 Perform Step 5 Adjust/replace S2
Pedal down: 10.7 to 13V
Pedal up: 0V Repair/replace
5 DCV JPC7-2 JPC7-1 Perform Step 6
wires

6 JPC11-4 Perform Step 7 Replace CCC

7 JPS25-4 Pedal down: 0V Perform Step 8 Replace

B–
Pedal up: 10V over-the-mast
8 JPT22-7 Replace VM cable

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 Models 5400/5500/5600 Maintenance Manual

Test I02 - Lower Mast Reference (24 in.) Switch

Test I02 - Lower Mast Run Test:

Reference (24 in.) Switch When the test is run, observe the following
results:
This test monitors the state of the lower mast Carriage Switch Operator
reference switch (S11). This test displays what Height Actuator Display
the CCC is reading from the switch.
Below 24 in.
Pressed Belw
For information on using Maintenance Mode, (61 cm)
refer to page 3-26. Above 24 in.
Released Abve
(61 cm)

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Use Active Maintenance to check that the

display indicates the lower mast reference
switch is Belw at all positions below 24 in.
(61 cm). Check that the display indicates the
24 in. (61 cm) switch is Abve at all positions
above 24 in. (61 cm).

Diagnosis and Repair

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

JPC8
1 disconnected PC8-2 PC8-3 Perform Step 2 Replace CCC
/DCV
6 to 13V
2 JPC8-2 Perform Step 3
S11-3 Repair/replace wires
3 Perform Step 4
DCV S11-1
4 S11-2 S11 Perform Step 5 Adjust/replace S11
Closed (below): 6-13V
5 JPC8-2 JPC8-1 Open (above): 0V Replace CCC Repair/replace wires

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Models 5400/5500/5600 Maintenance Manual

Test I03 - 60 in. Limit Switch

Test I03 - 60 in. Limit If these results are not observed, the test has
failed.
Switch Using Active Maintenance, check that the
display indicates the 60 in. switch is Belw at all
Using this test, the state of the 60 in. limit positions below 60 in. Check that the display
switch (S28) can be monitored. This test indicates Abve for all positions above the 60 in.
displays what the CCC is reading from the switch.
switch.
NOTE: This switch is not used with the Lift trucks without S28 require a jumper
intellispeed option. (P/N 114-008-958/002) between JPC3-3 and
JPC3-1.
For information on using Maintenance Mode,
refer to page 3-26.

Run Test:
When the test is run, observe the following
results:

Operator
Carriage Height Switch
Display

Below 60 in. Pressed Belw

Above 60 in. Extended Abve

Diagnosis and Repair

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

JPC3
1 disconnected PC3-2 PC3-3 Perform Step 2 Replace CCC
/DCV
6 to 13V
2 JPC3-2 Perform Step 3
S28-3
3 Perform Step 4
DCV S28-1 Repair/replace wires
4 S28-2 S28 Perform Step 5
Closed (below): 6-13V
5 JPC3-2 JPC3-1 Open (above): 0V Replace CCC

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 Models 5400/5500/5600 Maintenance Manual

Test I04 - Lift/Lower Inhibit Bypass (optional)

Test I04 - Lift/Lower

Inhibit Bypass (optional)
Using this test, the state of the lift inhibit
bypass switch (S7) can be tested. This test
displays what the CCC is reading from the
switch. This test is only visible on lift trucks
equipped with the Lift/Lower Inhibit Bypass
option.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
When the test is run, observe the following
results.

Lift Inhibit Switch (S7) Operator Display

Up Out

Pressed In

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPC6 Verify option Repair/replace wires

Released: open circuit
1 disconnected/ JC6-6 JC6-5 is turned on. and/or switch S7
Pressed: 0 ohms
ohms Replace CCC

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Models 5400/5500/5600 Maintenance Manual

Test I05 - Lift Inhibit Switch (optional)

Test I05 - Lift Inhibit

Switch (optional)
Using this test, the state of the lift inhibit
switch (S24) can be monitored. This test
displays what the VM is reading from the
switch. This test only works on lift trucks
equipped with the Lift/Lower Inhibit Bypass
option.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
When the test is run, observe the following
results:

Operator Carriage Operator Display

Below Switch (closed) Belw

Above Switch (open) Abve

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Diagnosis and Repair

Action/
Step Meter (+) Lead (–) Lead ExpectedResults Step Passed Step Failed
Setting

Pull pin from

JPT20-10.
1 JPT24-3 Perform Step 2 Replace VM
Backprobe
connection. 10.7 to 13V
2 JPT20-10 Perform Step 3 Repair/replace
S24-1
3 DCV Perform Step 4 harness
S24-3 Adjust or replace
4 S24-2 Perform Step 5
S24 S24
Closed: 10.7 to 13V Verify option is
Open: approx. 0V Repair/replace
5 JPT20-10 JPT22-2 turned on.
harness
Replace VM

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 Models 5400/5500/5600 Maintenance Manual

Test I15 - Horn Switch

Test I15 - Horn Switch

This test checks the input from the horn switch
(S3) to the CCC at JPC9-3 and JPC9-4.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
When the test is run, observe the following
results:

Horn Switch Position Operator Display

Out Out

Pressed In

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Diagnosis and Repair

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

S3 Repair/replace
1 DCV JPC9-3 JPC9-4 Closed: < 0.6V Replace CCC wires and/or
Open: Approx. 5.35V switch S3

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Models 5400/5500/5600 Maintenance Manual

Test I19 - Traction Motor RPM

Test I19 - Traction Motor

RPM
This test displays the output from the speed
encoder on the traction motor as seen by the
traction power amplifier.

Do this test in an area free of

obstructions with ample room for
maneuvering.

For information on using Maintenance Mode,

refer to page 3-26.

This test requires the use of Active Maintenance

to see correct test results.

Run Test:
NOTE: The OD shows RPM as measured by the
traction power amplifier. The RPM
reading should show a linear increase to
maximum RPM.

You should see:

Lift Truck Type Maximum RPM

Standard Duty 5532

Heavy Duty 4424

If these results are not observed, the test has failed. Perform diagnosis and repair.

Diagnosis and Repair

Action/
Step Meter (+) Lead (–) Lead ExpectedResults Step Passed Step Failed
Setting

1 JPTA1-26 Perform Step 2 Replace TPA

JPTA1-7
2 4.5 to 5.5V Perform Step 3 Troubleshoot/replace
JPTA2-1
3 JPTA2-4 Perform Step 4 harness

4 DCV JPTA1-31 Perform Step 5 Perform Step 6

Stationary: >3.5V
5 JPTA1-32 or <0.5V Replace TPA Perform Step 7
JPTA1-7
6 JPTA2-3 Running: approx.
2V Repair/replace Replace traction motor
7 JPTA2-2 harness speed encoder

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 Models 5400/5500/5600 Maintenance Manual

Test I20 - Lift Motor RPM (AC lift only)

Test I20 - Lift Motor RPM

(AC lift only)
This test displays the input from the speed
encoder on the lift motor as seen by the lift
power amplifier.

Do this test in an area free of

obstructions with ample room for lifting.

For information on using Maintenance Mode,

refer to page 3-26.

This test requires the use of Active Maintenance

to see correct test results.

Run Test:
NOTE: The OD shows RPM as measured by the
lift power amplifier. The RPM reading
should show a linear increase to
maximum RPM.

During lift, 2400 rpm max must be displayed.

Diagnosis and Repair

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

1 JPLA1-26 Perform Step 2 Replace LPA

JPLA1-7
2 4.5 to 5.5V Perform Step 3 Troubleshoot/replace
JPLA2-1
3 JPLA2-4 Perform Step 4 harness

4 DCV JPLA1-31 Perform Step 5 Perform Step 6

Stationary: >3.5V or
5 JPLA1-32 <0.5V Replace LPA Perform Step 7
JPLA1-7
6 JPLA2-3 Running: approx.
2V Repair/replace Replace lift motor
7 JPLA2-2 harness speed encoder

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Models 5400/5500/5600 Maintenance Manual

Test I23 - CAN Bus

Test I23 - CAN Bus

This test verifies the VM is communicating with
the Traction Power Amplifier, Lift Power
Amplifier, and Guidance Manager.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
NOTE: To enter this test, press and hold
both the UP and DOWN buttons and
turn the key switch ON.

The OD shows:
• V if the Vehicle Manager is communicating
with the Carriage Control Card
• T if the Traction Power Amplifier is
communicating with the Carriage Control
Card
• L if the Lift Power Amplifier is
communicating with the Carriage Control
Card (AC lift only)
• W if the Guidance Manager is
communicating with the Carriage Control
Card (Wire Guidance only)
NOTE: Wait at least 60 seconds after the test
shows on the display for letters to be
displayed.

If V, T, L, or W are not displayed, the test has

failed. Perform diagnosis and repair.

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair

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

If letter V is missing:

1 DCV JPTA1-1 B– B+ Perform Step 2 T/S B+ from K3 Relay

2 JPT14 and JPT14-11 JPSC1-2

JPSC1 Repair/replace
JPT14-4 JPSC1-1 0 ohms Replace VM
3 disconnected/ harness
ohms

If letter L is missing (AC Lift only):

1 DCV JPLA1-1 B– (on amp) B+ Perform Step 2 T/S B+ from K3 Relay

2 JPLA1 and JPLA1-23 JPSC2-2

JPSC2 Replace Lift Repair/replace
JPLA1-35 JPSC2-1 0 ohms
3 disconnected/ Amplifier harness
ohms

If letter T is missing:

1 DCV JPTA1-1 B– (on amp) B+ Perform Step 2 T/S B+ from K3 Relay

2 JPTA1 and JPTA1-23 JPSC1-2

Replace
JPSC1 Repair/replace
JPTA1-35 JPSC1-1 0 ohms Traction
3 disconnected/ harness
Amplifier
ohms

If letter W is missing (Wire Guidance only):

1 JPS2-11 JPS2-24 Perform Step 4 Perform Step 2

2 JPT20-19 TP4 Perform Step 3 Replace VM

DCV B+
Perform Step 1 Replace Fuse/Relay
3 TP1 JPF3-9
Card

Disconnect T/S wires and Replace Guidance

JPW1 and 2 Antenna Cards. Manager
and the Filter If OK, replace
Card at the Filter Card.
W shows on
4 GM. On GM N/A N/A On GM
display
1268588/001, 1268588/001,
only replace the GM.
disconnect
JPW1 and 2.

If no letters are displayed:

Perform Step 2 Repair/replace shorted

1 JPLA1, JPTA1, JT14-4 Open
Bus +/– cable
JPT14, JPS4
and JPC11 JT14-11 JTA1-23,
disconnected/ JLA1-23, Repair/replace
2 0 ohms Perform Step 3
ohms JS4-6, harness
JC11-3

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Run Test:

Diagnosis and Repair

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

One at a time, Letters for the Replace

disconnect all other devices disconnected
3 N/A N/A Replace CCC
devices on the come back on component
Bus display

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 Models 5400/5500/5600 Maintenance Manual

Test I24 - Home Position Proximity Sensor

Test I24 - Home Position

Proximity Sensor
This test displays what the VM sees from the
Home Proximity Sensor.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
When the test is run, observe the following
results:

Home
Operator Red LED on
Proximity
Display Sensor
Sensor

Over metal On On

Away from
Off Off
metal

If these results are not observed, the test has

failed. Perform diagnosis and repair.
NOTE: If the test fails in Active Maintenance,
pass a screwdriver or metal ruler under
the sensor to activate it. If the test
passes, adjust the switch. See Home
Proximity Sensor Adjustment on
page 7-20.

Diagnosis and Repair

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

1 JPA7-3 JPA7-2 Perform Step 3 Perform Step 2

10.5 to 13V Replace/replace
2 JPT20-9 JPT22-11 Replace VM
harness
DCV Adjust/replace
3 JPA7-3 JPA7-1 Sensor over metal: Perform Step 4
approx. 10V sensor
Sensor not over Replace/replace
4 JPT22-3 JPT20-9 metal: approx. 6V Replace VM
harness

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Test I25 - Steer Motor Encoder

Test I25 - Steer Motor

Encoder
This test displays the counts from the steer
motor encoder.

For information on using Maintenance Mode,

refer to page 3-26.

This test requires the use of Active Maintenance

to see correct test results.

Run Test:
A three digit number is displayed representing
the number of steer motor encoder counts.
When the count exceeds 255, it starts over at 0.
If the count goes below 0, it starts over at 255.
NOTE: Turn the steering slowly to make sure
that the display shows the encoder
counting correctly.

If these results are not seen, perform diagnosis

and repair.

Diagnosis and Repair

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

1 JPE4-1 10.5 to 13V Perform 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 Perform Step 4

4 DCV JPT22-9 Turning: Perform Step 5

approx. 2.5V Repair/replace
5 JPT22-10 Replace VM harness
JPT10-9
Repair/replace
6 JPT20-7 10.5 to 13V Replace VM
harness

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 Models 5400/5500/5600 Maintenance Manual

Test I26 - Flow Sensor Count

Test I26 - Flow Sensor Run Test:

Count A three digit number is displayed representing
the number of flow pulses counted. When the
NOTE: This test applies to lift trucks equipped count exceeds 255, it starts over at 0. If the
with the intellispeed option. count goes below 0, it starts over at 255.

This test displays the flow sensor pulses that Place test in Active Maintenance. The count
the VM reads. A successful test proves the VM should increase during lift and decrease during
is correctly reading pulses from the flow sensor. lower. If these results are not observed, the test
has failed. Perform diagnosis and repair.
For information on using Maintenance Mode,
refer to page 3-26. This test must be run from
Active Maintenance.

Diagnosis and Repair

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

1 JPY7-1 J21-A Perform Step 2

2 JPY7-2 J21-B Perform Step 3 Repair/replace

ohms 0 ohms
3 JPY6-1 J22-A Perform Step 4 wires

4 JPY6-2 J22-B Perform Step 5

5 JPY1 JPT20-2 JPY24-11 Perform Step 6 Replace VM

disconnected/ 12V Repair/replace
6 DCV JPY1-5 JPY1-3 Perform Step 7
wires

7 JPY7-1 JPY7-3 Perform Step 8 Replace cable

DCV 2.6V
8 JPY6-1 JPY6-3 Perform Step 9 and sensor

9 JPY7-2 JPY7-3 At rest: <2mV Perform Step 10

Lift/Lower: Ramps from
Lift or Lower/ Clean flow
approx 0 to between 200
10 mVAC JPY6-2 JPY6-3 Perform Step 11 sensor turbine
and 300mV as speed
increases

11 JPY1-1 Perform Step 12 Replace cable

12 JPY1-2 Perform Step 13 and sensor
Lift or Lower/ At rest: 0 to 5V
B–
13 DCV JPT22-13 Lift/Lower: approx 2.8V Perform Step 14 Repair/replace
14 JPT22-14 Replace VM wires

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Models 5400/5500/5600 Maintenance Manual

Test I35 - Steer Tiller Encoder 1

Test I35 - Steer Tiller

Encoder 1
This test displays the value that the CCC sees
from the Steer Tiller Encoder at JPC1. A
successful test proves the CCC is reading the
encoder correctly.

The VM uses the input from the CCC to

determine the rate and direction of steering.
The displayed number varies between 0 and
255. The value has little correlation to the
actual steering angle. The displayed value
should change as the drive unit is steered.

This test requires the use of Active Maintenance

to see correct test results.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
If the number displayed does not vary or the
count only changes from 0 to 1 or 0 to 255, the
test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

1 PC1-1 PC1-2 Perform Step 2

JPC1at CCC
2 disconnected/ PC1-3 PC1-2 5.3V Perform Step 3 Replace CCC
DCV
3 PC1-4 PC1-2 Perform Step 4

Will be either approx.

5.3V or approx. 0V
JPC1-3
when the tiller is
(CHB-E2) JPC1-2 Replace steer
4 DCV stationary. Replace CCC
JPC1-4 JPC1-2 encoder
Somewhere between
(CHA-E2)
0 and 5V when tiller
is moving.

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 Models 5400/5500/5600 Maintenance Manual

Test I36 - Steer Tiller Encoder 2

Test I36 - Steer Tiller Run Test:

Encoder 2 If the number displayed does not vary or the
count only changes from 0 to 1 or 0 to 255, the
This test displays the value that the CCC sees test has failed. Perform diagnosis and repair.
from the Steer Tiller Encoder at JPC21. A
successful test proves the CCC is reading the
encoder correctly.

The VM uses the input from the CCC to

determine the rate and direction of steering.
The displayed number varies between 0 and
255. The value has little correlation to the
actual steering angle. The displayed value
should change as the drive unit is steered.

This test requires the use of Active Maintenance

to see correct test results.

For information on using Maintenance Mode,

refer to page 3-26.

Diagnosis and Repair

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

1 JPC21 at PC21-1 PC21-2 Perform Step 2

CCC
2 PC21-3 PC21-2 5.3V Perform Step 3 Replace CCC
disconnected
3 /DCV PC21-4 PC21-2 Perform Step 4

Will be either approx.

5.3V or approx. 0V
when the tiller is
JPC21-3 (CHB-E2) JPC21-2 Replace steer
4 DCV stationary. Replace CCC
JPC21-4 (CHA-E2) JPC21-2 encoder
Somewhere between
0 and 5V when the
tiller is moving.

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Test I38 - EPO Switch

Test I38 - EPO Switch

This test monitors the state of the Emergency
Power Off (EPO) switch. A successful test proves
the CCC is correctly reading the EPO switch.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
When the test is run, observe the following
results:

Emergency Off Switch Operator Display

Out Out

In In

If these results are not observed, the test has

failed. Perform diagnosis and repair.
NOTE: After activating the EPO switch, cycle
the key switch OFF/ON.

Diagnosis and Repair

Action/
Step Meter (+) Lead (–) Lead ExpectedResults Step Passed Step Failed
Setting

1 JPC6-4 Perform Step 2 Replace CCC

Repair/replace wires or
2 JPC6-3 Perform Step 3
switch

3 JPC16-1 Perform Step 4 Replace CCC

DCV B– B+ Replace over-the-mast
4 JPF4-5 Perform Step 5
cable

5 JPF4-6 Perform Step 6 Replace Fuse Relay Card

Repair or replace wire

6 JPT22-21 Replace VM
from Fuse Relay Card

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 Models 5400/5500/5600 Maintenance Manual

Test I39 - Neutral Pulses

Test I39 - Neutral Pulses

This test displays the neutral pulses seen by
the VM from the Steer Power Amplifier.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
This test requires use of Active Maintenance to
see correct test results.

You should see:

On Deadman/TPC
Off Deadman
Contactor Closed

Quickly toggles
ON
between ON and OFF

If results do not match the preceding table, the

test has failed. Perform diagnosis and repair.
NOTE: If an error code exists, Active
Maintenance will not work. Refer to
“Test O44 - Steer Motor” on page 6-145
for troubleshooting.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

1 JPT6-6 10.5 to 13V Perform Step 2 Replace VM

DCV JPT6-4 Repair wiring or

2 JPT6-1 Deadman pedal up: >4V Replace VM replace Steer Power
Amplifier

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Models 5400/5500/5600 Maintenance Manual

Test I41 - Aux Mast Lift Switch S32 (CCC 1107833/101)

Test I41 - Aux Mast Lift NOTE: S31 (Aux lift left-hand deadman) must
also be pressed during this test.
Switch S32
Run Test:
(CCC 1107833/101)
You should see:
See “Test I41 - Aux Mast Lift Switch S32 (CCC
1275051/003)” on page 6-98 for more Aux Mast Lift Switch Operator Display
information about running this test on lift
trucks with CCC1275051/003. Out Off

Pressed On
This test monitors the state of the auxiliary lift
switch (S32). This switch causes the auxiliary
mast to lift. This test displays what the CCC is If results do not match the preceding table, the
reading from the switch. test has failed. Perform diagnosis and repair.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPC19
1 disconnected PC19-3 Perform Step 3 Perform Step 2
/DCV
B+ B+
Aux Card
Replace Aux
2 disconnected PC18-3 Replace CCC
Card
/DCV

JPC19
3 disconnected PC19-3 PC19-1 6 to 13V Perform Step 7 Perform Step 4
/DCV

4 JC18-8 JC18-1 B+ Perform Step 5

5 Aux Card JC18-5 5.3V Perform Step 6

disconnected Replace CCC
/DCV JC18-3 Replace Aux
6 JC18-7 12V Card, then
CCC

JPC19
connected,
Repair/replace wires
7 S31 and S32 B+ PC19-1 B+ Replace CCC
or switch
activated
/DCV

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 Models 5400/5500/5600 Maintenance Manual

Test I41 - Aux Mast Lift Switch S32 (CCC 1275051/003)

Test I41 - Aux Mast Lift NOTE: S31 (Aux lift left-hand deadman) must
also be pressed during this test. The S31
Switch S32 switch circuit must be functional.

(CCC 1275051/003) Run Test:

See “Test I41 - Aux Mast Lift Switch S32 (CCC You should see:
1107833/101)” on page 6-97 for more
information about running this test on lift Aux Mast Lift Switch Operator Display
trucks with CCC1107833/101.
Out Off
This test monitors the state of the auxiliary lift
Pressed On
switch (S32). This switch causes the auxiliary
mast to lift. This test displays what the CCC is
reading from the switch. If results do not match the preceding table, the
test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPC19
1 disconnected PC19-1 PC19-3 16-13V Perform Step 2 Replace CCC
/DCV

JPC19
Connected/
2 DCV/S31 JPC19-1 JPC19-3 Approx. 0.0V Replace CCC Perform Step 3
and S32
Activated

S32
3 Activated/ S32-1 S32-2 0.1 ohm Perform Step 4 Replace S32
ohms

Troubleshoot wiring
4 ohms S32-2 S31-1 0.1 ohm Perform Step 5
from S31 to S32

S31 Troubleshoot
5 Activated/ S31-2 S31-1 0.1 ohm wiring from Replace S31
ohms CCC to S31

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Test I42 - Aux Mast Lower Switch S33 (CCC 1107833/101)

Test I42 - Aux Mast NOTE: S31 (Aux lift left-hand deadman) must
also be pressed during this test.
Lower Switch S33
Run Test:
(CCC 1107833/101)
You should see:
See “Test I42 - Aux Mast Lower Switch S33
(CCC 1275051/003)” on page 6-100 for more Aux Mast Lower
information about running this test on lift Operator Display
Switch
trucks with CCC 1275051/003.
Out Off
This test monitors the state of the auxiliary Pressed On
lower switch (S33). This switch causes the
auxiliary mast to lower. This test displays what
the CCC is reading from the switch. If results do not match the preceding table, the
test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPC19
1 disconnected PC19-3 Perform Step 3 Perform Step 2
/DCV
B+ B+
Aux Card
Replace Aux
2 disconnected PC18-3 Replace CCC
Card
/DCV

JPC19
3 disconnected PC19-3 PC19-2 6 to 13V Perform Step 7 Perform Step 4
/DCV

4 JC18-8 JC18-1 B+ Perform Step 5

5 Aux Card JC18-5 5.3V Perform Step 6

disconnected Replace CCC
/DCV JC18-3 Replace Aux
6 JC18-7 12V Card, then
CCC

JPC19
connected,
Repair/replace wires
7 S31 and S33 B+ PC19-2 B+ Replace CCC
or switch
activated
/DCV

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 Models 5400/5500/5600 Maintenance Manual

Test I42 - Aux Mast Lower Switch S33 (CCC 1275051/003)

Test I42 - Aux Mast NOTE: S31 (Aux lift left-hand deadman) must
also be pressed during this test. The S31
Lower Switch S33 switch circuit must be functional

(CCC 1275051/003) Run Test:

See “Test I42 - Aux Mast Lower Switch S33 You should see:
(CCC 1107833/101)” on page 6-99 for more
information about running this test on lift Aux Mast Lower
trucks with CCC 1107833/101. Operator Display
Switch

This test monitors the state of the auxiliary Out Off

lower switch (S33). This switch causes the Pressed On
auxiliary mast to lower. This test displays what
the CCC is reading from the switch.
Diagnosis and Repair
Action/
Step Meter Setting (+) Lead (–) Lead Expected Results Step Passed Step Failed

JPC19
1 disconnected/ PC19-2 PC19-3 6 to 13V Perform Step 2 Replace CCC
DCV

JPC19
Connected/
2 JPC19-2 JPC19-3 Approx. 0.0V Replace CCC Perform Step 3
DCV/S31and
S33 Activated

S33 Activated/
3 S33-1 S33-2 0.1ohm Perform Step 4 Replace S33
ohms

Troubleshoot wiring
4 ohms S33-2 S33-1 0.1 ohm Perform Step 5
from S31 to S33

Troubleshoot
S31 Activated/
5 S31-2 S31-1 0.1 ohm wiring from Replace S31
ohms
CCC to S31

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Test I43 - Slack Chain Switch (CCC1107833/101)

Test I43 - Slack Chain NOTE: Either switch listed below can cause an
error. Run the tests below on both the
Switch S36 and S37 switches.

(CCC1107833/101) Run Test:

See “Test I43 - Slack Chain Switch (CCC You should see:
1275051/003)” on page 6-103 for more
information about running this test on trucks Switch Operator Display
with CCC 1275051/003)
Activated In
This test monitors the state of the auxiliary lift
Deactivated Out
switches, S36 and S37. These switches cause
the auxiliary mast to lift. This test displays
what the CCC is reading from the switches. If results do not match the preceding table, the
test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPC24
1 Disconnected JC24-2 JC24-3 Step 2 Replace auxiliary card
/DCV 12V
TS wiring from S36 to
2 S36/DCV S36-3 S36-1 Step 3
VM

TS wiring from
Switch engaged- 0.1 ohm
3 S36/ohm S36-2 S36-1 S36-2 and Replace S36
Switch disengaged - open
S36-1 to VM

Run Test:
You should see:

Switch Operator Display

Activated In

Deactivated Out

If results do not match the preceding table, the

test has failed. Perform diagnosis and repair.

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair

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

JPC22
1 Disconnected JC22-2 JC22-3 Step 2 Replace auxiliary card
/DCV 12V
TS wiring from S37 to
2 S37/DCV S37-3 S37-1 Step 3
VM

Switch engaged - 0.1

TS wiring from
ohm
3 S37/ohm S37-2 S37-1 S37-2 and Replace S37
Switch disengaged -
S37-1 to VM
open

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Test I43 - Slack Chain Switch (CCC 1275051/003)

Test I43 - Slack Chain NOTE: Either switch listed below can cause an
error. Run the tests below on both the
Switch S36 and S37 switches.

(CCC 1275051/003) Run Test:

See “Test I43 - Slack Chain Switch You should see:
(CCC1107833/101)” on page 6-101 for more
information about running this test on trucks Switch Operator Display
with CCC 1107833/101.
Activated In
This test monitors the state of the auxiliary lift
Deactivated Out
switches, S36 and S37. These switches cause
the auxiliary mast to lift. This test displays
what the CCC is reading from the switches. If results do not match the preceding table, the
test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPC24
1 Disconnected JC24-2 JC24-3 Step 2 Replace CCC
/DCV 12V
TS wiring from S36 to
2 S36/DCV S36-3 S36-1 Step 3
CCC

Switch engaged- 0.1 ohm TS wiring from

3 S36/ohm S36-2 S36-1 Replace S36
Switch disengaged - open S36-2 to CCC

Run Test:
You should see:

Switch Operator Display

Activated In

Deactivated Out

If results do not match the preceding table, the

test has failed. Perform diagnosis and repair.

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair

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

JPC22
1 Disconnected JC22-2 JC22-3 Step 2 Replace CCC
/DCV 12V
TS wiring from S37 to
2 S37/DCV S37-3 S37-1 Step 3
CCC

Switch engaged -
TS wiring from
0.1 ohm
3 S37/ohm S37-2 S37-1 S37-2 and Replace S37
Switch disengaged -
S37-1 to CCC
open

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Test I44 - Aux Mast Lift Ref Switch S34 (CCC 1107833/101)

Test I44 - Aux Mast Lift Run Test:

Ref Switch S34 You should see:

(CCC 1107833/101) Aux Mast Lift Ref

Operator Display
Switch
See “Test I44 - Aux Mast Lift Ref Switch S34
Switch Activated Belw
(CCC 1275051/003)” on page 6-106 for more
information about running this test on lift Switch Not Activated Abve
tricks with CCC 1275051/003.

This test monitors the state of the auxiliary lift If results do not match the preceding table, the
reference switch (S34). This switch causes the test has failed. Perform diagnosis and repair.
auxiliary mast to lift. This test displays what
the CCC is reading from the switch.
NOTE: S31 (Aux lift left-hand deadman) must
also be pressed during this test.

Diagnosis and Repair

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

JPC20
1 disconnected PC20-2 PC20-3 6 to 13V Perform Step 5 Perform Step 2
/DCV

2 JC18-8 JC18-1 B+ Perform Step 3

3 Aux Card JC18-5 5.3V Perform Step 4

disconnected Replace CCC
/DCV JC18-3 Replace Aux
4 JC18-7 12V Card, then
CCC

S34 Closed: 6-12V Repair/replace wires

5 DCV JPC20-2 JPC20-2 Replace CCC
Open: <1.5V or switch

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 Models 5400/5500/5600 Maintenance Manual

Test I44 - Aux Mast Lift Ref Switch S34 (CCC 1275051/003)

Test I44 - Aux Mast Lift NOTE: S31 (Aux lift left-hand deadman) must
also be pressed during this test.
Ref Switch S34
Run Test:
(CCC 1275051/003)
You should see:
See “Test I44 - Aux Mast Lift Ref Switch S34
(CCC 1107833/101)” on page 6-105 for more Aux Mast Lift Ref
information about running this test on lift Operator Display
Switch
tricks with CCC 1107833/101.
Switch Activated Belw
This test monitors the state of the auxiliary lift Switch Not Activated Abve
reference switch (S34). This switch causes the
auxiliary mast to lift. This test displays what
the CCC is reading from the switch. If results do not match the preceding table, the
test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPC20
1 disconnected PC20-2 PC20-3 Perform Step 2 Replace CCC
/DCV 12V
TS wiring from S34 to
2 S34/DCV S34-3 S34-1 Perform Step 3
CCC

Switch engaged
TS wiring from
3 S34/ohms S34-2 S34-1 0.1ohm\ Replace S34
S34-2 to CCC
Disengaged Open

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Test I45 - Slk S29 [Slack Chain 1 Switch (S29)]

Test I45 - Slk S29 [Slack

Chain 1 Switch (S29)]
The state of the slack chain switch (S29).

Run Test:
The state of the switch is displayed:

Deadman Pedal Operator Display

Activated In

Deactivated Out

If these results are not observed, the test has

failed. Perform diagnosis and repair. Check lift
chain tension.

Diagnosis and Repair

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

JPT20 and
JPT4 are
1 JT20-3 JT4-2 Step 2 Replace VM
Disconnected
/DCV
12V
TS wiring from JPS58
2 JPS58/DCV JPS58-1 JPS58-3 Step 3
to JPT20-3/JPT4-2

TS wiring from JPS58

3 S29/DCV S29-3 S29-1 Step 4
to S29

Switch disengaged TS wiring from

4 S29/ohm S29-2 S29-1 Replace S29
- open S29 to VM

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 Models 5400/5500/5600 Maintenance Manual

Test I46 - Slk Ch S30 [Slack Chain 2 Switch (S30)]

Test I46 - Slk Ch S30

[Slack Chain 2 Switch
(S30)]
The state of the Slack Chain Switch S30 is
displayed.

Run Test:
The state of the switch is displayed:

Switch Operator Display

Activated In

Deactivated Out

If these results are not observed, the test has

failed. Perform diagnosis and repair. Check lift
chain tension.

Diagnosis and Repair

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

JPT20 and
JPT4
1 JT20-4 JT4-2 Step 2 Replace VM
Disconnected
/DCV
12V
TS wiring from JPS59
2 JPS59/DCV JPS59-1 JPS59-3 Step 3
to JPT20-4 and JPT4-2

TS wiring from JPS59

3 S30/DCV S30-3 S30-1 Step 4
to S30

Switch engaged - 0.1

ohm TS wiring from
4 S30/ohm S30-2 S30-1 Replace S30
Switch disengaged - S30 to VM
open

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Test I65 - Rail Guidance Switch (optional)

Test I65 - Rail Guidance

Switch (optional)
NOTE: This test applies to lift trucks equipped
with rail guidance.

Using this test, the state of the rail guidance

switch (S15) can be verified.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
When the test is run, observe the following
results:

Rail Guidance Switch

Operator Display
(S15)

Pressed In

Released Out

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Diagnosis and Repair

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

Pull pin from

JPT18-4.
1 JPT24-5 Perform Step 2 Replace VM
Backprobe
connection. 10.5 to 13V
2 JPT18-4 Perform Step 3 Repair/replace
DCV S15-1
3 Perform Step 4 harness
S15-3
4 S15-2 S15 Perform Step 5 Adjust or replace S15
Closed: 10.7 to 13V Repair/replace
5 JPT18-4 JPT22-22 Open: <1V Replace VM
harness

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 Models 5400/5500/5600 Maintenance Manual

Test I66 - Auto/Manual Switch (optional)

Test I66 - Auto/Manual

Switch (optional)
This test displays the position of the Auto/
Manual switch (S4). A successful test proves
the CCC is correctly reading the Auto/Manual
switch.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
When the test is run, observe the following
results:

Switch Position Operator Display

O (open) Auto

| (closed) Manu

If these results are not observed, the test has

failed. Perform diagnosis and repair.
NOTE: If the wire between the Auto/Manual
switch and the CCC becomes
disconnected, the system defaults to
Auto.

Operation of the Auto/Manual switch and CCC

can also be checked by observing the green
triangles on the display. The green triangles
should illuminate when the switch is in Auto
and extinguish when the switch is in Manual.

Diagnosis and Repair

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

JPC9 Verify option is

Auto: open circuit Troubleshoot wires
1 disconnected JC9-1 JC9-2 turned on.
Manual: 0 ohms and switch
/ohms Replace CCC

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Test I67 - Sidegate Switches (optional)

Test I67 - Sidegate Run Test:

Switches (optional) The state of the sidegate switch is displayed.
Both sidegates must be down for the display to
Use this test to test the state of the sidegate change states.
switches (S60, S61). This test displays what the Sidegates Operator Display
CCC is reading from the switch. This test only
works on lift trucks equipped with the sidegate One sidegate up Up
switch option.
Both sidegates up Up

For information on using Maintenance Mode, Both sidegates down Down

refer to page 3-26.
If these results are not observed, the test has
failed. Perform diagnosis and repair.

Diagnosis and Repair

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

Right Sidegate - Switch S60

JPC14
1 disconnected PC14-2 PC14-3 Perform Step 2 Replace CCC
/DCV
10.7 to 13V
2 JPC14-2 Perform Step 3 Repair/replace
S60-3
3 Perform Step 4 harness
S60-1
4 DCV S60-2 Perform Step 5 Adjust or replace S60
S60
Closed: 6 to 12V Repair/replace
5 JPC14-2 JPC14-1 Open: 1V Replace CCC
harness

Left Sidegate - Switch S61

JPC13
1 disconnected PC13-2 PC13-3 Perform Step 2 Replace CCC
/DCV
10.7 to 13V
2 JPC13-2 Perform Step 3 Repair/replace
S61-3
3 Perform Step 4 harness
S61-1
4 DCV S61-2 Perform Step 5 Adjust or replace S61
S61
Closed: 10.7 to 13V Repair/replace
5 JPC13-2 JPC13-1 Open: <1V Replace CCC
harness

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 Models 5400/5500/5600 Maintenance Manual

Test I68 - Travel Cutout/Battery Gate and PSL Switch (optional)

Test I68 - Travel If these results are not observed, the test has
failed. Perform diagnosis and repair.
Cutout/Battery Gate and
PSL Switch (optional)
This test monitors the state of the travel cutout
switch (S27). This test displays what the VM is
reading from the switch.

This test is also used for trucks equipped with

battery gates and PSL. This test monitors your
battery gate switches.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
When the test is run, observe the following
results.

Carriage Position
Operator Display
(wrt S27)

Below Belw

Above Abve

Diagnosis and Repair

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

Pull pin from

JPT20-6.
1 JPT24-6 Perform Step 2 Replace VM
Backprobe
connection. 10.5 to 13V
2 JPT20-6 Perform Step 3 Repair/replace
DCV S27-1
3 Perform Step 4 harness
S27-3
4 S27-2 S27 Perform Step 5 Adjust or replace S27
Closed: 6 to 12V Repair/replace
5 JPT20-6 JPT22-6 Open: <1.5V Replace VM
harness

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Test I69 - Upper Mast Reference Switch

Test I69 - Upper Mast Run Test:

Reference Switch When the test is run, observe the following
results:
This test monitors the state of the upper mast Switch Operator
reference switch (S10). This test shows what the Carriage Height
Actuator Display
VM is reading from the upper mast reference
switch at JPT20-1 wrt JPT22-1. A successful Below Upper
Pressed Belw
test proves the VM is correctly reading the Reference Switch
upper mast reference switch. Above Upper
Released Abve
Reference Switch
For information on using Maintenance Mode,
refer to page 3-26.
If these results are not observed, the test has
failed. Perform diagnosis and repair.

Use Active Maintenance to check that the

display indicates the upper reference switch is
closed at all positions below the upper reference
switch. Check that the display indicates the
upper reference switch is not closed at all
positions above upper reference switch.

Diagnosis and Repair

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

Pull pin from JPF3-8

JPT20-1. (Fuse
1 Perform Step 2 Replace VM
Backprobe Relay
connection. Card) 10.5 to 13V
2 JPT20-1 Perform Step 3 Repair/replace
DCV S10-1
3 Perform Step 4 harness
S10-3
4 S10-2 S10 Perform Step 5 Adjust or replace S10
Closed: 10.5 to 13V Repair/replace
5 JPT20-1 JPT22-1 Open: <6.5V Replace VM
harness

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 Models 5400/5500/5600 Maintenance Manual

Test I70 - Pressure Switch (optional)

Test I70 - Pressure

Switch (optional)
NOTE: This test applies to 24V lift trucks
equipped with HiPro (except lift trucks
with EE option).

This test checks the input from the pressure

switch (PRESS SW1) to the VM at JPT22-5 and
JPT18-5.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
When the test is run, observe the following
results:

Switch Operator
Weight
Position Display

Greater than
Open Off
1000 lb.

Less than
Closed On
1000 lb.

If these results are not observed, the test has

failed. Perform diagnosis and repair.
NOTE: If the test fails in Active Maintenance,
make sure the pressure switch is set per
Pressure Switch Adjustment on
page 7-103.

Diagnosis and Repair

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

With forks elevated 1 Test wires, adjust/

JPT22 and
ft. (304.8 mm) replace pressure
JPT18
1 JPT22-5 JPT18-5 0 lbs. on forks: <1 ohm Replace VM switch (see Pressure
disconnected
1000 lbs. (453.6 kg) on Switch Adjustment on
/ohms
forks: >2 megohms page 7-103).

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Test I72 - End-of-Aisle Sensor 2 (optional)

Test I72 - End-of-Aisle

Sensor 2 (optional)
NOTE: This test applies to lift trucks equipped
with End-of-Aisle Detect.

This test displays what the VM sees from Aisle

Detect Sensor 2. Sensor 2 (S47A and B) is
located on the left side of the Antenna Card
bracket as you stand on the platform facing the
tractor.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
You have two choices when running this test:

Statically: If this test is to be run statically,

park the lift truck away from any magnets in
the floor. Obtain a magnet (P/N 591-552/002)
and pass the magnet under the sensor.
Remember that this is a transitional state.

The sensor reverts to its original position even if

the magnet remains under the sensor. It may be
helpful if two people are available for this test.
When a magnet is placed under the sensor, the
OD shows On briefly. Even if the magnet
remains under the sensor, the display changes
back to Off.

Active Maintenance: To run this test in Active

Maintenance, position the lift truck away from
any floor magnets. Select this test for Active
Maintenance. Have this test on the OD. While
observing the display, drive the lift truck so the
sensor passes over a floor magnet. The OD
shows On briefly. Even if the magnet remains
under the sensor, the display changes back to
Off.

If these results are not observed, the test has

failed. Perform diagnosis and repair.

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair

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

Pull pin
JPT10-7.
1 Approx. 10.5V Perform Step 2 Replace VM
Backprobe
connection
JPT24-9 T/S harness for
opens and shorts.
2 JPT10-7 Approx. 7.9V Perform Step 3 If OK, replace
sensor S47A or
S47B

If <4V, replace
3 S47B-5 Perform Step 4
S47A or S47B
DCV
S47B-8 Approx. 4V If <4V,
repair/replace
4 S47A-6 Perform Step 5
harness from
S47B-5 to S47A-6

If approx. 10.5V,
5 JPT10-7 Approx. 7.9V Perform Step 6 replace sensor
S47A
JPT24-9 S47A or S47B T/S harness for
Closed (sees magnet): 3.7V opens and shorts.
6 JPT10-8 Replace VM
Open (no magnet): approx If OK, replace bad
7.8V sensor

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Test I73 - End-of-Aisle Sensor 1 (optional) - Software versions 5.7 and below

Test I73 - End-of-Aisle

Sensor 1 (optional) -
Software versions 5.7
and below
NOTE: This test applies to lift trucks equipped
with End-of-Aisle Detect or Auto Steer
Center.

This test displays what the VM sees from Aisle

Detect Sensor 1. Sensor 1 (S46A and B) is
located on the right side of the Antenna Card
bracket as you stand on the platform facing the
tractor.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
You have two choices when running this test:

Statically: If this test is to be run statically,

park the lift truck away from any magnets in
the floor. Obtain a magnet (P/N 591-552/002)
and pass the magnet under the sensor.
Remember that this is a transitional state.

The sensor will revert to its original position

even if the magnet remains under the sensor. It
may be helpful if two people are available for
this test. When a magnet is placed under the
sensor, the OD shows On briefly. Even if the
magnet remains under the sensor, the display
changes back to Off.

Active Maintenance: To run this test in Active

Maintenance, position the lift truck away from
any floor magnets. Select this test for Active
Maintenance. Have this test on the OD. While
observing the display, drive the lift truck so the
sensor passes over a floor magnet. The OD
shows On briefly. Even if the magnet remains
under the sensor, the display changes back to
Off.

If these results are not observed, the test has

failed. Perform diagnosis and repair.

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair

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

Pull pin
JPT10-6.
1 Approx. 10.5V Perform Step 2 Replace VM
Backprobe
connection
JPT24-8 T/S harness for
opens and shorts.
2 JPT10-6 Approx. 7.9V Perform Step 3 If OK, replace
sensor S46A or
S46B

If <4V, replace
3 S46B-5 Perform Step 4
S46B
DCV
S46B-8 Approx. 4V If <4V, repair/
replace harness
4 S46A-6 Perform Step 5
from S46B-5 to
S46A-6

If approx. 10.5V,
5 JPT10-6 Approx. 7.9V Perform Step 6 replace sensor
S46A
JPT24-8 S46A or S46B T/S harness for
Closed (sees magnet): 3.7V opens and shorts.
6 JPT10-2 Replace VM
Open (no magnet): approx If OK, replace bad
7.8V sensor

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Test I73 - EOA2, Left - Software versions 5.8 and above

Test I73 - EOA2, Left - Run Test:

Software versions 5.8 The state of the switch is displayed:

and above Switch Operator Display

Activated On
NOTE: This test applies to lift trucks equipped
with End-of-Aisle Detect or Auto Steer Deactivated Off
Center.
While observing the display, drive the truck so
This test displays what the VM sees from Aisle the sensor passes over a floor magnet. The
Detect Sensor 1. Sensor 1 (S46A and B) is display should change from off to on.
located on the right side of the Antenna Card
bracket as you stand on the platform facing the If these results are not observed, the test has
tractor. failed. Perform diagnosis and repair.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
You have two choices when running this test:

Statically: If this test is to be run statically,

park the lift truck away from any magnets in
the floor. Obtain a magnet (P/N 591-552/002)
and pass the magnet under the sensor.
Remember that this is a transitional state.

The sensor will revert to its original position

even if the magnet remains under the sensor. It
may be helpful if two people are available for
this test. When a magnet is placed under the
sensor, the OD shows On briefly. Even if the
magnet remains under the sensor, the display
changes back to Off.

Active Maintenance: To run this test in Active

Maintenance, position the lift truck away from
any floor magnets. Select this test for Active
Maintenance. Have this test on the OD. While
observing the display, drive the lift truck so the
sensor passes over a floor magnet. The OD
shows On briefly. Even if the magnet remains
under the sensor, the display changes back to
Off.

NOTE: If these results are not observed, the test

has failed. Perform diagnosis and repair.

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 Models 5400/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair

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

Pull pin
JPT10-6. Perform Step
1 Approx. 10.5V Replace VM
Backprobe 2
connection
JPT24-8
T/S harness for opens
Perform Step and shorts. If OK,
2 JPT10-6 Approx. 7.9V
3 replace sensor S46A or
S46B

Perform Step
3 S46B-5 If <4V, replace S46B
4
DCV
S46B-8 Approx. 4V If <4V, repair/ replace
Perform Step
4 S46A-6 harness from S46B-5 to
5
S46A-6

Perform Step If approx. 10.5V,

5 JPT10-6 Approx. 7.9V
6 replace sensor S46A

S46A or S46B
JPT24-8 Closed (sees T/S harness for opens
6 JPT10-2 magnet): 3.7V Replace VM and shorts. If OK,
Open (no magnet): replace bad sensor
approx 7.8V

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Test I74 - Lower Inhibit Switch (optional)

Test I74 - Lower Inhibit

Switch (optional)
This test monitors the state of the lower inhibit
switch (S25). This test displays what the CCC is
reading from the switch.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
The state of the lower inhibit switch (S25) is
displayed.

Carriage Position
Operator Display
(wrt S25)

Below Belw

Above Abve

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Using Active Maintenance, check that the

display indicates the carriage is Belw at all
positions below the lower inhibit switch. Check
that the display indicates Abve for all positions
above the lower inhibit switch.

Diagnosis and Repair

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

JPC4
1 disconnected PC4-2 PC4-3 Perform Step 2 Replace CCC
/DCV
10.7 to 13V
2 JPC4-2 Perform Step 3 Repair/replace
S25-3
3 Perform Step 4 harness
S25-1
4 DCV S25-2 S25 Perform Step 5 Adjust or replace S25
Closed: 10.5 to
13V Repair/replace
5 JPC4-2 JPC4-1 Replace CCC
Open: 0V harness

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 Models 5400/5500/5600 Maintenance Manual

Test I75 - 180 in. Limit Switch (optional)

Test I75 - 180 in. Limit

Switch (optional)
This test monitors the state of the 180 in. limit
switch (S100). This test displays what the CCC
is reading from the switch.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
The state of the 180 in. limit switch (S100) is
displayed.

Carriage Position
Operator Display
(wrt S100)

Below Belw

Above Abve

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Using Active Maintenance, check that the

display indicates the carriage is Belw at all
positions below the lower inhibit switch. Check
that the display indicates Abve for all positions
above the lower inhibit switch.

Diagnosis and Repair

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

Pull pin from

JPT24-1.
1 JPT24-7 Perform Step 2 Replace VM
Backprobe 10.5 to 13V
connection.

2 JPT24-1 Perform Step 3 Repair/replace

DCV S100-1
3 10.7 to 13V Perform Step 4 harness
S100-3
4 S100-2 S100 Perform Step 5 Adjust or replace S100
Closed: 10.7 to 13V Repair/replace
5 JPT24-1 JPT22-4 Open: <1V Replace VM
harness

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Test I76 - Lift Cutout Switch (optional)

Test I76 - Lift Cutout

Switch (optional)
This test monitors the state of the lift cutout
switch (S124). This test displays what the CCC
is reading from the switch.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
The state of the lift cutout switch (S124) is
displayed.

Carriage Position
Operator Display
(wrt S124)

Below Belw

Above Abve

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Using Active Maintenance, check that the

display indicates the carriage is Belw at all
positions below the lower inhibit switch. Check
that the display indicates Abve for all positions
above the lower inhibit switch.

Diagnosis and Repair

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

Pull pin from

JPT20-8.
1 JPT18-7 10.5 to 13V Perform Step 2 Replace VM
Backprobe
connection.

2 JPT20-8 Perform Step 3 Repair/replace

DCV S124-1 10.7 to 13V
3 Perform Step 4 harness
S124-3
4 S124-2 S124 Perform Step 5 Adjust or replace S124
Closed: 10.5 to 13V Repair/replace
5 JPT20-8 JPT4-3 Open: <1V Replace VM
harness

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 Models 5400/5500/5600 Maintenance Manual

Test I91 - iPORT Communication

Test I91 - iPORT

Communication
Test I91 is an iPORT related code. Refer to
iPORT Kit Installation and Maintenance
Instructions (P/N 1089339).

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Test I92 - iPORT Error Bitmap

Test I92 - iPORT Error

Bitmap
This test is for factory use only.

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 Models 5400/5500/5600 Maintenance Manual

Test I93 - End Of Aisle EOA

Test I93 - End Of Aisle

EOA
This test displays position status used by the
EOA software. It displays either 0 or 1 to
indicate whether the program currently
considers the truck in or out of aisle.

For information on using Maintenance Mode,

refer to page 3-26.

Run Test:
This test requires use of Active Maintenance to
see correct test results.

You should see:

Truck Position Operator Display

Truck is in the aisle 0

Truck is out of the aisle 1

If results do not match the preceding table, the

test has failed.
NOTE: One of the magnets could have been
inadvertently tripped or the truck is in
the aisle. Refer to tests “Test I72 -
End-of-Aisle Sensor 2 (optional)” and
“Test I73 - End-of-Aisle Sensor 1
(optional) - Software versions 5.7 and
below”

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests
Section 6. Messages, Codes and Tests

Output Tests
A Diagnosis and Repair table is provided for
most tests. If a test fails, refer to the Diagnosis
and Repair table. Through the process of
elimination, these tables provide the technician
with a step-by-step approach to diagnosing a
problem and the necessary corrective action.
See the table below.
Example Diagnosis and Repair Table
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

This column
identifies the
action(s) required
(if any) before
testing the
circuit. If no
instructions are
given, all circuits
must be
The next
connected. The next
This is the Connection Connection action to be
Note: If action to be
order that point for point for The reading performed if
something was performed if
the testing the Positive the required to consider the
disconnected in the Expected
must be (+) meter Negative (–) the step a success. Expected
the prior step, Results are
performed. lead. meter lead. Results are
reconnect it met.
not met.
before
performing the
next step.

This column also

identifies the
required setting
on the meter for
this step.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Test O00 - Toggle the Traction Power Contactor

Test O00 - Toggle the

Traction Power
Contactor
This test toggles the TPC on and off.

For information on how to use Maintenance

Mode, refer to page 3-26.

Run Test:
PC Contactor Operator Display

Closed In

Open Out

The test is a success if the TPC contactor tracks

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

Diagnosis and Repair

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

JPTA1
1 disconnected JPTA1-6 JPTA1-13 Approx. 38 ohms Perform Step 2 T/S wires and coil
/ohms

2 JPTA1-13 TP4 B+ Perform Step 3

Replace Traction
DCV Test on: B+ Test contactor
3 B+ JPTA1-6 Power Amplifier
Test off: 0V for binding

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test O02 - Toggle the Lift Power Contactor

Test O02 - Toggle the Lift Run Test:

Power Contactor LPC Contactor Operator Display

Closed In
This test toggles the LPC on and off.
Open Out
For information on how to use Maintenance
Mode, refer to page 3-26. The test is a success if the LPC contactor tracks
the In/Out shown on the display. If these results
are not observed, the test has failed. Perform
diagnosis and repair.
Open the emergency lowering valve
before starting this test.

Diagnosis and Repair

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

AC Lift

JPLA1
T/S wires and
1 disconnected JPLA1-6 JPLA1-13 Approx. 18 ohms Perform Step 2
coil
/ohms

2 JPLA1-13 TP4 B+ Perform Step 3

Replace Lift
DCV Test on: B+ Test contactor
3 B+ JPLA1-6 Power Amplifier
Test off: 0V for binding

DC Lift

JPT18 and
JPF2 T/S wires and
1 JPF2-1 Approx. 38 ohms Perform Step 2
disconnected coil
/ohms

If B+ is not
present, T/S
JPT18-9 JPF2-1 on the
Contactor Test contactor Relay Fuse Card.
2 DCV TP4 Energized: approx. -0V for mechanical If voltage does
De-energized: B+ binding not change when
the test is
toggled, replace
the VM

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Test O11 - Toggle Load Holding Solenoid

Test O11 - Toggle Load

Holding Solenoid
This test turns the Load Holding (L/H) Solenoid
(SOL1) on and off.

Make sure the operator platform is fully

lowered before performing this test.

Turning the Load Holding Solenoid on

during this test causes the operator
platform to lower because the
proportional lift/lower valve is open in
Maintenance Mode.

For information on how to use Maintenance

Mode, refer to page 3-26.

Run Test:
1. Lower the operator platform to the floor.
2. Disconnect the wire from the Load Holding
solenoid L/H-1.
3. Connect an ammeter in series with the
L/H solenoid as follows:
• (–) lead to terminal of L/H-1
• (+) lead to wire removed from L/H-1

Ammeter Operator
L/H Solenoid
Reading Display

Open 0.5 to 1.0A On

Closed 0.0 to 0.02A Off

If these results are not observed, the test has

failed. Reconnect the wire to L/H-1.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPT18 and JPF2

T/S wires and
1 disconnected/ JPT18-10 JPF2-5 Approx. 38 ohms Perform Step 2
coil
ohms

T/S relays and

2 DCV JPF2-5 TP4 B+ Replace VM
Fuse Relay Card

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test O12 - Proportional Solenoid PWM Ramp

Test O12 - Proportional 3. Connect the (–) lead of a DVM to L/L-2 and
Solenoid PWM Ramp the (+) lead to L/L-1.
4. Turn the key switch ON and run this test.
This test ramps the proportional Lift/Lower
Voltmeter
(L/L) solenoid from 0% to 90%. Operator Display
Reading

A successful test proves the wiring, related 0 to 24V Ramp (15% increments)
circuitry in the VM, and proportional L/L
0 to 1V 0%
solenoid coil driver are all functioning correctly.
It also proves the harness is electrically
functional. It does not prove the L/L solenoid The percentage shown on the display starts at
itself is mechanically functional. 0%. Use the Up button to increase the
percentage up to 90% in 15% increments.
Ramping the proportional L/L solenoid should
not allow the operator platform to lower, since If the voltage ramps proportionally, the wiring
the Load Holding (L/H) valve must be closed. If and related circuitry are functional. (It does not
there is a fault in the L/H circuit or a fault in prove the L/L solenoid itself is mechanically
L/H solenoid itself, the operator platform may functional.)
lower. To guard against unexpected motion of
the operator platform, fully lower the operator If these results are not observed, the test has
platform before entering this test. failed.

For information on how to use Maintenance

Mode, refer to page 3-26.

Run Test:
1. Turn the key switch OFF.
2. Loosen the screw that secures the 90°
connector to the L/L solenoid. Unplug the
connector from the solenoid. Remove the
cover to expose the connector terminals.
Reconnect the connector.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPT20 dis-
T/S wires and
1 connected/ JPT20-16 JPT20-15 Approx 25 ohms Perform Step 2
coil
ohms

2 DCV JPT20-15 B+ Perform Step 3

Check valve for

Test on B– 24V truck: ramp B+ to 0V mechanical Replace VM
3 JPT20-16
/DCV 36V truck: ramp B+ to 12V binding or
contamination

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Test O18 - Toggle Horn

Test O18 - Toggle Horn

This test toggles the horn on and off.

For information on how to use Maintenance

Mode, refer to page 3-26.

Run Test:
The horn should sound when the test is
activated. If these results are not observed, the
test has failed.

Diagnosis and Repair

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

T/S wires and

1 H2 TP4 B+ Perform Step 2
Fuse Relay Card

2 DCV H1 Replace horn Perform Step 3

Horn off: <0.5V
TP1 T/S wires to
3 JPT18-16 Horn on: B+ Replace VM
horn

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test O19 - Audible Alarm

Test O19 - Audible

Alarm
Using this test, the operation of the audible
alarm in the CCC can be verified.

A successful test proves the audible alarm is

functioning.

For information on how to use Maintenance

Mode, refer to page 3-26.

Run Test:
Operator
Alarm
Display

Sounding Ramp

Off Off

This test generates a sound on the audible

alarm in the CCC.

If these results are not observed, the test has

failed.

Diagnosis and Repair

Replace Carriage Control Card.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Test O20 - Travel Alarm (optional)

Test O20 - Travel Alarm Run Test:

(optional) Connect a voltmeter at JPT20-17 wrt JPT18-18.

Operator
This test verifies the operation of the travel Voltage Output
Display
alarm.
0.0 to 1.0V Off
A successful test proves the wiring and related
22.0V On
circuitry in the VM are functioning correctly.

For information on how to use Maintenance When the display shows On, the optional device
Mode, refer to page 3-26. must be activated.

NOTE: In order to test the output portion of the If these results are not observed, the test has
VM, a device that causes a load in the failed.
circuit is required. The load holding coil
on the hydraulic manifold can be used
for testing purposes. Remove the load
holding coil and carefully connect wires
into the circuit. Use extreme caution
and make sure that the wires do not
short to any components.

Diagnosis and Repair

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

1 AL– Approx. 22V Replace alarm Perform Step 2

AL+
2 B+ Perform Step 3 Test wire to AL+
DCV
TP4 24V truck: approx. 2V
Repair/replace
3 JPT18-18 36V truck: approx. Replace VM
wire to AL–
14V

Connect Load
4 Holding JPT20-17 JPT18-18 Approx. 22V Replace alarm Replace VM
Coil/DCV

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test O25 - Toggle 2 Stage Select Solenoid (optional)

Test O25 - Toggle 2 4. Reconnect the battery connector and turn

the key switch ON. Run the test and
Stage Select Solenoid observe the following results.

(optional) Ammeter
Reading
Operator
Display

This test toggles the solenoid off and on, 0.0 to 0.02A Off
verifying its correct operation electrically. 1.0 to 2.0A On
NOTE: This test does not prove that the
solenoid valve is mechanically If the above results are not observed, the
functional. test has failed.
5. Turn the key switch OFF and disconnect
A successful test proves that the solenoid coil,
the battery connector. Remove the
coil driver, wiring and related circuitry in the
ammeter from the circuit and reconnect
VM are functioning correctly.
the wire.
For information on how to use Maintenance
Mode, refer to page 3-26.

Run Test:
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from the solenoid coil
at SOL-1.
3. Connect a digital ammeter in series with
the solenoid: (–) lead to SOL-1, (+) lead to
the wire removed from SOL-1.

Diagnosis and Repair

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

JPT18 and JPF2

T/S wires and
1 disconnected/ JPF2-5 JPC18-1 Approx. 28 ohms Perform Step 2
coil
ohms

T/S Fuse Relay

2 DCV JPT18-1 B– B+ Replace VM
Card

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Test O28 - Ramp Lift Motor (AC lift only)

Test O28 - Ramp Lift

Motor (AC lift only) Run Test:
This test ramps the lift motor by gradually The requested rpm is displayed. Use the Up
increasing the command to the lift power button to increase the rpm in increments of 25,
amplifier via the CAN bus. This test verifies that from a minimum of 775 rpm to a maximum of
the lift power amplifier can drive the lift motor. 1500 rpm.
NOTE: To prevent lift pump damage due to very
low rpm, the minimum lift motor speed
Running this test for an extended period request is 775 rpm.
of time can cause damage to the motor,
power amplifier, or wiring. When the maximum requested rpm is reached,
press Down to reset the request to 0. Press the
Enter button to exit the test.

Open the emergency lowering valve

before performing this test. See
“Emergency Lower Valve” on
page 2-11.

For information on how to use Maintenance

Mode, refer to page 3-26.

Diagnosis and Repair

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

If current does not ramp to

one or two phases, test the
Current cables to the motor. If OK,
probe Current must be replace the motor. If phases
(amp even on all phases Replace Lift are low or unequal, replace
1 N/A N/A
clamp) on and ramp up as the Amplifier the Lift Amplifier. If phases
phases U, percentage increases. are equal and high but the
V, and W motor runs slow, check for
binding. If no binding,
replace the lift motor.

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test O29 - Ramp Traction Motor

Test O29 - Ramp Traction When the maximum requested rpm is reached,
press Down to reset the request to 0. Press the
Motor Enter button to exit the test.

This test ramps the traction motor by gradually

increasing the command to the traction power
amplifier via the CAN bus. This test verifies that
the traction power amplifier can generate
current and drive the traction motor.

Running this test for an extended period

of time can cause damage to the traction
motor, power amplifier, or wiring.

The traction motor will rotate during this

test. Jack the drive wheel off the floor.

Use extreme care when the lift truck is

jacked up. Never block the lift truck
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an
overhead hoist to stabilize the mast if
jacking higher than described in this
section. Keep hands and feet clear while
jacking the lift truck. After the lift truck
is jacked, place solid blocks or jack
stands beneath it to support it. Lower
the lift truck onto the blocks or jack
stands. Do not rely on the jack or jack
stand alone to support the lift truck. See
Jacking on page 2-9.

For information on how to use

Maintenance Mode, refer to page 3-26.

Run Test:
Step on the deadman pedal and run the test.

The requested rpm is displayed. Use the Up

button to increase the rpm in increments of 25,
from 0 to a maximum of 1500 rpm.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Test O30 - Toggle Brake Solenoid

Test O30 - Toggle Brake

Solenoid
This test checks for correct brake coil operation.

For information on how to use Maintenance

Mode, refer to page 3-26.

Run Test:
Observe the following results:

Operator Display Brake

Up Applied

Down Released

NOTE: Deadman pedal must be pressed while

performing this test. Use Enter button
to cycle the test.

If these results are not observed, the test has

failed.
If this test passes, check brake adjustment. See
“Brake Adjustment” on page 7-63.

Diagnosis and Repair

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

JPT20 and
JPF2
1 JT20-14 JF2-2 Approx. 13 ohms Perform Step 2 T/S wires and coil
disconnected/
ohms

If no B+, T/S Fuse

Brake de-energized: B+ Relay Card. If
Inspect brake
Brake energized: voltage does not
2 DCV JP20-14 TP4 assembly for
36V truck = approx. 12V drop when
binding
24V truck = 0V energized, replace
the VM

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test O32 - Toggle Relay Enable

Test O32 - Toggle Relay NOTE: Removing K1 disables any key-power

accessories installed on the lift truck.
Enable If results do not match the preceding table, the
test has failed. Refer to diagnosis and repair.
This test toggles Fuse/Relay Card relays K1,
K2, K3, and K4 on and off.

Run Test:
NOTE: Off is displayed when entering the test,
even if the relays are closed.

Press the Enter button to toggle the test.

The following table gives the expected value at

each relay test point during the test.

Expected Values
Relay Lead Toggled Key
(+) (–) On Off OFF
K1 JPF2-9 or *TP1
K2 JPF2-1 or *TP2 <1V
TP4 B+ <1V
K3 JPF1-5 or *TP3
K4 JPF2-4 or *TP4 <1V
* TPs located on Fuse/Relay Card

It may be possible to quickly test a relay by

swapping K1 or K4 with the suspected relay
and performing the test again. Refer to relay
troubleshooting procedures on page 5-21.

Diagnosis and Repair

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

T/S Fuse
1 JF4-13 Perform Step 2
Relay Card

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

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Test O39 - Display Lights

Test O39 - Display Lights Run Test:

When the test is turned on, 13 LEDs on the
This test verifies all the lights operate correctly
display should light. See Figure 6-2. If all the
on the OD.
LED’s do not light, the test has failed.
For information on how to use Maintenance
Mode, refer to page page 3-26.

Yellow LED Yellow LED Red LED

Green LED

Red LED

Yellow LED

Green LED

6
Figure 6-2. Operator Display LED Identification

Diagnosis and Repair

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

Display not
1 JPD15-16 JPD15-15 illuminated. Perform Step 2
Perform Step 3
DCV Approx. 5.3V
Display not
2 JPC15-16 JPC15-15 illuminated. Replace CCC
Replace display

Disconnect Display not

JC15-1 JD15-1
JPC15 from illuminated,
3 through through Continuity Replace display
CCC and repair/replace
JC15-24 JD15-24
Display /ohms cable

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test O40 - Lift/Lower Alarm (optional)

Test O40 - Lift/Lower Run Test:

Alarm (optional) Use the Enter button to toggle the test on and
off. The OD shows on or off.
This test toggles the Lift/Lower Alarm on and
off. Connect a voltmeter at JPT20-17 wrt JPT20-18.

Operator
For information on how to use Maintenance Voltage Output
Display
Mode, refer to page 3-26.
0.0 to 1.0V Off
NOTE: In order to test the output portion of the
VM, a device that causes a load in the 22.0V On
circuit is required. The load holding coil
on the hydraulic manifold can be used
for testing purposes. Remove the load
holding coil and carefully connect wires
into the circuit. Use extreme caution
and make sure that the wires do not
short to any components.

Diagnosis and Repair

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

Lift/Lower
1 Approx. 22V Replace alarm Perform Step 2
Alarm (–)
Lift/Lower
DCV Test wire to
Alarm (+)
2 TP4 B+ Perform Step 3 Lift/Lower
Alarm (+)

Disconnect Lift/Lower Repair/replace

3 JPT20-18 0 ohms Perform Step 4
JPT20/ohms Alarm (–) wire

Connect Load
4 Holding JPT20-17 JPT20-18 Approx. 22V Replace alarm Replace VM
Coil/DCV

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Test O41 - Aux Select Solenoid (optional)

Test O41 - Aux Select 4. Reconnect the battery connector and turn
the key switch ON. Run the test and
Solenoid (optional) observe the following results.

Ammeter Operator
This test toggles the Aux Select Solenoid off and Reading Display
on, verifying its correct operation electrically.
0.0 to 0.02A Off

A successful test proves that the Aux Select 1.0 to 2.0A On

Solenoid coil, coil driver, wiring, and related
circuitry in the VM are functioning correctly.
If the above results are not observed, the
NOTE: This test does not prove that the Aux test has failed.
Select Solenoid valve is mechanically 5. Turn the key switch OFF and disconnect
functional. the battery connector. Remove the
For information on how to use ammeter from the circuit and reconnect
Maintenance Mode, refer to page 3-26. the wire.

Run Test:
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from the Aux Select
Solenoid coil at AUX SEL SOL-X.
3. Connect a digital ammeter in series with
the Aux Select Solenoid: (–) lead to AUX
SEL SOL-X terminal, (+) lead to the
removed wire.

Diagnosis and Repair

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

JPT18 and
JPF2 T/S wires and
1 JPT18-15 JPF2-3 Approx. 38 ohms Perform Step 2
disconnected coil
/ohms

T/S relays and

2 DCV JPF2-3 TP4 B+ Replace VM Fuse Relay
Card

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test O42 - Main Select Solenoid (optional)

Test O42 - Main Select SEL SOL-X terminal, (+) lead to the
removed wire.
Solenoid (optional) 4. Reconnect the battery connector and turn
the key switch ON. Run the test and
This test toggles the Main Select Solenoid off observe the following results.
and on, verifying its correct operation
Ammeter Operator
electrically. Reading Display

A successful test proves that the Main Select 0.0 to 0.02A Off
Solenoid coil, coil driver, wiring, and related
1.0 to 2.0A On
circuitry in the VM are functioning correctly.
NOTE: This test does not prove that the Main If the above results are not observed, the
Select Solenoid valve is mechanically test has failed.
functional.
5. Turn the key switch OFF and disconnect
For information on how to use Maintenance the battery connector. Remove the
Mode, refer to page 3-26. ammeter from the circuit and reconnect
the wire.

Run Test:
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from the Main Select
Solenoid coil at MAIN SEL SOL-X.
3. Connect a digital ammeter in series with
the Main Select Solenoid: (–) lead to MAIN

Diagnosis and Repair

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

JPT18 and
JPF2 T/S wires and
1 JPT18-14 JPF2-3 Approx. 38 ohms Perform Step 2
disconnected coil
/ohms

T/S relays and

2 DCV JPF2-3 TP4 B+ Replace VM Fuse Relay
Card

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Test O43 - Aux Load Hold Solenoid (optional)

Test O43 - Aux Load 4. Reconnect the battery connector and turn
the key switch ON. Run the test and
Hold Solenoid (optional) observe the following results.

Ammeter Operator
This test toggles the Aux Load Hold Solenoid off Reading Display
and on, verifying its correct operation
0.0 to 0.02A Off
electrically.
1.0 to 2.0A On
A successful test proves that the Aux Load Hold
Solenoid coil, coil driver, wiring, and related
If the above results are not observed, the
circuitry in the VM are functioning correctly.
test has failed.
NOTE: This test does not prove that the Aux 5. Turn the key switch OFF and disconnect
Load Hold Solenoid valve is the battery connector. Remove the
mechanically functional. ammeter from the circuit and reconnect
the wire.
For information on how to use Maintenance
Mode, refer to page 3-26.

Run Test:
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from the Aux Load
Hold Solenoid coil at AUX L/H SOL-X.
3. Connect a digital ammeter in series with
the Aux Load Hold Solenoid: (–) lead to
AUX L/H SOL-X terminal, (+) lead to the
removed wire.

Diagnosis and Repair

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

JPT18 and
JPF2 T/S wires and
1 JPT18-12 JPF2-3 Approx. 38 ohms Perform Step 2
disconnected coil
/ohms

T/S relays and

2 DCV JPF2-3 TP4 B+ Replace VM Fuse Relay
Card

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Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test O44 - Steer Motor

Test O44 - Steer Motor

This test ramps the steer motor by gradually
increasing the command to the steer amplifier.
This test verifies that the steer amplifier can
generate current and cause steering to occur in
both clockwise and counterclockwise direction.
The value ranges from -50 to +50 in increments
of five and is an approximate percentage of full
steer command. To prevent damage to the steer
amplifier, this test limits the steer current to
100A for about 10 seconds. Running the test for
an extended period of time can cause damage to
the steer motor or steer amplifier. Normal
current while steering on a smooth floor, lift
truck not traveling, is approximately 50 amps.
If it is considerably higher, check for binding.

Run Test:
1. The requested% of on-time is displayed.
Use the Up and Down buttons to increase
or decrease the steer request in
increments of 5%, from 0 to 50% and 0 to
-50%. Press the Enter button to exit the
test. Negative values cause the lift truck to
steer to the left and positive values cause
the lift truck to steer to the right.

Action/
step Meter (+) Lead (-) Lead Expected Results Step Passed Step Failed
Setting

While changing the

value from 5 to 50 Check
MS+ cable removed and -5 to -50, the brushes.
MS+
1 from motor MS- voltage should ramp Replace steer Perform Step 2
cable
steer/DCV from 0 to approx. motor if
11.5 volts positive necessary
and negative.

While changing the

DCV/Motor lead values from 5 to 50,
Perform Step
2 removed to prevent JPT6-5 JPT6-4 voltage should ramp Replace VM
3
movement. from approx. 11.5
to 8.00 volts.

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Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual

Run Test:

Action/
step Meter (+) Lead (-) Lead Expected Results Step Passed Step Failed
Setting

While changing the

DCV/Motor lead value from -5 to Replace
3 removed to prevent JPT6-2 JPT6-4 -50, voltage should Steering Replace VM
movement. ramp from approx. Amplifier
11.5 to 8.00 volts.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Section 7. Component Procedures

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

List of Component Procedures

List of Component Procedures

Component Locator Photos . . . . . . . . . . 7-5 Helical Gear/Spiral Pinion
Steering and Controls . . . . . . . . . . . . . 7-17 Gear Assembly . . . . . . . . . . . . . . . . 7-43
Steer Motor/Gearbox . . . . . . . . . . . . . . . . 7-18 Axle Assembly . . . . . . . . . . . . . . . . 7-44
Encoder Bearing Replacement . . . . . . . 7-18 Measuring Backlash. . . . . . . . . . . . 7-46
Home Proximity Sensor Adjustment . . . . . 7-20 Pivot Ring Assembly . . . . . . . . . . . . 7-47
Control Handle . . . . . . . . . . . . . . . . . . . . 7-21 Housing Cover Installation . . . . . . . 7-50
Removal . . . . . . . . . . . . . . . . . . . . . . . 7-21 Drive Unit - Heavy Duty . . . . . . . . . . . . . 7-51
Disassembly . . . . . . . . . . . . . . . . . . . . 7-21 Pivot Ring Inspection . . . . . . . . . . . . . 7-51
Lift/Lower Potentiometer and Spring Re- Drive Unit Removal. . . . . . . . . . . . . . . 7-51
placement . . . . . . . . . . . . . . . . . . . . 7-22 Pivot Ring Disassembly. . . . . . . . . . . . 7-52
Horn Switch Replacement . . . . . . . . 7-22 Main Cover and
Assembly. . . . . . . . . . . . . . . . . . . . . . . 7-22 Output Shaft Disassembly . . . . . . . . . 7-53
Travel Pot (VR1) Replacement . . . . . . . 7-23 Spiral Pinion Disassembly . . . . . . . . . 7-55
Travel Spring and Pinion . . . . . . . . . . . 7-24 Assembly Procedures . . . . . . . . . . . . . 7-56
Disassembly . . . . . . . . . . . . . . . . . . 7-24 Spiral Pinion Assembly. . . . . . . . . . 7-56
Assembly . . . . . . . . . . . . . . . . . . . . 7-24 Main Cover and
Lift/Lower Knob Output Shaft Assembly . . . . . . . . . 7-56
Installation/Adjustment . . . . . . . . . . . 7-25 Helical Gear Assembly . . . . . . . . . . . . 7-59
Cleaning and Inspection . . . . . . . . . . . 7-25 Calculate Shim Formulas . . . . . . . . 7-59
Hand Soldering Procedures . . . . . . . . . 7-26 Installing and Testing Shims . . . . . 7-60
Installation . . . . . . . . . . . . . . . . . . . . . 7-26 Measuring Backlash. . . . . . . . . . . . 7-61
Deadman Pedal . . . . . . . . . . . . . . . . . . . . 7-27 Main Cover Installation . . . . . . . . . 7-61
Switch Replacement . . . . . . . . . . . . . . 7-27 Pivot Ring Assembly . . . . . . . . . . . . 7-61
Drive and Brake . . . . . . . . . . . . . . . . . 7-29 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Traction Motor . . . . . . . . . . . . . . . . . . . . . 7-30 Brake Adjustment. . . . . . . . . . . . . . . . 7-63
Removal . . . . . . . . . . . . . . . . . . . . . . . 7-30 Brake Rotor Replacement . . . . . . . . . . 7-64
Installation . . . . . . . . . . . . . . . . . . . . . 7-30 Removal/Disassembly . . . . . . . . . . 7-64
Drive Unit - Standard . . . . . . . . . . . . . . . 7-31 Assembly/Installation . . . . . . . . . . 7-64
Pivot Ring Inspection . . . . . . . . . . . . . . 7-31 Drive Wheel. . . . . . . . . . . . . . . . . . . . . . . 7-67
Drive Unit Removal . . . . . . . . . . . . . . . 7-31 Removal . . . . . . . . . . . . . . . . . . . . . . . 7-67
Pivot Ring Disassembly . . . . . . . . . . . . 7-32 Installation . . . . . . . . . . . . . . . . . . . . . 7-67
Drive Unit Housing Disassembly . . . . . 7-34 Drive Tire Replacement. . . . . . . . . . . . 7-67
Radial Ring Removal . . . . . . . . . . . . 7-34 Electrical Components . . . . . . . . . . . . 7-69
Axle Shaft and Bevel Gear Removal . 7-34 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Spiral Gear and Helical AC Motor Service. . . . . . . . . . . . . . . . . . . 7-77
Gear Removal . . . . . . . . . . . . . . . . . 7-35 AC Motor Temperature Sensor . . . . . . 7-77
Bearing Cup and Shim Removal . . . 7-36 Traction Motor Replacement: . . . . . 7-77
Spur Gear Removal . . . . . . . . . . . . . 7-37 Lift Motor Replacement: . . . . . . . . . 7-77
Housing Cleaning and Inspection . . 7-37 AC Motor Bearing Encoder . . . . . . . . . 7-78
Axle Shaft Disassembly. . . . . . . . . . 7-37 Traction Motor Replacement: . . . . . 7-78
Bevel Gear Disassembly . . . . . . . . . 7-38 Lift Motor Replacement: . . . . . . . . . 7-79
Spiral Gear Disassembly . . . . . . . . . 7-39 Power Amplifiers . . . . . . . . . . . . . . . . . . . 7-80
Assembly Procedures. . . . . . . . . . . . . . 7-40 Installation . . . . . . . . . . . . . . . . . . . . . 7-80
Gear Set Assembly . . . . . . . . . . . . . 7-40 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Calculate Shim Formulas . . . . . . . . 7-40 Carriage Control Card Replacement . . . . 7-82
Spiral Pinion Gear EPROM/Microprocessor
Shim Calculation: . . . . . . . . . . . . . . 7-40 Removal/Replacement . . . . . . . . . . . . . . 7-84
Bevel Gear Shim Calculation: . . . . . 7-41 Removal . . . . . . . . . . . . . . . . . . . . . . . 7-84
Housing Bearing Cup and Installation . . . . . . . . . . . . . . . . . . . . . 7-84
Shim Assembly . . . . . . . . . . . . . . . . 7-42 Hydraulic Components . . . . . . . . . . . . 7-95

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

List of Component Procedures

Flow Sensor Service Notes . . . . . . . . . . . . 7-96

O-Ring Replacement . . . . . . . . . . . . . . 7-96
Disassembly . . . . . . . . . . . . . . . . . . . . 7-97
Assembly . . . . . . . . . . . . . . . . . . . . . . . 7-98
High Pressure Relief Valve Adjustment . . . 7-99
Lift/Lower and Load Holding Valves . . . . 7-100
Bleeding Lift Cylinders . . . . . . . . . . . . . . 7-101
Side Lift Cylinders . . . . . . . . . . . . . . . 7-101
Center Cylinder . . . . . . . . . . . . . . . . . 7-101
Lift Pump and Motor . . . . . . . . . . . . . . . 7-102
Removal. . . . . . . . . . . . . . . . . . . . . . . 7-102
Installation . . . . . . . . . . . . . . . . . . . . 7-102
Pressure Switch Adjustment. . . . . . . . . . 7-103
Side Lift Cylinder . . . . . . . . . . . . . . . . . . 7-104
Remove . . . . . . . . . . . . . . . . . . . . . . . 7-104
Installation . . . . . . . . . . . . . . . . . . . . 7-104
Cushion Service. . . . . . . . . . . . . . . . . 7-105
Cleaning . . . . . . . . . . . . . . . . . . . . . . 7-106
Seal Repacking . . . . . . . . . . . . . . . . . 7-107
Center Lift Cylinder . . . . . . . . . . . . . . . . 7-108
Installation . . . . . . . . . . . . . . . . . . . . 7-108
Service of Cylinder with Cushions . . . 7-108
Cushion Replacement . . . . . . . . . . 7-108
Seal Replacement . . . . . . . . . . . . . . . 7-110
Mast Section . . . . . . . . . . . . . . . . . . . 7-111
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . 7-112
Removal. . . . . . . . . . . . . . . . . . . . . . . 7-112
Installation . . . . . . . . . . . . . . . . . . . . 7-113
Mast Disassembly and Shimming . . . 7-118
Shimming Main Frame to
Outer Telescopic . . . . . . . . . . . . . . 7-118
Shimming Outer Telescopic to
Inner Telescopic . . . . . . . . . . . . . . 7-119
Shimming Inner Telescopic to
Carriage . . . . . . . . . . . . . . . . . . . . 7-120
Center Cylinder Ride Spring
Chain Anchors . . . . . . . . . . . . . . . . . . . . 7-124
Inspection . . . . . . . . . . . . . . . . . . . . . 7-124
Removal. . . . . . . . . . . . . . . . . . . . . . . 7-125
Installation . . . . . . . . . . . . . . . . . . . . 7-125
Installation . . . . . . . . . . . . . . . . . . . . 7-126
Installation . . . . . . . . . . . . . . . . . . . . 7-127

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

List of Component Procedures

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Component Locator Photos

Section 7. Component Procedures

Tether Attachment Point

Dome Light

Working Lights

Battery
Compartment
Sidegate

Storage
Compartment

Pallet Clamp Release

Skid Pads

Pallet Clamp

Deadman Pedal

Load Wheels
Forks

78C04050S.TIF
Figure 7-1. Model 5600 - Overall View

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Steering Indicator Lights Operator Display Key Switch

(Electronic Steering/Wire Guidance) Emergency
Guidance Indicator Lights Key Pad Power Off

Steer Tiller Lift/Lower Horn Switch Direction/Speed

Control Control
78C11036H.TIF
Figure 7-2. Operator Console

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Reservoir

Lift Motor

Lift Pump Lift/Lower

Solenoid

Lift/Lower
Manifold
High Pressure
Relief Valve

Load Holding
Solenoid (SOL2)

Pressure Test
Connection

Emergency
Lower Valve

7
Figure 7-3. Hydraulic Compartment Components

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Fuse/Relay
Card

Vehicle
Manager

Pendant
Steer Motor Connection

Contactor
Brake Panel
Assembly

Lift Power
Drive Motor
Amplifier

Guidance
Manager

Home Horn
Proximity
Sensor

7
Figure 7-4. Electrical Compartment Components

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Traction Power Steer

Amplifier Amplifier

TP4 Fuse/Relay
Card
7
Figure 7-5. Electrical Compartment Components (located on Upper Deck of Tractor)

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Steering Encoder Assembly

(behind steer tiller)

Carriage
Control Card

Pallet Clamp
Release

Deadman
Pedal

7
Figure 7-6. Platform Components

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Special Tools and Decals

Special Tools and Decals

Section 7. Component Procedures

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Special Tools Special Tools and Decals

Special Tools
The following tools are available from your local
authorized Raymond Sales and Service Center.

Table 7-1. Special Tools

Tool Part Number Purpose

Anti-static Field Kit 1-187-059

Anti-static Wrist Straps 1-187-058/001 ESD protection

Anti-static Wrist Strap Tester 1-187-060/100

Center Cylinder Service 401-000-058 Prevents damage to packing at the top of cylinder
Driver

Center Cylinder Service 401-000-059 Prevents damage to packing at the top of cylinder
Guide

Chain Gauge 939-10606 Lift chain inspection

Connector Unlatching 950-042 Separate AMP connectors

Crimp Tool 1069861 Crimp power cable lugs

Center Lift Cylinder with decel and staging end cap

End Cap 1090761/002
removal and installation

EPROM Extractor 950-032 Removing EPROM chips from socket on circuit board

Fork Wear Caliper 922-369 Fork inspection

Lift/Lower Pendant 114-020-848 Lift and Lower platform for service

Lock Nut Wrench 761-870/T03 Removing end play in drive unit bearings

Magnet 591-552/002 Testing EOA sensor

Nut Driver Tool 761-870/T04 Removing end play in drive unit bearings

Nut Driver Tool 761-870/T07 Removing end play in drive unit bearings

Pin Extraction Tool 950-009 AMP connector pin extraction

Pin Extraction Tool 950-026 MOLEX connector pin extraction

Seal Pressing Ring 828-004-901 Prevents damage to seals during installation

Side Cylinder Service Driver 401-000-050 Prevents damage to packing at the top of cylinder

Side Cylinder Service Guide 401-000-051 Prevents damage to packing at the top of cylinder

Snap Ring Pliers MI-Snapplier Removing and installing snap rings

FlashWare connection to lift truck for devices that do not

USB to Serial Adapter Cable 610-809/W7P
have a serial port

5-Ton Jack 990-807 Jacking lift truck

9-Pin Serial Cable 610-809/201 FlashWare connection to lift truck

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Special Tools and Decals Decals and Tags

Decals and Tags

Table 7-2. Decal and Tag Location Chart

Decal and Specification Tag Locations

Identifier Description

1 Raymond 21 in. (two places)

2 Raymond 11 in.

3 ACR (two places)

4 Emergency Lower (inside of the tractor)

5 Emergency Lower (top of the tractor)

6 Main Specification Tag

7 Attachment Tag

8 Mast Specification Tag

9 Battery Removal Warning (two places)

10 Driver Operating

11 Overhead Guard (ANSI/ITSDF

conformance)

12 Operator General Safety Decal

13 Bumper (optional)

14 Drive Unit Warning

15 EE Compliance (optional)

16 Attention

Note: Items in italics are safety decals.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Decals and Tags Special Tools and Decals

Figure 7-7.

16
3

11

15

14

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Special Tools and Decals Decals and Tags

Figure 7-8. Decal and Specification Tag Locations
Figure 7-8 (Cont.). Decal and Specification Tag Locations

12
7
6

10
4

13

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Decals and Tags Special Tools and Decals

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Steering and Controls

Section 7. Component Procedures

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Spur Gear Orientation

Steer Motor/Gearbox 9. Torque the bolts holding the motor to the

gear reducer to approx. 85 in. lb. (9.9 Nm).

B Side
Encoder Bearing Replacement End Bell
NOTE: Replace the shaft seal, the B side
bearing, and the brushes while the
motor is apart.
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the steer motor and gearbox.
A Side
3. Remove the B side end bell and brush End Bell
retainers. See Figure 7-9.
4. Remove the A side end bell bolts and pull
the end bell and rotor from the motor
housing. Push the wires and rubber
grommet out of the housing slot.
5. Loosen the two Phillips head screws that
are used with the small clips to retain the
bearing in the A side end bell.
6. Remove the A side end bell from the rotor.
7. Use a press to remove the old bearing. 7

Figure 7-9. Steer Motor and Gearbox

Spur Gear Orientation

New encoder bearings are mounted like
regular bearings except induction Spur gear installation is different between
heaters must not be used because they standard and heavy duty drive units. Install the
demagnetize the encoder. Also, care spur gear as shown in Figure 7-10 on
must be taken against ESD. See page 7-19.
page 2-8.

NOTE: When pressing a bearing onto a shaft,

press on the inner race, never the outer
race.
8. Press on the new bearing and reassemble
the motor. Place a small amount of good
quality grease between the new bearing
and the shaft seal. Take care to not
damage the pinion gear in the end of the
motor shaft.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Radial Rings

Standard Drive Unit

Heavy Duty Drive Unit
7

Figure 7-10. Spur Gear Orientation

NOTE: Make sure that the spur gear teeth

mesh fully with the teeth of the gear on
the drive unit.

Radial Rings
Make sure that the radial rings on the drive
unit do not bind any time the steering motor is
repaired or replaced. Rotate the drive unit full
left and full right while pumping grease into the
radial rings at both grease fittings.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Radial Rings

Home Proximity Sensor

Adjustment
1. Turn the key switch OFF and disconnect
the battery connector.
2. Loosen the two lock nuts that secure the
sensor to the bracket. See Figure 7-11.

Figure 7-11. Home Proximity Sensor

3. Adjust the vertical gap between the sensor

and the sensor rail to 0.060 +0.010/
–0.040 in. (1.5 +0.254/–1.016 mm).
4. Tighten the lock nuts.
5. Reconnect the battery connector and turn
the key switch ON.
6. Center the drive wheel. The sensor must
be located horizontally just over the end of
the sensor rail.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Radial Rings

Control Handle NOTE: Carefully slide the two fiber washers,

lift/lower spring, and third fiber washer
off the lift pot shaft. See Figure 7-12.
Removal
1. Turn the key switch OFF and disconnect
the battery connector. Fiber
Washer
2. Disconnect JPC9 and remove the control
handle from the lift truck.
NOTE: Observe the orientation of switches,
potentiometers (pot), and the routing of Lift/Lower
cables and wires as the handle is Spring
disassembled to make reassembly
easier.
7

Figure 7-12. Spacer Washer and L/L Spring Removal

3. Remove the three 3 mm socket head cap

Observe correct ESD precautions. See screws from the handle assembly. See
“Static Precautions” on page 2-8. Figures 7-13 and 7-14. Separate the cover
from the handle.
Before disassembly, determine what
components require replacement such as:
• Lift/Lower Pot, Spring, and/or Horn
Switch
• Travel Pot
• Travel Spring and/or Pinion
• Lift/Lower Knob

Disassembly
1. Remove the two 3/32 socket head nylon
7
set screws in the lift/lower knob (thumb Figure 7-13. Cover Retaining Screws - Bottom
lever). Use a small 1/8 in. (3.2 mm) blade
flat-head screwdriver to carefully back out
a stripped set screw, if needed.
2. Loosen the two metal set screws in the
lift/lower knob two full turns and remove
the lift/lower knob.

Figure 7-14. Cover Retaining Screw - Top

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Radial Rings

Lift/Lower Potentiometer and Spring Horn Switch Replacement

Replacement 1. Disconnect the horn switch connector. See
NOTE: Before sliding the potentiometer (pot) Figure 7-16.
bracket off the pot shaft, identify what
slot in the pot bracket is used to hold
the pot anti-rotate tab. The anti-rotate Plastic Nut
tab must be located in the slot furthest
from the pin in the pot bracket.
1. Remove the lift/lower pot and bracket
from the cover. See Figure 7-15.

Tab
Slot Cable Tie Connector

Figure 7-16. Horn Switch Removal

2. Remove the plastic nut and external tooth

washer securing horn switch. Remove the
cable tie.
3. Install the new horn switch assembly into
Bracket the handle cover. Install the external tooth
7
washer and plastic nut. Cable tie all wires
Figure 7-15. Anti-Rotate Tab together.

NOTE: The button, pin, and spring can easily Assembly

slide apart. Identify the correct position
of these components before 1. Make sure all wires are routed correctly.
disassembly. Tuck the common ground wire into the
handle between the bottom of the pot and
2. If replacing the pot, carefully remove heat the screw boss to prevent the wire from
shrink tubing from the terminals. Identify being pinched or interfering with the horn
the wires so they can be installed in the button.
same location on the new pot.
2. Install the cover onto the handle assembly
3. Carefully unsolder the harness wires from with the three socket head cap screws.
the lift/lower pot. Torque to 15-20 in. lb. (1.7-2.25 Nm).
4. Carefully solder harness wires to the 3. Install a fiber washer and lift/lower spring
correct terminals on the new lift/lower (lightly greased with P/N 990-635) on the
pot. Refer to Hand Soldering Procedures lift/lower pot shaft. Install the spring with
on page 7-26. the tangs straddling the pot bracket pin.
5. Slide lift/lower pot bracket onto the shaft. See Figure 7-12.
Make sure the anti-rotation tab is inserted
NOTE: Replace the spring if the tangs are not
into the correct slot on the bracket. See
parallel. Do not bend the spring.
Figure 7-15.
6. Press the lift/lower pot and bracket into 4. Install the two remaining fiber washers.
the handle cover. Make sure the key on the 5. Install the lift/lower knob. See “Lift/Lower
bracket engages the keyway in the handle Knob Installation/Adjustment” on
cover. page 7-25.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Radial Rings

Travel Pot (VR1) Replacement 3. Loosen the set screw on the gear two full
turns and slide the gear off the shaft. See
1. Remove the four hex head cap screws from Figure 7-20.
the front of the travel pot enclosure and
4. Remove the retaining nut and lock washer
remove cover. See Figure 7-17.
from the pot and separate from the
bracket. See Figure 7-20.
Hex Head Cap
Screws Set Screw

Retaining Nut and

Lock Washer
7 7

Figure 7-17. Travel Pot Cover Removal Figure 7-20. Travel Pot/Bracket Disassembly

2. Remove the two pan head machine screws 5. Carefully remove heat shrink tubing from
from the back of the enclosure. Carefully the terminals and identify the wires so
pull the travel pot/bracket assembly from they can be installed in the same location
the enclosure. See Figures 7-18 and 7-19. on the new pot.
6. Carefully unsolder the harness wires.
7. Slide 3/8 in. (9.5 mm) long shrink sleeving
over previously sleeved wires.
8. Solder all electrical components to the
harness. See “Hand Soldering Procedures”
on page 7-26.
9. Shrink sleeving as necessary.
10. Assemble the pot and bracket. Install the
Pan Head retaining nut and lock washer. When
Machine Screws installing the travel pot into the bracket,
7
leave the mounting nut finger tight. See
Figure 7-18. Travel Pot Bracket Screws Figure 7-20.
11. Install the gear on the pot shaft, aligning
the set screw with the flat portion of the
Travel Spring shaft.
12. Install the travel pot/bracket assembly
into the enclosure. Engage the travel pot
Button
Head Screw
gear with the shaft gear (there is one large
tooth that is used to align the gears).
Tighten the pot gear set screw and torque
to 3 to 4 in. lb. (0.3 to 0.4 Nm).

Figure 7-19. Travel Pot Enclosure (Cover Removed)

It is very easy to over torque and ruin
the gear.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Radial Rings

13. Tighten the two pan head machine screws such that when the spring is installed,
on the back of the enclosure while moving the spring sits on an even edge of the
the handle to make sure there is no pin and not on the gap.
binding. See Figure 7-18 on page 7-23.
NOTE: Replace the spring if the tangs are not
14. Install the handle in the lift truck. parallel. Do not bend the spring.
15. Adjust the travel pot. Run Test A04 - b. Make sure the washer and shims are
Throttle Potentiometer Voltage (Page 6-46) correctly aligned to allow the handle
and adjust the travel pot voltages to the shaft to slide easily through the
values given. enclosure. See Figure 7-21.
16. Tighten the retaining nut.
17. Install the cover on the travel pot
enclosure with the four hex head cap
screws. See Figure 7-17.
18. Run Learn. See “Learn Mode” on page 3-9.

Travel Spring and Pinion

Disassembly
1. Remove the four hex head cap screws from
the front of the travel pot enclosure and Washers/Shims
remove the cover. See Figure 7-17 on 7

page 7-23. Figure 7-21. Travel Pot/Bracket Assembly Installation

2. Use a pin extraction tool and pull pins 3
through 6 from JC-9. These wires pass 2. Route the lift/lower pot and horn wires
through the shaft to the lift/lower pot and through the enclosure. Carefully slide the
horn switch. shaft through the enclosure, passing
through the shaft gear assembly, washer,
NOTE: The washer and shims can easily slip off and shims.
the shaft gear. Observe the correct 3. Align the screw hole in the handle shaft
position of these components before with the hole in the shaft gear. Apply
disassembling them. thread-locking compound (P/N 990-412)
to the threads in the shaft and on the
3. Remove the button head screw from the
button head screw. Install the screw and
shaft gear and slide the shaft out of the
torque to 8-12 in. lb. (0.9 - 1.3 Nm).
enclosure. See Figure 7-19 on page 7-23.
4. Reinstall the wire pins into the connector.
4. Carefully rotate the shaft gear assembly to
disengage the spring tangs from the pin. 5. Inspect the tab on the plate ground to
Remove the shaft gear assembly from the make sure that it is in contact with the
enclosure. bronze handle shaft bushing. See
Figure 7-22.
Assembly
1. Slide the shaft gear assembly back into the
enclosure. Engage the travel pot gear with
the shaft gear (there is one large tooth that
is used to align the gears).
a. Make sure that the spring tangs
straddle the pin, keeping the tangs
parallel. If the spiral pins were
replaced, make sure they are installed

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Radial Rings

3. Rotate the lift/lower knob fully

counterclockwise and tighten the metal set
screws to 6-8 in. lb. (0.7 - 0.9 Nm).
Plate Ground 4. Check the pot for correct operation and
spring return to neutral. Correct any
binding.
5. Install and tighten the two nylon set
screws on top of the metal set screws.
6. Verify the pot reference voltages. Refer to
Test A05 - Lift/Lower Potentiometer
Voltage on page 6-47.
7. Run Learn. See “Learn Mode” on page 3-9.

Figure 7-22. Plate Ground

7
Cleaning and Inspection
6. Install the cover on the travel pot
enclosure with the four hex head cap
screws. See Figure 7-17 on page 7-23. When cleaning plastic parts, use a dry
rag or a cleaner that is safe on plastics.
Most chemicals can damage plastic.
Lift/Lower Knob
Installation/Adjustment While performing a repair on the control
handle, clean and inspect the parts listed in
1. Rotate the lift/lower pot shaft fully
Table 7-3.
counterclockwise.
2. Install the lift knob on the pot shaft. The
pin on the knob must fit between the tangs
of the pot return spring.
Table 7-3. Control Handle Checks

Part Check for:

Horn Button Assembly Cracks or deformation

Lift/Lower Pot Bracket Cracks, deformation, loose dowel pin, over round or oversized shaft hole

Travel Pot Gear Cracks, gear deformation, or stripped threads

Travel Shaft Gear Assembly Cracks, gear deformation, or loose spiral pin

Travel Pot Enclosure Cracks, loose spirol pin, stripped threads, deformation, or indents on external
stops

Handle Halves Cracks, damage, or deformation/indents on external stops

Lift/Lower Knob Cracks, deformation, stripped threads, loose dowel pin

Plate Ground Check for continuity between the control handle shaft and the lift truck frame

Other Hardware Stripped threads

All screw threads must be cleaned

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Radial Rings

Hand Soldering Procedures

When hand soldering is performed on solid
state potentiometers, the following is
recommended:
• Flux - rosin base
• Solder - 60/40 rosin core or equivalent
• Solder Iron - 55 watt max.
• Tip Size - 0.118 in. (3 mm) dia. x 1.182 in.
(30 mm) long screwdriver
• Tip Temperature - 500°F (260°C) max.
• Terminal Contact Time - 6 seconds max.
NOTE: Apply light soldering iron pressure on
the terminal. Make sure the tip is clean.
A dirty tip does not transfer heat well,
therefore requiring longer dwell time
and greater tip pressure.

Contact contamination can occur if

cleaning solvent is allowed to enter
switches or potentiometers.

After soldering, clean terminals with a brush

dampened with an alcohol based cleaner. Make
sure cleaner does not seep into the electrical
component.
NOTE: Components damaged due to solvent
saturation will not be covered under
warranty.

Installation
1. Install the control handle on the lift truck.
Connect JPC9.
2. Connect the ground wire to the lift truck
frame.
3. Reconnect the battery connector and turn
the key switch ON.
4. Perform Learn Controls and test lift truck
operation before returning to service. See
“Learn Mode” on page 3-9.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Radial Rings

Deadman Pedal 8. Install the springs and washers on the

deadman assembly. See Figure 7-24.

Switch Replacement
Spring
There are two deadman switches (S2 and S23).
1. Raise the operator platform high enough
(at least 3 ft. [91.44 cm]) to access the
bottom of the deadman pedal from under Washers
the platform.
2. Block the operator platform with a 4 x 4
in. (100 x 100 mm) wooden block. Washer
Post Stop
3. Turn the key switch OFF and disconnect
the battery connector. M8 Nut
4. Remove the deadman assembly by
77k10131s
removing the three retaining nuts under Figure 7-24. Deadman Pedal Springs and Washers
the carriage, and disconnecting the
harness. See Figure 7-23. 9. Install the deadman assembly on the
deadman weldment. See Figure 7-23 and
Figure 7-24.
10. Install the nut and washers on the center
post.
11. Torque the M8 nut against the shoulder of
the center post. Refer to “Torque Chart -
Metric (Ferrous)” on page A-9.
12. Attach the deadman assembly to the
carriage with the three retaining nuts and
connect the harness. See Figure 7-23.
13. Reconnect the battery connector, and turn
71447_019.tif the key switch ON.
Figure 7-23. Deadman Lock Nuts and Washers
14. Remove the block and lower the carriage.
5. Remove the M8 nut and washers from the 15. Test the lift truck operation before
bottom of the center post. returning to service.
6. Separate the deadman assembly from the
deadman weldment.
NOTE: Do not lose the springs or washers.
7. Replace the bad switch(es).

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Radial Rings

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive and Brake

Section 7. Component Procedures

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Traction Motor 5. Remove the traction motor.

Refer to AC Motor Service on page 7-77 for Installation

traction motor temperature sensor and encoder 1. Clean the motor mounting flange and drive
bearing replacement procedures. unit. Install a new gasket.
2. Install the pinion in the drive motor, if
Removal required, by following these steps.
1. Turn the key switch OFF and disconnect a. Clean the threads using thread-locking
the battery connector. compound primer (P/N 990-666).
2. Remove the brake assembly including the b. Install the key and gear.
rotor hub nut and rotor hub. See c. Apply thread-locking compound
Figure 7-25. Note the number of spacers (P/N 990-669) to the threads of the
used. motor and nut.
d. Torque the nut to 45 ft. lb. (61 Nm).
Brake Assembly
3. Mount the motor to the drive unit.
4. Install the drive motor retaining screws.
Refer to Component Specific
Service/Torque Chart on page A-4.
5. Install the power cables on the traction
motor.
6. Torque the power cable nuts to 18 ft. lb.
(24.4 Nm). See Power Cable Terminals on
page 7-74.
7. Install the brake assembly, including the
rotor hub nut and rotor hub.
8. Check brake adjustment. See Brake
Adjustment on page 7-63.

Figure 7-25. Drive Motor

3. Identify and remove the power cables from

the traction motor.
4. Remove the drive motor retaining screws.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit - Standard Drive Unit Removal

1. Turn the key switch OFF and disconnect
the battery connector.
Pivot Ring Inspection
2. Remove the bumper gate. See Figure 7-26.
Some play is expected between the pivot ring
bearings and the drive unit. As the rings wear,
the play may increase. If the play is permitted to
become extreme, it will become noticeable in
the drive unit.
Inspect the drive housing if worn rings are
suspected as the cause of excessive play in the
drive unit. determine if the bearing radial rings
must be replaced:
1. Jack the tractor of the lift truck up just
enough to permit the drive tire to clear the
floor.
Bumper Gate

7
Figure 7-26. Removing Drive Unit
Use extreme care when the lift truck is
3. If the lift truck is wire guided, remove the
jacked up. Never block the lift truck
sensor mounted on the backside of the
between the telescopic and the floor.
bumper gate.
Attach an appropriately rated rigging
device to the top of the mast, and an 4. If the drive tire is to be removed, loosen the
overhead hoist to stabilize the mast if lug nuts.
jacking higher than described in the 5. Remove the proximity sensor and
Jacking Safety section. Keep hands and associated hardware on the drive unit
feet clear while jacking the lift truck. casting.
After the lift truck is jacked, place solid
6. Remove the traction motor. See Traction
blocks or jack stands beneath it to
Motor on page 7-30.
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the NOTE: It is not necessary to separate the brake
jack or jack stand alone to support the assembly from the traction motor if the
lift truck. See Jacking on page 2-9. drive unit is the only item requiring
service.
2. Place a magnetic base dial indicator on the
deck plate and position the indicator point
on top of the drive unit top cover.
3. Adjust the dial indicator to zero, then
lower the lift truck to the floor.
4. Note the new indicator reading. If the
reading is 0.089 in. (2.26 mm) or less, the
radial rings do not have to be replaced. If
the reading exceeds 0.089 in. (2.26 mm),
the rings must be replaced. If the reading
is between 0.055 and 0.089 in. (1.4 and
2.26 mm), the bearing rings must be
checked during future scheduled
maintenance visits.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

14. Visually inspect the outside of the housing

for damage, wear, or cracks. Pay particular
attention to the area where hub wear may
Use extreme care when the lift truck is be evident.
jacked up. Never block the lift truck
between the telescopic and the floor. Pivot Ring Disassembly
Attach an appropriately rated rigging
device to the top of the mast, and an 1. Remove the bearing filler plug screws
overhead hoist to stabilize the mast if using a 1/2 in. socket. See Figure 7-28.
jacking higher than described in the
Jacking Safety section. Keep hands and
feet clear while jacking the lift truck.
After the lift truck is jacked, place solid
blocks or jack stands beneath it to
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the
jack or jack stand alone to support the
lift truck. See Jacking on page 2-9.

7. Jack and block the tractor so the drive tire

is off the floor.
8. Drain the oil from the drive unit. 71826_011.tif

9. Unbolt the lift/lower manifold from the Figure 7-28. Bearing Filler Plug Screws Removal
drive unit casting.
2. Remove the bearing filler plug with grease
10. Remove the steering motor/gear reducer
fitting.
assembly.
3. Remove the steel balls through the bearing
11. Remove the cap screws holding the drive
filler plug hole. To work the steel balls
unit assembly to the tractor frame.
forward, insert a putty knife between the
12. Lift the drive unit out of the tractor frame pivot ring and the housing. See
using a suitable lifting device. Figure 7-29. Use care to prevent damaging
13. Clean the outside of the drive unit the radial rings. Move the pivot ring
thoroughly and drain any remaining oil slightly from side to side while working the
from the drive unit by removing the drain putty knife toward the bearing filler plug
plug. hole.
NOTE: If the pivot ring will not spin or even
turn, it is an indication of damaged
radial rings and/or excessive wear to the
channel in the housing. If this is the
case, replace the entire drive unit. No
further disassembly is necessary.

71826_006.tif

Figure 7-27. Inspect Housing for Hub Wear

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Due to normal or excessive wear, the

edges of the radial rings could be very
sharp.

6. Use a mallet and a punch to remove the

spherical bearing and brass bushing from
the radial ring. See Figure 7-32.

1826_014.tif

Figure 7-29. Remove Steel Ball Bearings

4. After removing all the steel balls, remove

the pivot ring by lifting it off, toward the
drive end of the housing. See Figure 7-30.

71826_020.tif

Figure 7-32. Spherical Bearing and Brass Bushing

Removal

7. Remove the grease fittings using a punch

and a mallet. See Figure 7-33.

71826_015.tif

Figure 7-30. Radial Ring Removal

5. Use a screwdriver to remove the radial

rings and thrust ring from the pivot ring.
See Figure 7-31.

71826_022.tif

Figure 7-33. Grease Fitting Removal

8. Use a punch and mallet to remove the two

roll pins that are used to hold the radial
rings in position. See Figure 7-34. Inspect
the roll pins. If they are worn, replace with
new roll pins when reassembling the pivot
ring.
71826_018.tif

Figure 7-31. Radial and Thrust Ring Removal

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Due to normal or excessive wear, the

edges of the radial rings could be very
sharp.

2. Clean the grease from the radial ring

channel in the housing. Inspect the
channel for uneven wear. See Figure 7-36.
If there is excessive wear, no further
disassembly is necessary. The housing
must be replaced.
71826_024.tif

Figure 7-34. Roll Pin Removal

9. Clean the grease from the radial ring

channel in the pivot ring. Inspect the
channels for wear. If there is excessive
wear, replace the pivot ring.

Drive Unit Housing Disassembly

Excessive housing wear in the channel, pivot
ring, or hub areas are signs of a damaged
housing. If this occurs, replace the entire drive 71826_026.tif

unit. No further disassembly is necessary. Figure 7-36. Inspect Housing Channel

Radial Ring Removal Axle Shaft and Bevel Gear Removal

1. Use a screwdriver to remove the radial 1. Loosen the set screw locking the clamp
rings from the housing. See Figure 7-35. nut using a 4 or 5 mm Allen socket and a
breaker bar. See Figure 7-37. You may
need to use an Allen wrench if access is
limited.

71826_025.tif

Figure 7-35. Radial Ring Removal from Housing

71826_027.tif

Figure 7-37. Loosen Clamp Nut Set Screw

2. Use a screwdriver in the clamp nut slot to

turn the clamp nut off. See Figure 7-38.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Spiral Gear and Helical Gear

Removal
1. Turn the drive unit housing over to remove
the clamp nut from the spiral gear. Loosen
the set screw locking the clamp nut using
a 4 or 5 mm Allen wrench. See
Figure 7-41.

71826_029.tif

Figure 7-38. Turn Clamp Nut Off

3. Remove the axle from the housing using a

large mallet. See Figure 7-39.

71826_041.tif

Figure 7-41. Remove Clamp Nut Set Screw

2. Use a screwdriver in the clamp nut slot to

turn the clamp nut off. Inspect the clamp
nut for damage. See Figure 7-42.

71826_030.tif

Figure 7-39. Remove Axle from Housing

4. The bevel gear can now be lifted from the

housing. In cases where severe chipping is
present, you may need a mallet to knock
the bevel gear loose. See Figure 7-40.

71826_042.tif

Figure 7-42. Remove Clamp Nut

3. Use a brass drift punch and mallet to drive

the spiral pinion gear shaft through the
housing. The brass drift punch will
prevent damage to the threads on the end
of the spiral shaft. See Figure 7-43.
NOTE: It may be necessary to remove the spiral
pinion gear with a press or pressing
71826_038.tif device equivalent.
Figure 7-40. Lift Out Bevel Gear

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

71826_043.tif 71826_047.tif

Figure 7-43. Remove Spiral Pinion Figure 7-45. Lift Bearing from Housing

4. Lift the helical gear and spacer from the Bearing Cup and Shim Removal
housing. See Figure 7-44.
NOTE: The bearing cups and cones are usually
damaged during removal. They must be
replaced as sets.
1. Use the mallet and a long punch to drive
the spiral gear bearing cup from the
housing. Take care not to damage the
shims. Save the shims for reference in
reassembly. See Figure 7-46.

71826_045.tif

Figure 7-44. Lift Helical Gear from Housing

5. Inspect the helical gear and the spiral gear

for damage or wear.
NOTE: The bevel gear and spiral gear are a
matched set. Their alignment is critical.
Do not replace them separately.
71826_053.tif
6. Lift the bearing the spiral shaft goes
Figure 7-46. Spiral Gear Bearing Cup Removal
through from the housing to remove it. See
Figure 7-45. 2. Use the mallet and a punch to drive the
helical gear bearing cup from the housing.
See Figure 7-47.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Spur Gear Removal

Check the spur gear for damage or wear. If the

spur gear is damaged, use a drift punch and
mallet to remove it from the housing. See
Figure 7-49.

71826_055.tif

Figure 7-47. Helical Gear Bearing Cup Removal

3. Remove the axle shaft bearing cup from

the housing using the punch and mallet.
See Figure 7-48.
71826_059.tif

Figure 7-49. Spur Gear Removal

Bevel Gear
Bearing Cup Housing Cleaning and Inspection

Thoroughly degrease the housing. Visually

inspect the entire housing again for excessive
damage, cracks, or wear.

Axle Shaft
Axle Shaft Disassembly
Bearing Cup

71826_057.tif

Figure 7-48. Axle Shaft and Bevel Gear Bearing Cup Always watch for pinch points when
Removal using a press or pressing tools.

4. Use the mallet and a punch to drive the 1. Place a bearing puller clamp between the
bevel gear bearing cup from the housing. axle seal and beneath the axle bearing
Take care not to damage the shims. Save cone.
the shims for reference during reassembly. 2. Press the bearing from the axle using a
5. Visually inspect the housing bores and bearing press and a 6 in. tube. See
sealing surfaces for damage or wear. Figure 7-50.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Bevel Gear Disassembly

Always watch for pinch points when

using a press or pressing tools.

1. Place the bearing puller clamp on the bevel

gear beneath the bearing. See Figure 7-53.

71826_032.tif

Figure 7-50. Bearing Removal

3. Lift the axle seal from the axle. See

Figure 7-51.

71826_039.tif

Figure 7-53. Puller Clamp on Bevel Gear

2. Press the bearing from the bevel gear

using a bearing press and an 8 in. tube.
See Figure 7-54.

71826_034.tif

Figure 7-51. Lift Seal Removal

4. Inspect the axle for damage or wear. See

Figure 7-52.

71826_040.tif

Figure 7-54. Press Bearing from Bevel Gear

71826_035.tif

Figure 7-52. Axle Inspection

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Spiral Gear Disassembly

1. Place a bearing puller clamp beneath the
bearing cone on the spiral gear. See
Figure 7-55.

71826_051.tif

Figure 7-55. Puller Clamp on Spiral Gear

2. Press the bearing from the spiral gear

using a bearing press. See Figure 7-56.

71826_052.tif

Figure 7-56. Pressing Bearing from Spiral Gear

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Assembly Procedures

Bearing Cone

Safety glasses are required.

Prepare the housing for assembly by running a

Spiral Gear
tap through all bolt and screw holes. Cleaning
the threads makes sure that there is no
damage. It also enables you to determine the
correct tooling to use in the assembly process.

Record the bearing seat data stamped on the 71018_015.tif

housing before beginning assembly of the drive Figure 7-58. Press Bearing onto Spiral Gear
unit. Record the setting distance information
stamped on the bevel and spiral gears. This
data is used in the formula to determine shim
thickness later on.
Always watch for pinch points when
using a press or pressing tools.
Gear Set Assembly
1. Press the bearing cone on the bevel gear 3. Use a bearing zero offset tool and the
until it is seated. Place the matching formulas below to determine the shim
bearing cup on the bearing cone for thickness that is required to assemble the
measuring purposes. See Figure 7-57. gear set in the housing.

Calculate Shim Formulas

Spiral Pinion Gear Shim Calculation:

• A = Dimension A (See Figure 7-59.)
stamped on housing (4.438)
• B = Number (See Figure 7-60.) etched on
gear (S/D 2.378)
• C = Zero Offset (See Figure 7-61.)
Use a dial indicator to determine the zero
offset. Turn the spiral gear as if seating the
bearings. Record the data from the dial
71826_064.tif
indicator to use in the formula.
Figure 7-57. Press Bearing on Bevel Gear
• D = Plug Height (2.025)
2. Press the bearing cone on the spiral gear • E=B+C+D
until it is seated. Place the matching
• F=A-E
bearing cup on the bearing cone for
measuring purposes. See Figure 7-58. F = Shim thickness required

This calculation is used to determine the shim

amount behind the bearing cup in the main
housing. The shim(s) positions the spiral gear
for correct backlash.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Bevel Gear Shim Calculation:

• G = Dimension B (see Figure 7-62)
stamped on housing (2.506)
• H = Number (see Figure 7-63) etched on
gear (S/D 0.541)
• J = Zero Offset (see Figure 7-64)
Use a dial indicator to determine the zero
offset. Turn the bevel gear as if seating the
bearings. Record the data from the dial
indicator to use in the formula.
• K = Plug height (1.875)
71826_060.tif
• L=H+J+K
Figure 7-59. Record Bearing Seat Data from Housing
• M=G-L
M = Shim thickness required

This calculation is used to determine the shim

amount behind the bearing cup in the main
housing. The shim(s) positions the bevel gear
for correct backlash.

71826_071.tif

Figure 7-60. Record Bearing Seat Data from Spiral Gear

Dial
Indicator
71826_061.tif

Figure 7-62. Record Bearing Seat Data from Housing

Pinion
Gear

Gear
Checking
Fixture

7pingear.tif

Figure 7-61. Check Zero Offset of Spiral Gear

71826_072.tif

Figure 7-63. Record Bearing Seat Data from Bevel Gear

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Spiral Gear
Bearing Cup

Dial
Indicator

71018_014.tif

Crown Figure 7-66. Drive In Bearing Cup

Gear
3. Place the bevel gear shim in the housing,
7crngear.tif
followed by the bearing cup. Use a press or
Figure 7-64. Check Zero Offset of Bevel Gear mallet to press the bearing cup into the
housing bore. See Figure 7-67.
Housing Bearing Cup and Shim NOTE: Make sure to wipe away any chips or
Assembly excess metal pieces resulting from
driving the race to seat it.
1. Place the spiral gear shims in the housing,
then place the bearing cup in the housing.
See Figure 7-65.

71826_080.tif

Figure 7-67. Bevel Gear Bearing Cup Installation

71826_076.tif
4. Place the drive axle bearing cup in the
Figure 7-65. Spiral Gear Bearing Cup Installation
housing. Use a mallet or press to seat the
axle bearing cup in the housing. See
2. Install the bearing cup into the housing
Figure 7-68.
bore. See Figure 7-66.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

71826_084.tif 71826_087.tif

Figure 7-68. Axle Bearing Cup Installation Figure 7-70. Preheat Bearing Cone

5. Turn the drive unit housing over. Install NOTE: Steps 2 through 5 need to be completed
the helical bearing cup in the housing. Use before the bearing cools to provide a
a press or mallet to seat the bearing cup in correct installation.
the housing. See Figure 7-69.
2. Install the heated bearing cone in the
bearing cup in the housing.
3. Place the spacer over the bearing cone,
then place the helical gear into the
housing.

71826_085.tif

Figure 7-69. Helical Bearing Cup Installation

Helical Gear/Spiral Pinion Gear

Assembly
71826_089.tif

NOTE: The pinion shaft and bevel gear are a Figure 7-71. Install Helical Gear
matched set. Their alignment is critical.
Do not replace them separately. 4. Install the spiral pinion gear shaft up
through the helical gear. Push up until the
spiral gear bearing is seated against its
race. See Figure 7-72.

The bearing can become extremely hot.

Use gloves to protect hands from burns.

1. Preheat the bearing cone with a bearing

heater. See Figure 7-70.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

71826_091.tif 71018_028.tif

Figure 7-72. Spiral Pinion Gear Installation Figure 7-74. Removing End Play

5. Apply three vertical lines of thread-locking 7. Tighten the clamp nut the distance of a
compound (P/N 990-669) to the pinion spanner nut space to preload the gears.
shaft. Place the clamp nut on the end of 8. Back the nut off, then hand tighten it.
the spiral pinion gear shaft and hand
tighten until the bearing cools. See 9. Apply thread-locking compound
Figure 7-73. (P/N 1013829) to the bolt in the clamp
nut. Torque the clamp bolt to 128 in. lbs.
(14.5 Nm). Make sure the open end of the
clamp nut does not touch. See
Figure 7-75.

71018_027.tif

Figure 7-73. Install Clamp Nut

6. When the bearing has cooled, spin the

helical gear to check for end play. Remove 71826_094.tif

any end play in the bearings between the Figure 7-75. Applying Locking Compound to Screw
helical gear and the spiral gear using a nut
driver tool (P/N 761-870/T04) and a 10. Spin the helical gear to make sure there is
wedge. Slowly tighten the clamp nut on no end play or that the bearings are not
the end of the spiral gear until there is no too tight.
end play between the gears. Use a spin
and tighten method to tighten clamp nut Axle Assembly
as the bearings are seating in the races.
1. Lubricate the oil seal. Place the seal over
See Figure 7-74.
the axle shaft with the spring side toward
the oil.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

71826_096.tif 71826_100.tif

Figure 7-76. Axle Seal Installation Figure 7-78. Apply Gasket Compound to Sealing Surface

2. Place the axle bearing cone over the axle 4. Place the bevel gear into the housing. See
shaft. Press the bearing cone on the axle Figure 7-79.
shaft until it is seated. See Figure 7-77.

Always watch for pinch points when

using a press or pressing tools.

71826_101.tif

Figure 7-79. Bevel Gear Installation

5. Place a seal pressing ring

(P/N 828-004-901) beneath the axle seal.
Install the axle shaft through the bevel
gear. See Figure 7-80.
71826_097.tif

Figure 7-77. Axle Bearing Cone Installation

3. Apply a thin layer of gasket compound to

the housing to seal the axle seal. See Seal Pressing Ring
Figure 7-78.

71826_102.tif

Figure 7-80. Axle Seal Pressing Ring

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

6. Press the axle into the housing until the 12. Loosen the clamp nut, then retighten it to
seal is fully installed. See Figure 7-81. 5 ft. lbs. (7 Nm) using the rotate tightening
process until the clamp nut does not turn
any further.
13. Apply thread-locking compound
(P/N 1013829) to the bolt in the clamp nut.
See Figure 7-83. Torque the bolt to 128 in.
lbs. (14.5 Nm). Make sure the open end of
the clamp nut does not touch.

71826_103.tif

Figure 7-81. Press Axle into Housing

Always watch for pinch points when

using a press or pressing tools.
71826_107.tif

7. Remove the seal pressing ring. Figure 7-83. Applying Locking Compound to Clamp
Screw
8. Apply three vertical lines of thread-locking
compound (P/N 990-669) to the threads of
the axle.
Measuring Backlash
9. Install the clamp nut shoulder side down. NOTE: Backlash tolerance is critical to the
Hold the axle to keep it from turning as performance of the drive unit.
the clamp nut is tightened. Incorrectly adjusted units will
experience premature failure.
10. Use clamp nut tool (P/N 761-870/T07)
and torque the clamp nut to 18 ft. lbs. 1. Place a gear-locking tool on the helical
(24 Nm). See Figure 7-82. gear and secure. See Figure 7-84.

Crown
Gear Gear
Fixture

71826_106.tif

Figure 7-82. Tighten Clamp Nut to Seat Bearings

7gearfixt.tif

11. Rotate the axle and tighten the clamp nut. Figure 7-84. Gear Locking Tool
Repeat this step six times to make sure the
bearing cones are seated into the cups.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

2. Position the probe of the dial indicator at 5. Repeat steps 1 through 3 of this procedure
the heel of the bevel gear tooth. Position until the backlash is between 0.004 and
the dial indicator probe perpendicular to 0.006 in.
the gear tooth surface. 6. Install the pivot ring when backlash is
within the acceptable range.

Crown Pivot Ring Assembly

Gear
1. Place a light coating of thread-locking
compound (P/N 990-544) in the hole on
the pivot ring assembly.
2. Line up the grease fitting hole with the
Dial grease fitting port. See Figure 7-87.
Indicator

7dial.tif

Figure 7-85. Dial Indicator Position

3. Zero the indicator. Clasp the bottom of the

gear and rotate it. Read the backlash
measurement on the dial indicator. Total
backlash tolerance is between 0.004
and 0.006 in.
71826_111.tif

Gear Figure 7-87. Spherical Bearing Alignment

Locking
Fixture 3. Install the spherical bearing using a mallet
or press. See Figure 7-88.
Crown
Gear

Dial Transmission
Indicator Housing
7backlsh.tif

Figure 7-86. Measure Backlash

71826_112.tif
4. If the tolerance is not within the
Figure 7-88. Install Spherical Bearing
acceptable limits, calculate any necessary
adjustments to the shims. Remove the 4. Install the grease fitting in the pivot ring
clamp nut, axle assembly, and bevel gear. assembly using a grease fitting driver and a
Install the correct amount of shims, and mallet or press. See Figure 7-89.
repeat steps 3 and 4 of “Housing Bearing
Cup and Shim Assembly” procedure on
page 7-42.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Radial Rings

71826_113.tif 71018_036.tif

Figure 7-89. Grease Fitting Installation Figure 7-91. Radial Ring Installation

5. On the inside of the pivot ring, make sure 8. Install the brass bushing using a mallet or
the roll pins are installed and in good press. See Figure 7-92.
condition on either side of the bearing filler
plug hole. If they are missing or damaged,
install new roll pins. See Figure 7-90.

Pivot Ring

Roll Pin

71826_125.tif

Figure 7-92. Brass Bushing Installation

71018_035.tif

Figure 7-90. Roll Pin Installation

6. Clean the surface of the radial ring grove.

7. Install the radial rings so that the gap
aligns with the bearing hole. Install the flat
radial ring on the inside flat surface of the
pivot ring. Then install the chamfered radial
rings to the pivot ring. The chamfered edges
will face the steel balls. The ends of the
radial ring are against the roll pins. See
Figure 7-91.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit Assembly

Drive Unit Assembly

\

1. Install the radial rings on the housing.

Stagger the ends of the rings around the
housing so the gaps are off-set at 3, 6, and
9 o’clock. The beveled edges will face the
steel balls. See Figure 7-93.

71018_038.tif

Figure 7-95. Ball Bearing Installation

4. Place the bearing filler plug in the filler

hole. The grease fitting should face the
spur gear.

71826_116.tif

Figure 7-93. Radial Ring Installation on Housing

2. Install the pivot ring assembly to the

housing. The spherical bearing should face
the spur gear. See Figure 7-93.

71826_119.tif

Figure 7-96. Bearing Filler Plug Installation

5. Install the filler plug bolts and flat washers

on each side of the grease fitting. Tighten
to 17 ft. lbs. (23 Nm). See Figure 7-97.

71826_117.tif

Figure 7-94. Pivot Ring Installation

3. Place one steel ball at a time into the pivot

ring filler hole. Use a screwdriver to direct
the steel balls first to one side then the
other. See Figure 7-95.
NOTE: Count the steel balls as they are
inserted in the pivot ring assembly for
correct pivot ring operation. The 71826_121.tif

standard drive unit requires 67 balls. Figure 7-97. Filler Plug Bolt Installation
Too many balls will cause binding and
too few balls will cause excessive 6. Grease and then test the pivot ring. Check
motion. to see that it spins freely.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Drive Unit Assembly

Housing Cover Installation

1. Clean old sealant from the gear housing
and cover plate. Remove any paint from
the sealing surface of the inside face of the
plate.
2. Clean the sealing surfaces of the gear
housing and cover plate with an alcohol
based cleaner.
3. Apply liberal amounts of silicone sealing
compound (P/N 990-659) in a continuous
bead around the perimeter on the surface
71826_124.tif
of the gear housing. Go completely around
Figure 7-99. Tighten Cover Bolts
the bolt holes. Start the bead on a flat
surface between holes. Make sure there is 6. Apply thread-locking compound
a 0.5 in. overlap when completing the (P/N 990-626) to the drain plug.
bead. The bead width should be 0.12 in.
minimum and 0.25 in. maximum. 7. Install the drain plug in the cover plate and
See Figure 7-98. tighten.
4. Install the cover plate with the unpainted 8. Fill the gear housing with oil.
surface contacting the RTV.

71826_123.tif

Figure 7-98. Apply Gasket Compound

5. Install six screws and torque in a star

pattern and repeat. Refer to Component
Specific Service/Torque Chart on
page A-4. See Figure 7-99.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit Assembly

Drive Unit - Heavy Duty Drive Unit Removal

1. Turn the key switch OFF and disconnect
the battery connector.
Pivot Ring Inspection
2. Remove the bumper gate. See
The fit of pivot ring bearings in the drive unit is Figure 7-100.
such that some play is expected, however, as
the radial rings wear, the play may increase. If
the play is permitted to become extreme, it will
become quite noticeable in the drive unit.
If worn rings are suspected as the cause of
excessive play in the drive unit, inspect the
drive housing to determine if the bearing radial
rings must be replaced:
1. Jack the tractor of the lift truck up just
enough to permit the drive tire to clear the
floor.

Bumper Gate

7
Figure 7-100. Removing Drive Unit
Use extreme care when the lift truck is
jacked up. Never block the lift truck
3. If the lift truck is wire guided, remove the
between the telescopic and the floor.
sensor mounted on the back side of the
Attach an appropriately rated rigging
bumper gate.
device to the top of the mast, and an
overhead hoist to stabilize the mast if 4. If the drive tire is to be removed, loosen the
jacking higher than described in the lug nuts.
Jacking Safety section. Keep hands and 5. Remove the proximity sensor and
feet clear while jacking the lift truck. associated hardware on the drive unit
After the lift truck is jacked, place solid casting.
blocks or jack stands beneath it to
6. Remove the traction motor. See Traction
support it. Lower the lift truck onto the
Motor on page 7-30.
blocks or jack stands. Do not rely on the
jack or jack stand alone to support the NOTE: If the drive unit is the only item
lift truck. See Jacking on page 2-9. requiring service, separating the brake
assembly from the traction motor is not
2. Place a magnetic base dial indicator on the necessary.
deck plate and position the indicator point
on top of the drive unit top cover.
3. Adjust the dial indicator to zero then lower
the lift truck to the floor.
4. Note the new indicator reading. If the
reading is 0.089 in. (2.26 mm) or less, the
radial rings do not have to be replaced. If
the reading exceeds 0.089 in. (2.26 mm),
the rings must be replaced. If the reading
is between 0.055 and 0.089 in. (1.4 and
2.26 mm), the bearing rings must be
checked during future scheduled
maintenance visits.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Drive Unit Assembly

Bearing Filler
Plug
Use extreme care when the lift truck is
jacked up. Never block the lift truck
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an
overhead hoist to stabilize the mast if
jacking higher than described in the
Jacking Safety section. Keep hands and
feet clear while jacking the lift truck. Pivot Ring
After the lift truck is jacked, place solid 71018_003.tif

blocks or jack stands beneath it to Figure 7-101. Grease Fitting and Filler Plug Removal
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the 2. Turn the pivot ring to remove the steel balls
jack or jack stand alone to support the through the bearing filler plug hole. See
lift truck. See Jacking on page 2-9. Figure 7-102.

7. Jack and block the tractor so the drive tire NOTE: If the pivot ring will not spin or even
is off the floor. turn, it is an indication of damaged
radial rings and/or excessive wear to the
8. Drain the oil from the drive unit. channel in housing. If this is the case,
9. Unbolt the lift/lower manifold from the replace the entire drive unit. No further
drive unit casting. disassembly is necessary.
10. Remove the steering motor/gear reducer
assembly.
11. Remove the cap screws holding the drive
unit assembly to the tractor frame.
12. Lift the drive unit out of the tractor frame
using a suitable lifting device.
13. Clean the outside of the drive unit
thoroughly and drain any remaining oil
from the drive unit by removing the drain
plug.
14. Visually inspect the outside of the housing
for damage, wear, or cracks. 71018_002.tif

Figure 7-102. Remove Steel Ball Bearings

Pivot Ring Disassembly
3. After removing all the steel balls, remove
1. On the pivot ring, remove the grease fitting the pivot ring by working it off toward drive
and the bearing filler plug. Inspect the end of the housing. See Figure 7-102.
bearing filler plug hole for uneven wear.
See Figure 7-101.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit Assembly

Main Cover and Output Shaft

Disassembly
1. Visually inspect the housing around the
main cover for wear outside the cover
bolts.
NOTE: Excessive housing wear outside the
cover bolts can make them difficult to
remove. If this occurs, replace the entire
drive unit. No further disassembly is
necessary.

71018_004.tif
2. Remove the main cover bolts.
Figure 7-103. Pivot Ring Removal 3. Using a mallet, knock the flanged output
shaft to break the seal on the main cover.
4. Remove the radial rings from the channel in 4. Remove the main cover and output shaft
the housing and inside the pivot ring. See assembly. See Figure 7-105.
Figure 7-104.

Radial Rings

Main Cover

71018_005.tif

71018_001.tif
Figure 7-105. Cover and Output Shaft Removal
Figure 7-104. Radial Ring Removal
NOTE: A press and 8 x 6 in. tube are required
5. Remove the roll pins and grease fittings
to remove the bearing cup on the end of
from the pivot ring to enable thorough
the output shaft.
cleaning.

Always watch for pinch points when

Due to normal or excessive wear, the
using a press or pressing tools.
edges of the radial rings could be very
sharp.
Safety glasses are required after this
point in disassembly.
6. Clean the grease from the radial ring
channel in the housing. Inspect the
5. Place the main cover assembly, gear side
channel for uneven wear. Clean and
down, on the tube under press. Press the
inspect the inside of the pivot ring.
output shaft down slightly to create a
space between the bevel gear and the
output bearing spacer. See Figure 7-106.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Drive Unit Assembly

7. Place the main cover assembly, gear side

up, on a 12 x 6 in. tube so the bearing
puller clamp is resting on the tube. Press
Output Shaft out the flanged output shaft and the
output bearing spacer.
8. Remove the exterior retaining ring.
9. To remove the bevel gear, support the
main cover assembly on an 8 x 6 in. tube
under press. Press the output shaft down
through the bevel gear. The bearing cone is
Bevel Gear
removed at the same time. See
Figure 7-108.
71018_010.tif

Figure 7-106. Press Down Output Shaft

6. Tighten a bearing puller clamp under the

lip of the output bearing spacer, being
careful not to catch the exterior retaining
ring. See Figure 7-107. Output Shaft

71018_012.tif

Figure 7-108. Bevel Gear Removal

10. Remove the bearing cup from the main

cover with a race driver and pry bars.
11. Remove the lip seal from the main cover.
See Figure 7-109.
71018_010.tif

Figure 7-107. Bearing Puller Clamp Installation

Lip Seal

71018_003.tif

Figure 7-109. Bearing Cup and Lip Seal Removal

12. Remove the output shaft bearing cone in

the base of the housing using two pry
bars. Insert the pry bars under the bottom
edge of the cone on opposite sides. Apply

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit Assembly

even pressure on both tools to lift the cone 2. Using a brass punch and hammer, drive
out. See Figure 7-110. the spiral pinion gear shaft out of the
housing. See Figure 7-112.
NOTE: You may need to remove the spiral
pinion with a press or pressing device
equivalent.

Output Bearing
Cone

71018_009.tif

Figure 7-110. Output Shaft Bearing Cone Removal

13. Remove the shims from the housing bore.

Save shims for reference only, as they are
usually damaged when removing the 71018_007.tif

bearing cone. Figure 7-112. Spiral Pinion Removal

14. Remove the cover shims. Save the shims 3. Remove the helical gear and the bearing
for reference only. cone from the housing.
4. Drive out the bearing cup. Inspect the
Spiral Pinion Disassembly bearing cup and housing bores for wear.
See Figure 7-113.
NOTE: The spiral pinion and bevel gear are a
matched set. Their alignment is critical. NOTE: The bearing cups and cones are usually
Do not replace them separately. damaged during removal. They must be
replaced as sets.
1. Loosen the set screw on the clamp nut on
the spiral pinion gear shaft. Using Tool
761-870/T03, remove the clamp nut. See
Figure 7-111.

Bearing Cup

Clamp Nut

71018_008.tif

Figure 7-113. Bearing Cup Removal

5. Thoroughly wash the housing and visually

71018_006.tif
inspect the entire housing again for
Figure 7-111. Clamp Nut Removal
excessive damage, wear, or cracks.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Drive Unit Assembly

Assembly Procedures

Safety glasses are required. Bearing Cone

Prepare the housing for assembly by running a

tap through all bolt and screw holes. Cleaning
the threads also makes sure that there is no
damage. Spiral Pinion

Spiral Pinion Assembly

71018_015.tif

1. Using a press or mallet, install the bearing Figure 7-115. Pressing Bearing onto Spiral Pinion
cup into the housing bore. See
Figure 7-114. Main Cover and Output Shaft
Assembly
1. Before installing the output shaft lip seal,
apply a thin layer of sealing adhesive
around the seal surface of the main
housing. Install the lip seal, spring side
down, in the housing. See Figure 7-116.

Bearing Cup

71018_014.tif
Lip Seal
Figure 7-114. Bearing Cup Installation

2. Install the second bearing cup into the

housing bore on the opposite side.

71018_016.tif
Always watch for pinch points when
Figure 7-116. Press Lip Seal
using a press or pressing tools.
2. Press the lip seal into the housing until it
3. Press the bearing cone onto the spiral is just below flush with the housing
pinion gear shaft until it is seated. See surface.
Figure 7-115.
3. Press the output bearing cup into the
main cover until it is seated. Place the
bearing cone into the bearing cup. See
Figure 7-117.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit Assembly

cone down over the output shaft. See

Figure 7-119.

Bearing Cone
Output Bearing Cup

71018_017.tif

Figure 7-117. Pressing Output Bearing Cup Output Shaft

71018_021.tif
4. Push down on the bearing and turn to seat
Figure 7-119. Install Main Cover and Bearing Cone
the bearing into the cup.
5. Using dial indicators, measure dimension 10. Press the bearing cone onto the output
D from the edge of the bearing cone to the shaft. See Figure 7-120.
main cover flange surface. See
Figure 7-118.

71018_020.tif

Figure 7-120. Pressing Bearing Cone

71826_127.tif

Figure 7-118. Bearing Cone to Flange Measurement 11. Place the bevel gear down over the output
shaft, teeth side up. Press the bevel gear
6. The reading on the two dial indicators down, seating the bearing cone into the
should be the same. If they are different, bearing cup. See Figure 7-121.
repeat steps 4 and 5 until the readings are
identical. Record the final reading as
dimension D on the flange surface. This is
required during final assembly.
7. Remove the bearing cone in preparation
for installing the flanged output bearing
shaft.
8. Use a light oil on the surface of the lip seal
and inside the bearing cup.
9. Place the main cover down over the output
shaft, flange side up. Place the bearing

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Drive Unit Assembly

Bevel Gear

Bearing Cone

71018_022.tif 71018_024.tif

Figure 7-121. Pressing On Bevel Gear Figure 7-123. Eliminate Backlash

12. Install the external retaining ring on the 16. Place a bearing cup onto the bearing and
output shaft. Pull up on the bevel gear to rotate the cup while applying downward
make sure the external retaining ring is pressure to seat the bearing. See
installed securely. Figure 7-123.
13. Place the output bearing spacer, with the 17. Using dial indicator(s), check that the
recessed area down, over the output shaft. bearing is correctly seated. The readings
Place the bearing cone on top of the output on the two dial indicators should be the
shaft. See Figure 7-122. same. If they are different, repeat steps 15
and 16 until the readings are identical.
See Figure 7-124.

Output Bearing Spacer

71018_023.tif

Figure 7-122. Pressing Down Bearing Cone

71826_130.tif

14. Press the bearing cone down until it is Figure 7-124. Bearing Cup to Flange Measurement
fully seated against the spacer and snap
ring. 18. Record the final readings as Dimension E.
15. Press the bearing cone into place. At the This is required during final assembly.
same time, pull the gear sideways to
eliminate any backlash in the spline area.
See Figure 7-123.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit Assembly

Helical Gear Assembly • B = Dimension B stamped on housing

(3.409/3.412)
NOTE: The pinion shaft and bevel gear are a
• C = Number etched on back of gear
matched set. Their alignment is critical.
(nominal 1.812)
Do not replace them separately.
• D = Distance from bearing to flange
surface (see Figure 7-126)
• E = Distance from bearing cup to flange
surface (see Figure 7-127)
The bearing can become extremely hot.
Use gloves to protect your hands from
burns.

1. Preheat the bearing cone with a bearing

heater. Install the heated bearing cone in
the bearing cup in the housing.
NOTE: Steps 2 through 4 need to be completed
before the bearing cools.
2. Place the helical gear into the housing.
3. Install the spiral pinion gear shaft up
through the helical gear.
71826_127.tif
4. Apply three vertical lines of thread-locking
Figure 7-126. Bearing Cone to Flange Measurement
compound (P/N 990-669) to the pinion
shaft. Put the clamp nut on the end of the
spiral pinion gear shaft and hand tighten
until the bearing cools. See Figure 7-125.

Clamp Nut

71826_130.tif

Helical Gear Figure 7-127. Bearing Cup to Flange Measurement

71018_027.tif S1 = (B - A - E + D + C)
Figure 7-125. Helical Gear and Pinion Installation
S1 = Shim amount behind bearing cup in main
5. While the bearing cone is cooling, housing to position gear for correct backlash
calculate the formula for determining the (S1).
required shim thickness.
S2 = E + S1 - B - 0.006 preload
Calculate Shim Formulas
S2 = Shim amount between cover plate face to
• A = Dimension A stamped on housing set preload of bearings for output shaft (S2).
(2.102/2.108)

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Drive Unit Assembly

Installing and Testing Shims

1. Remove any end play in the bearings Spiral Gear
between the helical gear and the spiral
gear using lock nut wrench
(P/N 761-870/T03). Wedge the helical gear
and tighten the clamp nut until there is no
end play between the gears. See
Figure 7-128.

71018_029.tif

Figure 7-129. Marking Spiral and Bevel Gears

6. Place the predetermined shims into the

housing bore for the bearing cup. Install
the bearing cup into the housing bore over
the shims. See Figure 7-130.
7. Install the cover shims. See Figure 7-130.

71018_028.tif

Figure 7-128. Removing End Play

2. Preload the helical gear for 0.000 to Bearing Cup Shims

0.002 in.
3. Remove any oil from the clamp nut. Apply
thread-locking compound (P/N 1013829)
to the bolt in the clamp nut. Tighten the
bolt to 128 in. lbs. (14.5 Nm). Make sure
the open end of the clamp nut does not
touch. Cover Shims
4. Spin the helical gear to make sure that the 71018_030.tif
bearings are not too tight. Figure 7-130. Cover Shims Installation
5. One tooth on the spiral gear is etched or
marked with an X. With a marker, mark 8. Place the main cover assembly over the
that tooth surface for the purpose of lining shims, making sure to line up the marked
up the spiral and bevel gears to check teeth on both the spiral and bevel gears.
backlash. One tooth on the matching bevel See Figure 7-131.
gear is also marked. Mark that tooth
surface also. See Figure 7-129.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit Assembly

assembly and the bearing cup, and adjust

the shims.
Spiral and
Bevel Gears Repeat steps 6 through 9 in “Installing and
Testing Shims” until backlash is between
0.004 and 0.006 in.
3. When backlash is within acceptable range,
remove the main cover assembly and the
cover shims.

Main Cover Installation

1. Clean the cover mating surface on the
71018_031.tif housing, then apply thread-locking
Figure 7-131. Lining Up Spiral and Bevel Gears compound (P/N 990-411) sparingly.
2. Install the cover shims and the main cover
9. Install four housing cover bolts, evenly
assembly. Install the main cover bolts and
spaced, and torque to 40 ft. lbs. (54 Nm).
torque to 40 ft. lbs. (54 Nm).

Measuring Backlash

Safety glasses are required.

Backlash tolerance is critical to the Pivot Ring Assembly

performance of the drive unit.
Incorrectly adjusted units will 1. On the inside of the pivot ring, make sure
experience premature failure. the roll pins are installed and in good
condition on either side of the bearing filler
1. Wedge the helical gear, then slightly turn plug hole. If they are missing or damaged,
the output shaft to determine backlash. install new roll pins. See Figure 7-133.
Backlash reading on the dial indicator
must be between 0.004 and 0.006 in. See
Figure 7-132. Pivot Ring

Roll Pin

71018_035.tif

Figure 7-133. Roll Pin Installation

71826_131.tif
2. Install the grease fitting on the outside of
Figure 7-132. Measuring Backlash the pivot ring.
3. Screw in the grease fitting in the bearing
2. Calculate any necessary adjustments to filler plug.
the shims. Remove the main cover

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Drive Unit Assembly

4. Using radial rings, install the flat radial

\

ring on the inside flat surface of the pivot

ring. Place the ends of the chamfered
radial rings against the roll pins to install
them in the pivot ring. See Figure 7-134.

71018_038.tif

Figure 7-136. Install Ball Bearings

Radial Rings 9. Fit the bearing filler plug with the grease
fitting pointing toward the steering ring
gear. See Figure 7-137.
71018_036.tif

Figure 7-134. Radial Ring Installation

5. On the housing, install the radial rings. See

Figure 7-135.

Radial Rings

71018_040.tif

Figure 7-137. Bearing Filler Plug Installation

10. Install the bolts and washers on either side

of the bearing filler plug and tighten to
71018_037.tif 17 ft. lbs. (23 Nm).
Figure 7-135. Outer Radial Ring Installation 11. Grease and then test the pivot ring,
checking to see that it spins freely.
6. Lift the drive end of the housing and slide
the pivot ring over the housing, being
careful not to jar the radial rings out of
place. Slide the pivot ring into place just
behind the steering ring gear.
7. Make sure that the pivot ring bearing filler
plug hole is on top, in preparation for
installing the steel balls.
8. Put one ball at a time into the pivot ring
filler hole. Use a screwdriver to direct the
steel balls first to one side then the other.
Continue until all 70 balls are installed.
See Figure 7-136.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit Assembly

Brake the armature disk. Brake wear is indicated

if the total gap is greater than 0.015 in.
(0.38 mm).
The brake assembly is mounted on top of the
traction motor. The brake is spring applied and NOTE: Different thickness shims and spacers
electrically released. The brake can be manually are available to maintain correct brake
released by installing the brake release bolts. gap.
See Figure 7-138. 4. Add and remove shims as necessary to
achieve the correct gap.

When brake release bolts are used,

make sure they are removed before the
lift truck is returned to service. If the
bolts are not removed, the brake will
not work correctly.

Brake Adjustment
Perform the brake gap inspections on a regular
schedule.

Use extreme care when the lift truck is

jacked up. Never block the lift truck
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an
overhead hoist to stabilize the mast if
jacking higher than described in the
Jacking Safety section. Keep hands and
feet clear while jacking the lift truck.
After the lift truck is jacked, place solid
blocks or jack stands beneath it to
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the
jack or jack stand alone to support the
lift truck. See Jacking on page 2-9.

1. Jack and block the tractor so the drive tire

is off the floor.
2. With the brake de-energized (fully applied),
use a feeler gauge to measure the total
gap. See Figure 7-138.
3. Take measurements at three
equally-spaced locations around the
armature disk. The total gap must be
0.010 to 0.015 in. (0.25 to 0.38 mm). The
gap must be uniform all the way around

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Drive Unit Assembly

Assy
Compression Spring (Qty. 8) Brake Release Bolt
Screw (Qty. 3) (Qty. 2)
normally stowed on frame
Shims (can be
located above or
below the spacer)
Brake Coil Assy
Armature Total Gap
Disk

Spacer
(Qty. 3)

Brake Rotor Mounting Brake Assy Mtg

(wearable material) Plate Bolt (Qty. 3)
7
Figure 7-138. Brake Assembly Components

Brake Rotor Replacement Assembly/Installation

1. Slide the new rotor into the assembly. The
Replace the rotor if worn to a thickness of rotor is positioned between the armature
0.236 in. (6 mm) or less. disk and the brake mounting plate. See
Figures 7-139 and 7-140.
Removal/Disassembly
2. Install the one assembly screw removed to
1. Turn the key switch OFF and disconnect replace the rotor. Make sure to install any
the battery connector. spacers removed. Torque the three M6
2. Remove the covers from the tractor. screws that secure the coil to the assembly
to 9 ft. lb. (12 Nm) with the threads
3. Disconnect the electrical cable to the
lubricated.
brake assembly.
3. Carefully center the rotor within the
4. Remove the three screws that secure the assembly and remove the brake release
brake to the drive unit. bolts.
5. Remove the cable support. 4. Measure the total gap as shown below. The
6. Lift the brake unit up and off the drive total gap must be between 0.010 in.
unit. Take the assembly to a workbench. (0.25 mm) and 0.015 in. (0.38 mm). If the
You will need the brake release screws gap is not within tolerance, add or remove
located on the tractor. shims and/or spacers as necessary.
7. Insert the brake release screws into the Different thickness shims and spacers are
brake assembly. Tighten the two brake available.
release screws to release the brake
completely.
8. Remove one of the three screws that hold
the brake assembly together. Use care not
to lose any shims that may be used.
9. Slide the rotor out of the assembly.

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Drive Unit Assembly

If the total gap exceeds 0.015 in.

(0.38 mm), brake release problems will
result particularly when the brake is hot
and/or the battery is low.

Shims (can be located above Brake Release Bolt (Qty. 2)

or below the spacer) normally stowed on tractor frame

Total Gap

Spacers Armature Disk Mounting Plate Brake Rotor

7
Figure 7-139. Installing Brake Rotor

Brake Coil Assy Rotor Hub Nut

(Normal coil resistance at room torque to 75 ft. lb. (105 Nm)

temp is approx 13.5 ohms)

Rotor Hub
(part of brake assy)
Assy Screw
torque to 9 ft. lb. (12.6 Nm) Brake Release Screws
(normally stowed on tractor frame)

Mounting Screw
torque to 12 ft. lb.
(16.8 Nm)

Traction Motor

7
Figure 7-140. Brake Assembly - Section View

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Drive Unit Assembly

5. After the correct gap is achieved, torque

the assembly screws as specified in step 2.
6. Inspect the splines on the rotor hub (on
the traction motor). If the splines on the If the brake does not work while
rotor hub have excessive wear, replace the performing the next step, the lift truck
hub before proceeding. Using a rotor hub will not stop but will coast for
with worn splines may cause rotor damage approximately 30 ft. (9 m).
when the lift truck is driven.
13. Test the brake. In an open area allowing
7. Carefully install the brake assembly on the
for travel over a long distance, perform the
traction motor. It is critical that the splines
following:
on the rotor are not damaged during
assembly. a. Drive the lift truck approximately 2-3
mph (3.2-4.8 km/h).
b. Push the EPO switch. The lift truck
should stop within approximately 2 to 4
Damaging the splines on the brake rotor
ft. (0.6 to 1.2 m).
may cause brake failure.

8. Install the cable clamp that holds the

power cables on the traction motor.
9. Secure the brake assembly to the traction Stepping off the deadman pedal does
motor. Apply thread-locking compound not test the brake.
(P/N 990-462). Torque the three mounting
screws to 12 ft. lb. (16.8 Nm). NOTE: During acceleration a slight rattle from
the brake rotor is considered normal
10. Connect the brake to the lift truck and does not affect brake durability or
electrical circuit. function.
11. If the rotor hub nut was removed, apply
14. Install covers.
thread-locking compound (P/N 990-462)
to the threads on the rotor hub nut. Install
the rotor hub nut on the rotor hub. Torque
to 25 ft. lb. (35 Nm).

Make sure the brake release bolts are

removed before placing the lift truck
back into service. If the brake release
bolts are not removed, the brake will
not work correctly.

12. Reconnect the battery connector and turn

the key switch ON.

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Drive Unit Assembly

Drive Wheel Drive Tire Replacement

Removal
Any misalignment of the tire and hub
1. Turn the steering wheel all the way to the while the tire is being pressed onto the
right so you can access the drive wheel hub can damage the hub. For this
mounting bolts. reason, chamfers are provided on the
2. Turn the key switch OFF and disconnect outside edge of the hub and on the end
the battery connector. of the inside diameter of the tire’s metal
insert. The chamfers help to center the
hub and tire during the pressing
operations and reduce the possibility of
misalignment. To prevent damage, the
Use extreme care when the lift truck is
hub must be installed on the circular
jacked up. Never block the lift truck
ram with its chamfered side up.
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an Outside
OutsideofofHub
Huband
overhead hoist to stabilize the mast if and
Tire Tire Assembly
Assembly
jacking higher than described in the
Jacking Safety section. Keep hands and
feet clear while jacking the lift truck.
New Tire
New Tire
After the lift truck is jacked, place solid
blocks or jack stands beneath it to
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the WornTire
Worn Tire
jack or jack stand alone to support the
lift truck. See Jacking on page 2-9.

3. Jack and block lift truck under the tractor Circular

CircularRam
Ram
frame.
4. Remove the bumper plate. PressTable
Table
Press
5. Remove the drive wheel mounting bolts. 7

6. Remove the drive wheel. Figure 7-141. Drive Tire Installation

1. Check the inside surface of the metal

Installation insert on the new tire. Use sandpaper to
remove any scaling or rust. Clean the
1. Install the drive wheel on the drive wheel
inside of the metal insert and lubricate it
shaft.
with a soap solution.
2. Install the drive wheel mounting bolts.
2. Place a circular ram on the press table.
Torque to 170 ft. lbs. (230 Nm).
See Figure 7-141. The length of the ram
3. Install the bumper plate. must be longer than the width of the old
4. Remove the block and lower the tractor tire to allow complete removal of the old
with a jack. tire. The outside diameter of the ram must
be small enough to fit loosely in the insert
5. Reconnect the battery connector and turn
of tire but must be large enough to rest
the key switch ON. Test the lift truck
squarely on the flat surface on the outer
operation before returning to service.
edge of the hub.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Drive Unit Assembly

3. If the outside edge of the hub is not flush

with the edge of the metal insert in the old
tire, measure how far the hub is recessed
inside the tire. The new tire must be
placed in the same position the old tire
was installed on the hub. You can use a
spacer (slightly smaller in diameter than
the inside diameter of the tire insert and
the same thickness as the depth of the
recess) to obtain the correct amount of
recession.
4. Position the hub assembly with the old tire
on top of the circular ram so the outside of
the wheel is positioned upward. The
outside edge of the hub has a chamfer to
help guide the new tire onto the wheel. The
chamfered edge must always be the
leading edge when a tire is pressed onto
the hub.
5. Center the hub assembly on top of the ram
and make sure that they mate squarely.
6. Position the new tire with its chamfered
insert facing the hub. Align the new tire
and hub so that they are concentric.
7. Begin pressing the new tire onto the hub
and the old tire off the wheel. Run the
press slowly for the first few inches of
travel, because this is the critical stage of
the operation. If the tire begins to cock to
one side, stop the press and realign the
tire. A sharp jar with soft-headed mallet
usually realigns the tire on the hub.
NOTE: If the new tire does not press on with a
minimum of 5 tons (68,947 kPa) of
pressure, replace the hub.
8. Release the press. Remove the wheel, tire
assembly, and old tire from the press
table. Inspect the wheel and tire assembly.

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Electrical Components
Section 7. Component Procedures

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Battery Procedures

Battery Procedures touching and causing a short circuit.

Do not allow the metal cable end to
touch the battery. Use insulated tools
and avoid contact with the battery case
or cable ends.
Before working on the battery, review
1. To remove a cable from the connector,
“Battery Safety”, beginning on
push the retainer down while pulling the
Page 2-5. Batteries for this lift truck
battery cable towards the rear and out of
weigh between 1980 and 3250 lb. (898
the connector. See Figure 7-142 and
to 1475 kg). Use extreme care during
Figure 7-143.
replacement. Use a suitable battery
moving device or hoist for lifting.
Do not extend a battery more than 1/3
of its length outside the battery
compartment without being attached to
a battery-moving device.

Battery Connector/Cables
Inspection
1. Turn the key switch OFF and disconnect
the battery connector.
2. Check the battery connector for damaged
cables.
3. Check to see if the battery cables are
pulling out of the connector.
Figure 7-142. Battery Cable and Connector
4. Check the cables at the battery terminals.
Connections should be tight, with no
corrosion.
5. Look inside the connector. Check all
internal contacts for damage, dirt, or
corrosion. Do not use a metal object to
clean the connector.
NOTE: Some degreasers and parts cleaners
cause the connector shell to
disintegrate. Avoid contacting battery
connectors with solvents.

Removal, Replacement, and

Installation

The cables to either half of the connector have a

lip on their forward end. This lip snaps over a
spring-loaded retainer that is part of the Figure 7-143. Battery Cable Removal from Connector
connector.
NOTE: When replacing battery cable ends, 2. Do not attempt to repair battery cables by
remove only one end at a time from the crimping new terminals. Replace the
connector, to avoid the cable ends cable.

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Battery Connector/Cables

Battery Exterior Cleaning 6. Wash dirty batteries (or any that have had
electrolyte spilled on them) with a solution
1. Read, understand, and follow procedures, of 1 lb. (0.45 kg) of baking soda added to
recommendations, and specifications in 0.5 gal. (1.9 liters) of hot water.
the battery and battery charger
manufacturer’s manuals. 7. Use a brush with flexible bristles to clean
the entire top of the battery with the soda
solution. Wait until all foaming stops,
indicating that the battery exterior is
neutralized.
8. Rinse the battery with clean water.
9. Dry the battery completely before
reinstalling it.
10. Reinstall the battery in the lift truck, using
a suitable battery moving device.
2. Wear personal protective equipment. See Reconnect the battery connector.
“Battery Safety” on page 2-5.
3. Turn the key switch OFF and disconnect Testing, Charging, and Maintenance
the battery connector. Remove the battery
from the lift truck. For information on testing, charging, and
maintaining your lift truck battery, consult the
4. Inspect the battery cables to make sure battery manufacturer’s specifications and
they are not frayed or loose. Inspect the instruction manual.
battery connector to make sure there is no
foreign material inside the connector. NOTE: Never plug the battery charger into the
Make sure the filler plugs are tight and the lift truck. This severely damages the lift
vent holes in the filler plugs are open. truck’s electrical system. Plug the
charger only into the connector from the
battery.
Battery Cable

Filler Plug
Vent Hole
Battery State-of-Charge
Figure 7-144. Battery Cable and Filler Plug
Battery State-of-Charge (BSOC) is a feature that
5. Keep the top of the battery clean and dry. monitors and remembers the charge level of the
Corrosion, dust, and moisture provide a battery connected to the lift truck and prevents
conducting path to short-circuit cells or excessive discharging of that battery. Operating
create shorts to ground. a lift truck using a discharged battery can
NOTE: Do not clean the top of the battery with damage both the battery and the electrical
the soda solution while it is installed in components of the lift truck. See page 5-5 for a
the lift truck. Water can seep into the detailed description of how BSOC works.
electrical components and cause serious
damage.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Power Cables

Power Cables Table 7-4. Cable Jacket Strip Length - Short Barrels
AWG Lug P/N Strip Length
Check power cables for: 1/0 1002215/001-004 11/16 in. (17 mm)
• evidence of overheating 2/0 1002215/005-008 13/16 in. (21 mm)
• burned spots in the cable
3/0 1002215/009-012 1 in. (25 mm)
• nicks in the insulation
4/0 1002215/013-015 1-1/16 in. (27 mm)
• damaged or overheated terminal lugs
• damaged mounting hardware or brackets Table 7-5. Cable Jacket Strip Length - Long Barrels

Replace damaged cables or mounting hardware AWG Lug P/N Strip Length
as necessary. 1/0 1002217/001-003

Power cables are marked on the terminal lug 2/0 1002217/004-006 1-9/16 in. (40 mm)
with the location where they belong. If the
3/0 1002217/007-009
marking is missing or is not readable, remark
the cable with the correct information. 4/0 1002217/010-011 1-11/16 in. (43 mm)
NOTE: Terminal lugs may be replaced in the
field using the appropriate crimping 5. Insert the cable into the terminal.
tools. Crimping tool, lugs, and 6. Place the cable and terminal into the tool
heat-shrink are available through the die and crimp. Refer to Figures 7-145 and
Parts Distribution Center. Failure to use 7-146.
correct cables, terminal hardware, and
torque values can result in overheating
and damage to components.

Power Cable Repair

Traditional lug crimping techniques for power
cables on DC motors may not meet the higher
current requirements of AC motors. Use the
Manual Crimp Tool (P/N 1069861) when
crimping power cables for all AC motors. This
tool may also be used to repair power cables for
DC motors.
1. Remove the bad cable(s).
2. Using the removed cable(s) for reference,
cut an appropriate amount of replacement
cable of the same gauge.
Figure 7-145. Short Barrel Terminal
3. Set the adjustment screw on the manual
crimp tool head to match the cable gauge.
4. Strip the cable jacket to fit the terminal to
be crimped. Refer to Table 7-4 and
Table 7-5.

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Power Cable Repair

Figure 7-146. Long Barrel Terminals

7. Apply heat-shrink tubing (P/N 611-035) to

the terminal after crimping.
a. For short barrels, use 1.75 in. (45 mm)
of tubing. Apply 1 in. (25 mm) over the
jacket extending 0.75 in. (19 mm) over
the barrel.
b. For long barrels, use 2.5 in. (64 mm) of
tubing. Apply 1 in. (25 mm) over the
jacket extending 1.5 in. (38 mm) over
the barrel.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

General

Motors DC Motor Service

Motor Brushes
General
Inspection
Power Cable Terminals
Table 7-6. Power Cable Terminal Torques
Spring
Location/Stud Brush
Torque
Size/Type
Brush Shunts
Traction Motors Top Nut: 12.5 to 18.4 ft. lb.
(23 to 25 Nm)
Lift Motor - AC Bottom Nut: 10.7 to 11 ft. lb.
(14.5 to 15 Nm)

Top Nut: 7.5 to 9.2 ft. lb.

(10.2 to 12.4 Nm)
Lift Motor - DC
Bottom Nut: 9.2 to 11.6 ft. lb.
(12.4 to 15.8 Nm)

Top Nut: 7.5 to 9.2 ft. lb.

(10.2 to 12.5 Nm)
Steer Motor Figure 7-147. Motor Brush Location
Bottom Nut: 9.2 to 11.7 ft. lb.
(12.5 to 15.9 Nm)
Conduct a partial inspection of the motor
95 to 105 in. lb. during scheduled maintenance. If the lift truck
Power Amplifiers
(10.7 to 11.8 Nm) is operated in a severe or caustic environment
or is used in an extended duty cycle
Contactor - M6
50 in. lb. (5.6 Nm) application, inspect the motor more frequently.
steel

Contactor - M8 Set up and rigidly adhere to a strict inspection

180 in. lb. (20.3 Nm)
steel schedule to obtain the maximum efficiency
from the electrical equipment.
Contactor - M8
70 in. lb. (7.8 Nm)
brass/copper
Each partial inspection of the motor must
include:
DC Motor Troubleshooting 1. Inspect the brushes for wear and for
correct contact with the commutator.
See “DC Motors” on page 5-10. Record the level of wear on the brushes.
This history provides an indication of
AC Motor Troubleshooting whether a brush must be changed or if it
can wait until the next inspection. Refer to
Table 7-7, “Minimum Brush Length and
See “AC Motors” on page 5-14.
Spring Tension,” on page 7-76 for
acceptable brush length.
NOTE: Overloading a unit is ultimately reflected
in the motor and brush wear; therefore,
you must take this into account when
considering brush replacement.
2. Check brush spring tension. Refer to
“Motor Brush Spring Tension”.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

DC Motor Service

3. Clean brushes and holders. Wipe the 5. Blow any dust out of the motor with clean,
commutator with a dry, lint-free cloth. Do compressed air at a maximum of 30 psi
not use lubricants of any kind on or (207 kPa).
around the commutator.
4. Check brush holders for a solid connection Motor Brush Spring Tension
to the mounting support. Tighten the
mounting screws as necessary. Inspection
5. Check the cap screws that hold the brush 1. Turn the key switch OFF and disconnect
cross-connectors to the brush holder the battery connector.
body. 2. Remove the tractor covers.
6. Make sure the motor terminals are 3. Slide the brush up slightly in its holder.
secured tightly to the motor frame. Use
care not to strip the threads or crush the 4. Insert a paper strip between the brush
insulating parts. See “Power Cable face and the commutator. See
Terminals” on page 7-74. Figure 7-148.

7. Check all the cap screws around the frame

for tightness. Spring Scale
8. Keep the outside frame of the motor clean
and free from dirt. Maintain a free air
passage around the motor to permit heat
radiation.

Replacement
NOTE: If one brush needs replacement, always
replace the entire set of brushes.
Leather
Loop
Use only genuine Raymond brushes. Using
another type of brush could cause damage to
the commutator or cause excessive brush wear
and voids your warranty.

If the end of the brush is not already contoured

Paper
to fit the commutator, seat the brush to the
commutator:
NOTE: If the motor commutator is not
accessible, form the brush contour
using a brush seating stone.
Rotation
1. Move the motor brush springs out of your Pull paper in direction of rotation
way.
2. Wrap a piece of 00 sandpaper around the Figure 7-148. Motor Brush Spring Tension Inspection
commutator. Do not use emery cloth to
seat brushes. 5. Place a small leather loop around the coil
spring for the brush. If the brush spring
3. Move the brushes back down into their has a loop at the brush, hook the spring
holders. Rotate the armature until the face scale directly to the spring.
of the brushes are contoured to match the
curve of the commutator. 6. Attach a 5 lb. (2.27 kilogram) spring scale
to the leather loop.
4. Remove the sandpaper.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Polishing the Commutator

7. While gently pulling the scale outward, 4. Using minimal pressure, run the stone
slowly pull the paper strip in the direction back and forth across the commutator
that the commutator normally rotates. until it is polished. Do not pass the stone
8. When the paper strip begins to move over the ends of the commutator
freely, the spring scale will read the brush segments.
spring tension. 5. Thoroughly blow out the motor with
9. Refer to Table 7-7 for correct spring compressed air.
tension. 6. Inspect the commutator. Reinstall the
10. Repeat steps 3 through 9 for the armature or brush and any removed
remaining brushes. covers.
Table 7-7. Minimum Brush Length and Spring Tension 7. Check operation.

Min. Brush Brush Spring

Motor
Length Tension

0.62 in. 40 to 65 oz.

Lift (15.7 mm) (1134 to 1842
grams)

0.50 in.
Steer N/A
(13 mm)

Polishing the Commutator

NOTE: Wrap the stone with narrow (1/2 to 3/4
inch wide) masking tape in a spiral
configuration. Leave only enough stone
exposed to make contact with the
commutator. As the length of the stone
becomes shorter with use, peel back and
remove portions of the tape.

Make sure loose clothing and hair are

tied back. Do not wear jewelry. Wear
insulated gloves to protect your hands
during this procedure.

1. If the motor has four or more brushes,

remove an accessible brush from the
motor with the motor still installed in the
truck. If the motor only has two brushes or
the commutator is not accessible with the
stone, the armature must be installed in a
lathe or replaced. If so, go to step 4.
2. Activate the motor.
3. With the motor turning, carefully insert
the commutator stone into the brush box
area.

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Polishing the Commutator

AC Motor Service 8. Install the top end bell in the position that
was previously marked. Verify correct
stator installation and install the snap ring
AC Motor Temperature Sensor using snap ring pliers.
9. Secure the top end bell to the bottom end
Temperature sensors in the AC traction and lift bell using the four bolts previously
motors are integral to the motor. When a motor removed.
temperature sensor fails, it can be replaced 10. Install the brake mounting motor flange
using the procedures below. with new mounting bolts.
11. Re-install the brake assembly including
Traction Motor Replacement: the rotor hub mount and rotor hub.
1. Turn the key switch OFF and disconnect 12. Check the brake adjustment. See “Brake
the battery connector. Adjustment” on page 7-63.
2. Remove the brake assembly including the 13. Install the terminal board, reconnect
rotor hub nut and rotor hub. Note the JPTA3, and power cables. Torque the
number of spacers used. motor cable securing nuts to 18 ft. lb. (24
• Disconnect the temperature sensor Nm).
connector JPTA3. 14. Reconnect the battery connector and turn
• Disconnect the power cables making the key switch ON.
sure that you note locations for
reassembly later. Lift Motor Replacement:
• Remove the terminal board. 1. Turn the key switch OFF and disconnect
the battery connector.

Use correct electrostatic discharge

precautions. See “Static Precautions” on Use correct electrostatic discharge
page 2-8. precautions. See “Static Precautions” on
page 2-8.
3. Mark the position of the top end bell and
bottom end bell relative to the stator, then 2. Disconnect the temperature sensor
remove the snap ring using snap ring connector JPLA3.
pliers.
3. Disconnect the cables and motor harness
4. Remove the brake mounting motor flange. connections, making sure that you note
NOTE: Use new flange mounting bolts when locations for reassembly later.
reassembling. 4. Separate the pump assembly from the lift
5. Remove the four bolts that secure the top pump motor and remove the lift pump
end bell to the bottom end bell. motor. See “Lift Pump” and “Lift Motor” on
page 7-7.
6. Remove the top end bell using a puller.
Use care that the encoder bearing remains 5. Remove the four bolts that secure the top
in the bottom end bell to reduce the end bell to the bottom end bell.
chance of damaging the bearing. 6. Remove the top end bell. Use care that the
7. Install a new temperature sensor using bearing remains in the bottom end bell to
high temperature silicone (neutral curing). reduce the chance of damaging the
Mount the sensor close to the location of bearing.
the original. Secure the cable with a cable
tie to one of the power leads for stress
relief.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Polishing the Commutator

7. Install a new temperature sensor using the 5. Remove the nut that secures the pinion
high temperature silicone (neutral curing) gear. Remove the gear and key using a
supplied with the temperature sensor. suitable puller.
Mount the sensor close to the location of 6. Mark the position of the top end bell and
the original. Secure the cable to one of the bottom end bell relative to the stator, then
power leads with a cable tie. remove the snap ring using snap ring
8. Carefully press the top end bell to the pliers.
stator. Do not pinch the cables or allow 7. Remove the brake mounting motor flange.
contact with the rotor. Verify correct stator
installation. NOTE: Use new flange mounting bolts when
reassembling.
9. Secure the top end bell to the bottom end
bell using the four bolts previously 8. Remove the four bolts that secure the top
removed. end bell to the bottom end bell.
10. Reinstall the lift motor to the lift pump 9. Remove the top end bell and bottom end
assembly. bell using a puller.
11. Reconnect JPLA3, and power cables. 10. Remove the clamps that secure the
12. Reconnect the battery connector and turn encoder bearing cable.
the key switch ON. 11. Remove the encoder bearing from the rotor
using a suitable puller, pulling on the
outer race only.
AC Motor Bearing Encoder
12. Remove the oil seal to allow pressing of the
bottom end bell to the stator for later
Traction Motor Replacement:
reassembly.
1. Turn the key switch OFF and disconnect 13. Make sure that the O-ring and wave
the battery connector. washer are correctly positioned in the
2. Remove the brake assembly including the bottom bell bearing pocket.
rotor hub nut and rotor hub. Note the 14. Position the new encoder bearing in the
number of spacers used. bottom end bell with the cable oriented in
• Disconnect the temperature sensor the middle of the notch in the side of the
connector JPTA3. bearing pocket.
• Disconnect the bearing encoder 15. Use an assembly bushing on the outer
connector JPTA2. race and press the bearing into place. Do
not press on the encoder part of the
• Disconnect the power cables making
bearing.
sure that you note locations for
reassembly later. 16. Re-install the encoder bearing cable
• Remove the terminal board. clamps.
17. Install the top end bell in the position that
was previously marked. Verify correct
stator installation and install the snap ring
Use correct electrostatic discharge using snap ring pliers.
precautions. See “Static Precautions” on
18. Carefully press the bottom end bell to the
page 2-8.
stator.
3. Remove the steering position reference 19. Secure the top end bell to the bottom end
bracket. bell using the four bolts previously
removed. Re-install the oil seal.
4. Remove the traction motor. See “Traction
Motor” on page 7-30. 20. Install the key, pinion gear, and nut to the
bottom of the traction motor. Re-install the

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Polishing the Commutator

traction motor. See “Traction Motor” on 9. Carefully press the top end bell to the
page 7-30. stator. Do not pinch the cables or allow
21. Install the brake mounting motor flange contact with the rotor. Verify correct stator
with new mounting bolts. installation.

22. Re-install the brake assembly including 10. Secure the top end bell to the bottom end
the rotor hub mount and rotor hub. bell using the four bolts previously
removed.
23. Check the brake adjustment. See “Brake
Adjustment” on page 7-63. 11. Install the lift motor and reconnect the lift
pump assembly. See “Lift Pump and
24. Install the terminal board, reconnect Motor” on page 7-102.
JPTA2, JPTA3, and power cables. Torque
the motor cable securing nuts to 18 ft. lb. 12. Reconnect JPLA2, JPLA3, and the power
(24 Nm). cables.

25. Re-install the steering position reference 13. Reconnect the battery connector and turn
bracket and filler tube if previously the key switch ON.
removed.
26. Reconnect the battery connector and turn
the key switch ON.

Lift Motor Replacement:

1. Turn the key switch OFF and disconnect
the battery connector.

Use correct electrostatic discharge

precautions. See “Static Precautions” on
page 2-8.

2. Disconnect the bearing encoder sensor

connector JPLA2.
3. Disconnect connectors JPLA2, JPLA3,
cables, and motor harness connections,
making sure that you note locations for
reassembly later.
4. Separate the pump assembly from the lift
pump motor and remove the lift pump
motor. See “Lift Pump and Motor” on
page 7-102.
5. Remove the four bolts that secure the top
end bell to the bottom end bell.
6. Remove the top end bell using a suitable
puller.
7. Remove the encoder bearing from the
rotor, pulling on the outer race only.
8. Install the new encoder bearing by
applying steady pressure to the inner ring.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Removal

Power Amplifiers 2. Position the power amplifier and install the

four mounting screws.
NOTE: If the power amplifier being removed is 3. Tighten the mounting screws to 7.4 ft. lb.
to be returned to stock, a power (10 Nm).
amplifier reset must be performed. See
page 3-27.
Do not attempt to repair power cable
Removal terminal lugs without approved tools. If
a power cable has worn or damaged
lugs, either replace the cable or replace
the lugs. Refer to “Power Cable Repair”
on page 7-72. Failure to use correct
Before removing a power amplifier, cables, flanged nuts, and torque values
discharge the amplifier’s internal can result in overheating and damage to
capacitor by jumpering the + and – components.
terminals with a 100 ohm 25W resistor.
4. Reconnect the power cables to the correct
1. Turn the key switch OFF and disconnect terminals. Torque to 85 to 94 in. lb. (9.6 to
the battery connector. 10.6 Nm).
2. Disconnect JT1 from the power amplifier.
NOTE: When correctly torqued, the cable and
3. Disconnect the power cables from the terminal can rotate up to 5° in either
power amplifier. direction.
4. Remove the four mounting screws. 5. Reconnect JT1.
5. Lift the power amplifier off the mounting 6. Reconnect the battery connector and turn
plate. the key switch ON.

75077_037.TIF

Figure 7-149. Traction Power Amplifier

Installation
1. Install new thermal conductive material
(provided with new power amplifier)
between the base of the power amplifier
and the heatsink.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Horn Removal

Horn
NOTE: For replacement parts information refer
to the Parts Manual.

Horn Removal
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the tractor cover.
3. Disconnect the wires from the horn.
4. Remove the horn mounting bolt.

Horn Installation
1. Attach the horn to the floor of the tractor
frame and tighten the mounting bolt. See
“Horn” on page 7-8 for location. Make sure
the horn bracket is isolated from the lift
truck frame.
2. When replacing an old style three prong
horn with a new style two prong horn,
install 0.5 in. (12.7 mm) heat shrink
tubing over the unused spade connector.
3. Connect Horn (+) and Horn (-) wires to the
new horn.
4. Fasten the unused wire back to the
harness using a cable tie or equivalent.
5. Reconnect the battery connector and turn
the key switch ON.
6. Test the horn operation.
7. Install the tractor cover before returning
the lift truck to service.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Horn Installation

Carriage Control Card 7. Check the software in the motor

controllers. The motor controller software
Replacement should be version 12.115 or newer.
NOTE: Re-key the lift truck between loading
each motor controller.
8. Update the software versions if they are
Observe proper ESD precautions. See older than 12.115.
Static Precautions on page 2-8. 9. Cycle the key switch OFF and ON. The lift
truck goes through self-test and becomes
The CCC has lift truck specific information operational.
programmed in the microprocessor. See
NOTE: Re-key the lift truck if it does not
Figure 7-153. This information includes Model
complete self-test and sound the horn.
Number, Serial Number (S/N), Date of
The lift truck may need to be re-keyed
Manufacture, Hour Meters, and a list of enabled
multiple times.
Options. A backup copy of this information is
also stored in the VM. 10. Verify continuity between the fuse relay
card ground screw and the lift truck frame
If a blank CCC is installed, the information using a digital multimeter. Resistance
from the VM is uploaded into the CCC. A should be less than 0.5 ohm. See
Pre-programmed CCC must be ordered and Figure 7-150.
installed any time the Error Code corrective
actions tells you to or if the CCC and VM are
being replaced at the same time. Another way to
retain the correct programming for the specific
lift truck is to remove the microprocessor from
the CCC being replaced and install it in the new
CCC. See “EPROM/Microprocessor
Removal/Replacement” on page 7-84. This can
be done only if the error code being corrected
does not instruct you to install a
pre-programmed CCC. Some error codes
indicate the possible corruption of the data
stored in the microprocessor.
Figure 7-150: Fuse/Relay Card Ground Screw examples
1. Verify that the FlashWare version on your
computer is 7.8 or newer. 11. Check the ground for the CCC, from the
2. Verify that you have the most current top right mounting screw to the truck
software installed on your computer as frame. See Figure 7-151.
listed on the SAP Portal.
3. Use cable P/N 610-809/W7P to connect
the computer to the 9-pin RS-232 port on
the VM. Consult FlashWare Help for
correct configuration, if required.
4. Turn the key switch ON.
5. Establish communication with the vehicle
using FlashWare.
6. Save the lift truck FlashWare configuration
settings.

Figure 7-151. CCC Ground Screw.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Horn Installation

12. Install the new CCC following standard NOTE: The Model Number Table can be
ESD precautions. accesses by going to Service >
Software > Software Download > Truck
NOTE: If the current CCC has a jumper located
and Component Software > MODEL
in P3, transfer it from the old CCC to the
NUMBER TABLE.
new card. If your lift truck is equipped
with an auxiliary card, remove it and 17. Verify that the lift truck FlashWare
connect the cables to the new configuration settings and lift truck hours
connection points shown in are the same as what was saved in step 6.
Figure 7-153. 18. Enter the Learn menu on the lift truck
display and perform a control handle
PC3 learn.
19. Use the Configure Mode Menu to check
the existing GM software version. See
Table , “Ve r s i o n ,” on page 3-17. If the
version is older than 3.4, follow the steps
below to update the GM firmware.
a. Observe ESD precautions while
performing this procedure. See “Static
Precautions” on page 2-8 for more
Auxiliary Card information.
(not on all models)
b. Turn the key switch OFF and
Figure 7-152. Old Carriage Control Card disconnect the battery connector.
c. Unplug the connections and remove the
GM from the lift truck.
PC3 d. Remove the Filter Card and the original
GM firmware.
e. Install the new GM firmware
[P/N 073-802-083/034] and re-install
the Filter Card. See
“EPROM/Microprocessor
PC20
Removal/Replacement” on page 7-84.
PC19 f. Re-install the GM and connections.
g. Connect the battery and turn the key
switch ON.
Figure 7-153. New Carriage Control Card h. Follow the steps in “Learning Wire
Frequency: Software Versions Below
13. Make sure the upper right mounting screw 3.4” on page 3-21.
is installed and tightened. This screw 20. Update the software in the VM to version
provides a ground path through a 9.3 or newer using FlashWare.
capacitor to reduce noise.
21. Test lift truck operation.
14. Connect to FlashWare and then click
Other Device Software.
15. Verify the newest software version using
the Model Number Table in the SAP Portal
as reference.
16. Select the CCC and then load it with the
newest software version.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Horn Installation

EPROM/Microprocessor Installation
Removal/Replacement 1. Inspect the chip. Make sure there are no
bent, broken or missing pins or other
signs of physical damage. See
Removal Figure 7-155.
2. Make sure there is no corrosion on the
1. Turn the key switch OFF and disconnect
firmware chip or socket. If present, remove
the battery connector.
and insert the chip (M11) several times
using the “Removal” procedure.

Observe proper ESD precautions. See Good Bad

Static Precautions on page 2-8.

Failure to use approved EPROM

Extraction Tool (P/N 950-032) may
result in damage to the chip or socket.

2. Look at the circuit chip’s socket on the

circuit board. Of the four slots in the Damaged Pins
corners of the socket, two diagonally 71896_015.TIF

opposite slots open into the chip cavity. Figure 7-155. Chip Inspection
These holes receive the prongs of the
removal tool. 3. Notice the beveled corner and the arrow in
3. Insert the prongs of the extraction tool into the socket. Notice the beveled corner and
the holes identified in step 2. Hold the tool the dot on the beveled edge of the chip.
straight up. See Figure 7-154. 4. Apply a thin bead of Nyogel
4. Gently but firmly squeeze the jaws of the (P/N 1180917/001) on the electrical
tool together. The prongs will retract, contact surfaces of the sockets.
lifting and loosening the chip from its 5. Position the chip so the dot is aligned with
socket. Do not rock or pull on the chip to the arrow on the socket and the beveled
release it. corner is aligned with the beveled corner of
the socket.
6. Gently press the chip into the socket with
your thumb. Make sure it is completely
seated on all four edges. See Figures 7-156
and 7-157.

Beveled
Corner
71896_011.TIF

Figure 7-154. Chip Removal

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Horn Installation

Not Fully Seated

71896_013.TIF

Figure 7-156. Chip Incorrectly Seated In Socket

Fully Seated

71896_014.tif

Figure 7-157. Chip Fully Seated In Socket

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Wiring and Harness Repair

Wiring and Harness When replacing wires, follow these guidelines:

• Use the appropriate tools to remove and
Repair insert terminations at each connector.
• Remove damaged terminations and
discard. Never reuse a termination from a
General Connector Repair wire.
Procedures
• Do not cut away a terminal lug and reuse
the wire strands that were crimped into
Inspection the original lug.

Whenever working on the lift truck, use care • When stripping wire, use new wire strands
around wiring harnesses. for new terminations. Make sure to use a
new wire with extra length to allow for
• Carefully connect and disconnect all cutting and stripping of the ends to install
connections. new terminations.
• Do not pry connectors apart with • Use a new wire that is the same gauge
unspecified tools. (typically gauge 18 AWG), size, type, and
color as the wire it is replacing.
There should be a wire marker at each
termination. If the marker is missing or • Use a hand stripper capable of stripping
unreadable, remark the wire to allow easier by wire gauge number. Use care not to
identification. nick or cut any of the wire strands.
Discard and replace a wire with damaged
NOTE: It is normal to find unused connectors strands. Insert the wire strands the
for uninstalled options that have had correct length into termination before
heat shrink applied over them and have crimping.
been strapped to the harness.
Soldering Procedures
Repair
To prevent damage from excessive heat when
soldering small components in assemblies,
follow these guidelines:
Use correct electrostatic discharge
• Make sure the soldering tip is clean. A
precautions. See “Static Precautions” on
dirty tip does not transfer heat well and
page 2-8.
encourages long dwell time and greater
pressure. Apply light pressure on the
When pulling a wire out through a bundle, cut
terminal.
off the pin or socket so it does not snag. When
replacing wires, in some cases you can tape or • Flux: rosin base
solder one end of a new wire to one end of the • Solder: 60/40 rosin core or equivalent
failed wire. Then you can pull the old wire out of
• Solder Iron: 15-25 watt “pencil-type”
the bundle and pull the new wire into the
maximum
bundle, all at the same time. Make sure to
disconnect the old wire from the new wire. • Tip Size: 3 mm (0.118 in.) diameter x
30 mm (1.182 in.) long screwdriver tip.
In other cases, it is easier to secure a new wire Make sure the tip is clean.
to the outside of the existing wire bundle with • After soldering, clean the terminals with a
cable ties of an appropriate size. The failed wire brush dampened with an alcohol based
can be left in the bundle, or can be pulled by cleaner. Do not allow any cleaner to seep
one end to remove it from the bundle. into the switches or potentiometers, or
contact contamination may occur.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Molex Connectors

Molex Connectors Pin Extraction

Molex connectors have pins with locking ears To remove a pin from a Molex connector, use
that engage ridges in the plastic connector the pin extraction tool (P/N 950-026). See
body. See Figure 7-158. Figure 7-159.
1. Insert the extraction tool over the pin and
Pin
push all the way into the connector. This
releases the locking ears on the pin.
2. Pull the wire and pin from the connector.
Socket
Pin Insertion
1. To insert a pin into a Molex connector,
insert the pin into the back side of the
connector and push the wire all the way in
until it clicks.
Locking Ears
2. The locking ears have now engaged the
Figure 7-158. Molex Connectors - End View connector.

To remove a pin from a Molex connector, these

locking ears must be pressed far enough to
clear the ridge in the connector.

Tool Inserted Over Pin

Top View

Locking Ears

Extraction Tool

Side View

Figure 7-159. Pin Extraction Tool

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

AMP Water-Resistant Connectors

AMP Water-Resistant
Connectors
AMP connectors provide water-resistant
connection by the use of seals between wires
and connectors and between the mating
connector halves. See Figure 7-160.

Wire Seal

Interface
Seal

Contact
Cavity
Wire Seal Jack Housing

Pin Contact

Pin Housing

Sealing Plug

Figure 7-160. AMP Water-Resistant Connector

Extraction Tool
To maintain the integrity of water-resistant
seals, use the following procedures when
working with AMP connectors.

Pin Extraction

To aid in separating AMP connectors, use an

unlatching tool (P/N 950-042). To remove a pin
from an AMP connector, use a pin extraction
tool (P/N 950-009).
1. While holding the wire seal, push the
selected wire forward, then insert the Locking Lance
extraction tool into the contact socket. See Figure 7-161. AMP Pin Extraction
Figure 7-161.
2. Pull the wire gently until you feel the
contact locking lances disengage.
3. Holding the wire seal and connector
housing together, rotate the wire while
pulling it through the wire seal. This
prevents damage to the seal. See
Figure 7-162.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

AMP Water-Resistant Connectors

Rotate and Pull

Pin Contact
Figure 7-162. Removing Wire

Figure 7-164. Wire Insertion

Pin Insertion
1. Make sure the connector has a wire seal Seals
attached to the connector back. See
Figure 7-163. 1. Use a wire seal at the back (wire end) of
each connector half. See Figure 7-163.
2. Plug unused pin positions with sealing
Wire Seal plugs. See Figure 7-165.
3. Align the split tapered end of the sealing
plug with the unused opening in the wire
seal. Push the plug through the wire seal
into the connector until it snaps into
position.
Pin Housing 4. Remove sealing plugs by pulling with
needle-nose pliers while grasping the wire
Figure 7-163. Wire Seal seal and connector.

2. If re-inserting a wire previously removed,

check the pin contact locking lances to Sealing Plug
make sure they are extended to their
original position.
3. Grasp the wire close behind the contact
insulation barrel and push the wire
straight through the wire seal into the
socket until it clicks. Pull back gently to
make sure the contact is locked in place.
See Figure 7-164.

Figure 7-165. Sealing Plug

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

AMP Water-Resistant Connectors

5. Use an interface seal between pin and jack

halves of the connector. To prevent
damage to the seal, use the matching
connector cap to slide the interface seal
over the contact silos on the pin housing.
See Figure 7-166.

Interface Seal

Pin Housing

Figure 7-166. Interface Sea

6. When mating connectors, make sure

polarized silos are correctly oriented. Push
pin and jack halves of the connector
together until locking latches engage. See
Figure 7-167.

Locking
Latches

Figure 7-167. Latching AMP Connector

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

AMP Harness/Traction Power Amplifier Connector

AMP Harness/Traction Power

Amplifier Connector
Connector Components

Plug and Header Assembly

Colors are mechanically keyed to
mate only with identical colors. Header Assembly

Mating Seal

Plug Assembly

Retention Leg

Wedge Lock

Housing

Figure 7-168. Power Amp Connector Components Contact Insertion

The axial concentricity of the crimped contact

Disassembly (Contact Removal) must fall into an area defined by a 2 mm
diameter cylinder whose center is the centerline
1. Insert a 4.8 mm screwdriver blade between of the contact front end. See Figure 7-170.
the mating seal and one of the red wedge
lock tabs. See Figure 7-168.
Assembly
2. Pry the wedge lock to the open position.
3. While rotating the wire back and forth over Make sure the wedge lock is open.
a half turn (1/4 turn in each direction), 1. To insert a contact, push it straight into
gently pull the wire until the contact is the appropriate circuit cavity as far as it
removed. See Figure 7-169. goes. See Figure 7-170. (a) and (b).
2. Pull back on the contact wire with a force
of 1 or 2 lbs. to make sure the retention
fingers are holding the contact. See
Figure 7-170. (c).

Wedge
Lock Tab

Figure 7-169. AMP JPT1 Connector

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

AMP Harness/Traction Power Amplifier Connector

Contact Wire Seal Retention

(Partially Fingers
Inserted)

Centerline
of Circle
and contact

2 mm Diameter

Diaphragm Mating Seal Wedge Lock

(Shown in Open
Position)
(a)

(b)

(c)

Pull Back
on Wire
Retention Fingers
Holding Contact
Figure 7-170. Contact Insertion

3. After all contacts are inserted, close the

wedge lock to its locked position. Release Be very careful when putting the wedge
the locking latches by squeezing them lock in the locked position. Forcing the
inward. See Figure 7-171. wedge lock can cause damage to the
connector. Make sure the wedge lock is
aligned correctly. If resistance is felt,
slightly adjust the wedge lock until it
slides in freely.

4. Slide the wedge lock into the housing until

it is flush with the housing. See
Figure 7-172.
Squeeze Locking
Latches to Seat
Wedge Lock
(Both Sides)
Figure 7-171. Wedge Lock Latches

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

AMP Harness/Traction Power Amplifier Connector

Wedge lock
flush with
housing

Figure 7-172. Wedge Lock Flush With Housing

Testing

Do not pierce wire insulation with a sharp point

while troubleshooting.

The wedge lock has slotted openings in the

forward (mating) end. These slots accommodate
circuit test tabs that are approximately 3.3 by
0.6 mm and prevent damage to the receptacle.
For circuit testing in the field, use a flat probe
such as a pocket knife blade. Do not use a
probe with a sharp point.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

AMP Harness/Traction Power Amplifier Connector

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Hydraulic Components
Section 7. Component Procedures

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Flow Sensor Service 5. Run Test I26 - Flow Sensor Count

(Page 6-92) to make sure the pickup
Notes functions correctly.

Servicing of the hydraulic flow sensor is limited

to checking the turbine assembly inside the J22 not visible in photo
hydraulic flow sensor for cleanliness and
freedom of movement. Flow Sensor
NOTE: The flow sensor is electrically isolated
from the lift truck chassis with
insulating material and orange
non-conductive hydraulic hose. Be
careful that the connector plugs do not
cause shorts between the body of the
flow sensor and the lift truck chassis.

J21
The flow sensor must be electrically
isolated. When servicing the flow
sensor, make sure there is at least 2
megohm resistance between the body of
the flow sensor and the lift truck chassis
with JPY6 and JPY7 disconnected from
the flow sensor pickups.

Make sure the connectors are reconnected to

the correct pickup. Identify connector
placement for correct reassembly. See
Figure 7-173.
Figure 7-173. Flow Sensor

O-Ring Replacement
1. To make sure of correct alignment during
reassembly, use a pencil to mark the block
and pickup on the small black nut, the
large gold nut and the main block in a
straight line.
2. Remove the assembly by unscrewing the
large gold nut closest to the main block.
Make sure the small black nut does not
turn in relation to the large gold nut or the
calibration of the pickup is altered.
3. Remove the bad O-ring and install a new
one.
4. Install the pickup back into the main
block and tighten the large gold nut. Make
sure the marks made in step 1 are aligned.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Disassembly
Flow
Disassemble the flow sensor in a clean area to Snap Turbine Sensor
Ring
prevent contamination from entering the
turbine section of the flow sensor.
1. Remove the snap ring from the inlet port
using snap ring pliers. See Figure 7-173.

Figure 7-176. Turbine Assembly Removed

3. With the turbine assembly removed,

inspect the turbine blades for damage
and/or for debris that may have become
entangled around the turbine. If the
turbine is damaged, the entire assembly
must be replaced.
4. Wash the turbine assembly in clean
mineral spirits (or equivalent) and shake
dry.
7

Figure 7-174. Snap Ring Removal

2. Use a soft object (like the eraser end of a Do not use compressed air to dry the
pencil) to carefully push the turbine turbine. Compressed air may
assembly out of the sensor body from the over-speed the turbine, damaging the
outlet end. See Figures 7-175 and 7-176. bearing surfaces.

5. With the longer section of the turbine

assembly pointed up, compress the
turbine shaft and spin the turbine using
your fingers. The turbine should spin
freely for several seconds without
chattering. If the turbine does not spin
freely, the entire flow sensor assembly
must be replaced.

Figure 7-175. Removing Turbine Assembly

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Assembly
1. Reinstall the turbine assembly in the body
of the sensor so that one of the vanes of
the straightening section is between two
stake marks located in the turbine bore.
See Figure 7-177.

Stake Marks

Vane Positioned
Between Stake
Flow Sensor
Marks as Shown

Figure 7-177. Reinstalling Turbine Assembly in Flow Sensor

2. Use a soft object (like a pencil eraser) to

press the turbine assembly into the flow
sensor body. Reinstall the inlet snap ring
using snap ring pliers.
3. Reinstall the flow sensor in the lift truck.
4. Bleed the hydraulic system and refill the
reservoir. Check for leaks.
5. Run Learn. See Learn Hgt/Wgt on
page 3-19.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

High Pressure Relief

Valve Adjustment
1. Install a calibrated pressure gauge
(3000 psi/20,682 kPa) in the test port. See
Figure 7-178.
2. Back-out the high pressure relief.
3. Make sure that the Emergency Lower
Valve is closed.
4. Place a rated load plus 200 lb. (90.7 kg) on
the forks.
5. Start the lift system and turn the pressure
relief screw clockwise until the platform
starts to lift. Note the pressure required
when the platform starts to elevate.
Continue lifting until the third stage of the
mast starts lifting. Record the pressure
reading.
6. Lower the platform and remove the weight.
7. Chain the mast sections together and lift
or lift against the stops.
8. Adjust the pressure relief valve to a
pressure 100 to 300 psi (689.4 to
2068 kPa) greater than the values
recorded in step 5.
9. Tighten the relief valve lock nut after the
adjustment is complete.
10. Check the lift system for correct operation.

Emergency
High Pressure Lower Valve
Relief Valve

Test Port

Figure 7-178. High Pressure Relief Valve Adjustment

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Lift/Lower and Load 4. Inspect the sealing surface for

contaminants. Clean the surface as
Holding Valves necessary.
5. Lubricate O-rings with clean hydraulic
Use this procedure when it is necessary to fluid.
remove and install a lift/lower or load holding 6. Install the valve. See Figure 7-179.
valve.

When servicing hydraulic components,

keep the work area clean.
Contaminants can cause damage to the
hydraulic system.

1. Make sure the operator platform is

completely lowered.
2. Turn the key switch OFF and disconnect
the battery connector.
3. Remove the valve.

Tighten the valve cartridge 1/2 turn,

then loosen 1/4 turn. Continue this
sequence until a torque value of
120-150 in. lb. (13.6-17.0 Nm) is
achieved. (Tightening the valve in this
manner reduces the chance of
damaging the seal.)

20°-30°

30-35 in. lb.

(3.38-3.95 Nm)
(4 places)

Tighten nut holding coil to 4-5 ft. lb. (5.6-7 Nm)

7
Figure 7-179. Lift/Lower and Load Holding Valves Installation

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Bleeding Lift Cylinders

Bleed the lift cylinders after maintenance or
Bleed Screw
when operation indicates that air has entered Access Holes
the system (such as a bouncing operator
platform).

Side Lift Cylinders

NOTE: For lift trucks with an OACH of less than
95 in. (241 cm), see Figure 7-180.
1. For lift trucks with an OACH above 95 in.
(241 cm), elevate the operator platform
approx 3 in. (7.6 cm).
2. Loosen, do not remove, the bleed screw
near the top of the side cylinder just
enough to bleed the air from the cylinder.

The bleed screw should only be

loosened enough to allow the air to
escape. 7

Figure 7-180. Bleed Screw Access - Lift Trucks with OACH

of Less Than 95 in. (241 cm)
3. When only oil flows from the cylinder,
tighten the bleed screw. Repeat the
process on the other cylinder.

Center Cylinder
To bleed the center cylinder:
1. Elevate the operator platform enough to
extend the center cylinder approx 3 in.
(7.6 cm).
2. Carefully loosen (do not remove) the bleed
screw located on the left side of the center
cylinder.
3. When only oil flows from the cylinder,
tighten the bleed screw.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Lift Pump and Motor 10. Check the lift pump for leaks.

For 36V lift trucks, refer to “AC Motor Service”

Suction Hose
on page 7-77 for motor temperature sensor and
encoder bearing replacement procedures.

Removal
1. Turn the key switch OFF and disconnect
the battery connector. Motor

2. Clamp the suction hose closed. See

Figure 7-181.
3. Remove the two mounting bolts securing
the lift pump to the lift motor.
4. Carefully separate the pump from the
motor, taking care not to damage the
toothed spline. Pump
5. Remove the hydraulic fittings from the lift
pump.

Installation
1. Attach the hydraulic fittings to the pump.
2. Apply molybdenum anti-seize compound
(P/N 990-638) to the mating surfaces of
the lift motor spline and pump.
3. Apply thread-locking compound
(P/N 1013829) to the lift pump mounting
bolts.
4. Carefully mate the lift pump spline to the 7

lift motor and attach the lift pump to the Figure 7-181. Lift Pump and Motor
lift motor with the two mounting bolts.
Torque lift pump mounting bolts to 43 ft.
lb. (58 Nm) AC motors; 15 ft. lb. (20 Nm)
DC motors.
5. Unclamp the suction hose and add
hydraulic fluid to the reservoir if
necessary.
6. Reconnect the battery connector and turn
the key switch ON.
7. Adjust the high pressure relief valve. See
page 7-99.
8. Bleed the hydraulic system.
9. Test the lift function for smooth and
correct operation.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Pressure Switch
Adjustment
This procedure applies to all 24V
non-intellispeed lift trucks equipped with the
High Performance Lift (Hi-Pro) option (except
EE rated lift trucks).
NOTE: The VM only looks for the switch when
initiating lift.
1. Locate JPT18 and JPT22 at the VM.
2. Connect a meter using back probes, to
terminals JPT22-5 and JPT18-5.
3. Raise the operator platform approximately
2 ft. (610 mm) with a 1000 lb. (454 kg)
load on the forks for a model 5400 lift
truck and a 2500 lb. (1134 kg) load for a
model 5500 lift truck.
4. Adjust the screw on the back of the switch
until the switch just closes.
5. Turn the screw until the switch just
opens.
6. Adjust the screw until the switch
re-closes.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Side Lift Cylinder 7. Remove the snap ring from the bottom of
the cylinder using snap ring pliers. See
Figure 7-183.
NOTE: A mirror enables you to see the snap
ring at the bottom of each cylinder
housing in the side lift cylinder
procedures.

Washer
Remove
1. Elevate the carriage just enough to access
the tubing connected to the bottom of the
side lift cylinder but not far enough to
extend the side cylinder. Block the Snap Ring
carriage.
2. Remove the tubing from the bottom block
on the cylinder that is to be removed. Cap
both the tubing and the fitting to the side 7

lift cylinder. Figure 7-183. Bottom View of Housing (Using Mirror)

8. Remove the bolt that attaches the cylinder

housing to the main frame of the lift truck.
Side Lift Cylinder
See Figure 7-184.

Hydraulic Tubing
Connector

Cylinder
7
Retaining
Figure 7-182. Hydraulic Connection, Side Cylinder, Bottom Bolt

3. Unblock and lower the carriage to the

floor.
4. Remove the bolt in the top of the side lift
cylinder that connects it to the bracket on 7

the mast. Figure 7-184. Side Cylinder

5. Elevate the carriage until it clears the
cylinder assembly enough to allow cylinder 9. Remove the side lift cylinder from the lift
removal. truck.
6. Block the carriage.
Installation
1. Install the cylinder in the lift truck.
2. Install the bolt that attaches the cylinder
housing to the main frame of the lift truck.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

3. Install the snap ring on the bottom of the 5. Pull the piston out of the housing. Place
cylinder housing using snap ring pliers. the piston on a cushioned stand. Do not
4. Unblock and lower the carriage enough to damage the piston surface.
collapse the other outer cylinder but still 6. Push the cushion into the piston at the
have access to the fitting at the bottom of base of the piston.
the cylinder.
5. Block the carriage. Connect the tubing to
the bottom of the cylinder.
6. Unblock and lower the carriage to the The cushion is under extreme pressure.
floor. Install the bolt in the top of the side Keep pressure on the cushion when
lift cylinder that connects it to the bracket removing the items in the next step.
on the mast. Failure to do so could cause injury from
projectile parts.
7. Bleed the hydraulic system. See Bleeding
Lift Cylinders on page 7-101.
7. Remove the snap ring using snap ring
8. Lift and lower the carriage completely to pliers, and retaining ring. See
check lift function. Figure 7-186.

Cushion Service Piston

Spring
1. Remove the cylinder from the lift truck.
See Side Lift Cylinder on page 7-104.
Seal Cushion
2. Remove the snap ring using snap ring
pliers, and wiper. See Figure 7-185.

Retaining
Adapter Ring
(Brass)

Snap Ring
Seal

Wiper Figure 7-186. Cushion, Removed

Retaining 8. Release the pressure on the cushion. Pull

Ring the cushion out of the piston. See
Figure 7-186.
Snap 9. Remove the spring.
Rings

Figure 7-185. Piston Removal

3. Remove the snap ring in the cylinder

housing using snap ring pliers.
4. Pull the piston until the piston stop
pushes the retaining ring, packing, and
adapter out of the cylinder.
See Figure 7-185.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

10. Remove the seal from the cushion. 12. Install the spring. Make sure it is fully
seated in the cushion piston.
13. Install the cushion piston.
14. Install the retaining ring and snap ring
using snap ring pliers.
15. Install the cylinder in the lift truck. See
Side Lift Cylinder on page 7-104.
Cushion
1
2 Piston
3

Figure 7-187. Cushion Piston Seal Kit, Shown In Order of

Installation

Do not separate the piston from the

piston plug unless necessary. If 7

disassembly is required, use a strap Figure 7-189. Cushion Assembly

wrench only. Do not damage the piston
surface. Cleaning
NOTE: When repacking the cylinder, replace all 1. Flush the inside of the housing.
packings. See the Parts Catalog for 2. Wipe the piston with clean kerosene or a
packing kits. suitable industrial solvent.
11. Install the seal kit on the cushion piston. 3. Inspect all surfaces for galling or heavy
See Figure 7-187. scratches. Remove minor damage with a
fine emery cloth.
NOTE: Twist the fiber rings prior to installation
to help them retain their “memory.” See 4. Inspect all parts. Replace as necessary.
Figure 7-188.

Fiber
Ring

Figure 7-188. Twisting Fiber Rings

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Seal Repacking
1. Remove the cylinder. See Side Lift Cylinder Ram
on page 7-104. Housing

Adapter Service
(Brass) Service Driver
Guide

Seal

Wiper

Retaining
Ring 7

Figure 7-191. Using Cylinder Service Tools

Snap
Rings 5. Slide the brass adapter on the piston.
6. Install the piston assembly into the
7
housing.
Figure 7-190. Packing Components on Side Cylinder
7. Install the service guide. See Figure 7-191.
8. Dip the seal in oil and slide over the
piston, back first.
Do not damage the chrome plating on 9. Drive the seal into the assembly with a
the piston. service driver. See Figure 7-191.
10. Remove the service guide.
2. Remove the snap rings using snap ring
11. Install the packing backup ring.
pliers, seals, retaining ring, and brass
adapter. See Figure 7-190. 12. Install a snap ring using snap ring pliers.
3. Dip all packings in clean hydraulic fluid. 13. Install the wiper.
4. Lubricate the inside of the cylinder 14. Install a snap ring using snap ring pliers.
housing with hydraulic fluid. 15. Install the cylinder. See Side Lift Cylinder
NOTE: To prevent damage to packings at the on page 7-104.
top of the cylinder, use the following
tools:
• Service driver (P/N 401-000-050)
• Service guide (P/N 401-000-051)

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Removal

Center Lift Cylinder Service of Cylinder with

Cushions
Removal Cushion Replacement
1. Remove the carriage. See Carriage on
Refer to Figure 7-195 on page 7-110 for the
page 7-112.
following steps.
2. Remove the snap ring, using snap ring
pliers
7

Snap
Ring

Snap
Ring

Washer

7
Figure 7-193. Center Cylinder, Top View
Figure 7-192. Center Cylinder, Bottom View

1. Remove the snap ring using snap ring

3. Remove the washer from the bottom of the
pliers, for older production cylinders. See
center cylinder. See Figure 7-192.
Figure 7-193.
4. Remove and cap the hydraulic hoses. 7

5. Remove the U-shaped bracket.

6. Remove the center cylinder.

Installation
1. Install the center cylinder. Make sure the
bushing is on the mounting bolt.
2. Install the washer.
3. Install the snap ring to the bolt under the
center cylinder using snap ring pliers. See
Figure 7-192.
Figure 7-194: Threaded End Cap, Side View
4. Install the U-shaped bracket.
5. Install the carriage. See Carriage on 2. Remove threaded end cap with Raymond
page 7-112. tool (P/N 1090761/002) for current
production. See Figure 7-194.
6. Install the end cap and hydraulic hoses on
the center cylinder. 3. Remove the top bearing.
7. Reconnect the battery connector and turn NOTE: When the snap ring or end cap is
the key switch ON. removed, a spring behind the top
8. Bleed the hydraulic system. See Bleeding bearing may push the bearing out of the
Lift Cylinders on page 7-101. housing.

9. Test the lift function for smooth and 4. Remove the spring and pressure ring.
correct operation.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Removal

5. Remove the three staging screws located threaded end-cap for current production.
about 6 in. from the top of the housing. Refer to Component Specific
6. Remove the piston from the cylinder Service/Torque Chart (Page A-4).
housing.
7. Remove the cushion assembly.
8. Coat the threads of the new cushion
assembly with thread-locking compound
primer (P/N 990-666). Allow the primer to
cure a minimum of 1 minute.
9. Apply thread-locking compound
(P/N 990-575) on the internal threads of
the piston rod.
10. Start threading the cushion assembly into
the piston.
11. Apply thread-locking compound
(P/N 990-575) on the external threads of
the cushion assembly.
12. Continue installing the assembly into the
piston.
NOTE: Assemble components within 30
seconds of application as the
thread-locking compound begins to cure
immediately.
13. Allow the assembly to cure a minimum of
10 minutes.
14. Re-install the piston assembly in the
cylinder housing.
15. Re-install the three staging screws. Refer
to Component Specific Service/Torque
Chart (Page A-4).
16. Lightly oil a new seal. Install the seal in
the pressure ring. Check to make sure the
small orifice in the pressure ring is not
obstructed.
17. Install the spring.
18. Remove the bad parts from the top
bearing.
19. Lightly oil a new seal, O-ring, backup ring
and wiper. Install them into the top
bearing.
20. Install the top bearing.

21. Install the snap ring using snap ring

pliers, for older model cylinders or

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Removal

Seal Wiper
End Cap

Cushion Assembly Spring

Top End, Current Style

See View B See View A

Piston

Staging Screw
Backup Ring Top Bearing
Seal Wiper
Pressure Ring
O-Ring
Seal
Bleed Screw
Snap Ring

View B
View A
7

Figure 7-195. Center Lift Cylinder, Three-Stage with Cushions

Seal Replacement 7. Install the top bearing.

8. Install the snap ring, using snap ring
Refer to Figure 7-195 for the following steps.
pliers, for older model cylinders or
threaded end-cap for current production.
1. Remove the snap ring using snap ring
Refer to Component Specific
pliers, or threaded end-cap, depending on
Service/Torque Chart (Page A-4).
your style cylinder, and the top bearing.
NOTE: When the snap ring or end-cap is
removed, a spring behind the top
bearing may push the bearing out of the
housing.
2. Remove the spring and pressure ring.
3. Check to make sure the small orifice in the
pressure ring is not obstructed.
4. Lightly oil a new seal and install in the
pressure ring.
5. Remove the bad parts from the top
bearing.
6. Lightly oil a new seal, O-ring, backup ring,
and wiper. Install them into the top
bearing.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Mast Section
Section 7. Component Procedures

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Carriage Snap Ring Chain

Rocker
Assembly
Removal
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the operator console cover. Center
Cylinder
3. Remove the mast guard.
4. Remove the electrical over-the-mast cable
from the bottom pulley on the carriage.
See Figure 7-196.
5. Disconnect the cable tension spring from
7
the carriage. See Figure 7-196.
Figure 7-197. Center Cylinder, Top View

Cable 9. Attach a suitable hoist to the carriage and

Tension lift approximately 1 ft. (30.5 cm).
Spring 10. Remove the rocker assembly, its
associated hardware, and chain from the
center cylinder. Place the chain on the
Cable operator platform.
11. Remove the end cap from the center
cylinder.
Pulley
12. Remove the two carriage stops from the
inner telescopic.
13. Remove the 5 flat head and 12 hex head
mounting bolts from the inside of the
7

Figure 7-196. Electrical Over-the-Mast Cable battery compartment.

14. Pound in the locator pins until the
6. Disconnect JPC8 and JPC9 from the carriage can clear the telescopic. See
Carriage Manager. Cut the cable tie from Figure 7-198 and Figure 7-199.
the tractor side.
Locator
Pin
Do not place hands between the masts
before blocking the carriage.

7. Feed the cable through the carriage to the

tractor.
8. Use 90° snap ring pliers to remove the
snap ring holding the chain rocker
assembly to the center cylinder. See
Figure 7-197. Carriage
Stop
7

Figure 7-198. Inner Telescopic, Top Corner

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

4. Position the operator platform 3 ft. (1 m)

from the floor.
5. Install the rocker assembly, the snap ring
using snap ring pliers, and the chain on
Locator the center cylinder. See Figure 7-197 on
Pin page 7-112.
6. Install the end cap pulley on the center
cylinder.
7. Feed the chains for the center cylinder and
over-the-mast cable.
8. Feed the over-the-mast cable through the
back of the carriage to the Carriage
Manager. Connect to JPC8 and JPC9.
7
9. Use cable ties to secure the electric cables
Figure 7-199. Inner Telescopic, Top Corner, Stops Removed
to the operator platform.
15. Remove the operator platform. 10. Install the carriage stops at the top of the
inner telescopic. See Figure 7-198 on
page 7-112.
Installation
11. Lower the carriage. Install the cable on the
1. With a suitable hoist, lower the bottom bottom pulley of the carriage. Install the
bearings on the carriage into the channel cable retainer spring. See Figure 7-196 on
on the inner telescopic. page 7-112.
2. Make sure there are sufficient shims to NOTE: There is 5 1/2 in. (140 mm) from the top
prevent side play. See Upper Mast Bearing of the spring on the carriage to the
Replacement on page 7-117. center of the bolt in the cable clamp.
3. Make sure the two switches (S36 and S37)
12. Mate the tractor to the mast, engaging the
at the bottom of the carriage are riding on
locating pins in the tractor with the holes
their switch rail correctly. See
in the mast frame.
Figure 7-200.
13. From the battery compartment, thread 12
hex head bolts and five socket flat head
Switches
bolts through the tractor frame in the
center, left side, and right side into the
mast. See Figure 7-201 on page 7-114.

Switch
Rail

Figure 7-200. Underside of Carriage

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Flat Head
Mounting Bolts
Qty. 5

Hex Head
Mounting Bolts
Qty. 12

Figure 7-201. View of Battery Compartment

14. Torque the hex head bolts. Refer to

“Component Specific Service/Torque
Chart” on page A-4.
15. Install the console cover.
16. Install the mast guard.
17. Reconnect the battery connector and turn
the key switch ON.
18. Lift and lower the platform fully. Check the
functions of the lift system. Look for:
• Hydraulic fluid leaks
• Cables on pulleys
• Switch actuation
• Unusual bearing noise

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Mast Shimming

Mast Shimming Compare the wear pattern on the rail (where the
roller rides) to the examples shown in
Figure 7-202.
Shimming a mast makes a smooth running unit
• If the wear pattern is optimal, shimming is
that is not too tight or too loose. If you find any
adequate.
marks within the telescopics or main frame
where the rollers have been running, remove • If the wear pattern is excessive, shimming
them using a sanding disc and 80 grit paper. Do is too tight.
not attempt to remove all marks, only the • If the wear pattern varies between optimal
ridges. Shim the bearings to the tightest spot on and excessive, the telescopic weldment is
the assembly (as the rollers run up and down suspect.
the rail). Buff small areas that are slightly
higher than the rest of the web to avoid NOTE: Uneven wear can also indicate if a
shimming the major portion of the rail too loose. bearing set is too tight.
The shims used under each roller bearing come
in the following sizes: thin, medium, and thick.
Although you can use different combinations of Approx. 1 in. (25.4 mm)
wide wear pattern
shims to obtain the correct adjustment, you
should try to maintain equal shim thickness on
each side of the mast.
OPTIMAL
Mast and Bearing Inspection WEAR
PATTERN
Observe mast operation in free and main lift
Shimming is
with no load.
adequate
• When stopping a lift or lower, there should
be a slight bounce.
• If the bounce dampens out quickly, the
mast may be shimmed too tight.
Side of rail bearing rides on
Observe the mast operation at full elevated
height, just short of hitting the hard stops, with
no load.
• The telescopics should all act as one.
EXCESSIVE
• The interface between the telescopics WEAR
should be snug with no excessive relative PATTERN
motion between the telescopics when the
lift truck is moved back and forth slightly. Shimming is
If motion is excessive, the mast may be too tight
shimmed too loose. Example of good
• If a 0.010 in. feeler gauge can be inserted wear pattern on a
between the roller and beam web at the mast with several
tightest spot, they are shimmed too loose. hundred hours
Wear pattern greater than
Some telescopics can be narrower at the 1 in. (25.4 mm) wide
top or bottom, therefore shimming
clearance should be measured at the
tightest location.
Figure 7-202. Mast Bearing Wear Patterns

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Shimming Procedure

Shimming Procedure 13. If the inner race of the bearing does not
protrude past the end of the bearing stud
1. Elevate the mast to gain access to the when the bearing is fully seated, bend the
bearings. flat washer to contact the bearing to
2. Place a block between the outer telescopic prevent the bearing from walking on the
crosstie and the main frame. stud shaft.
3. Fully lower the carriage.
4. Turn the key switch OFF and disconnect
the battery connector.
NOTE: When removing the upper bearings, use
caution not to let the bearing fall down
into the mast assembly. If the bearings
are worn or damaged, replace them.
5. Remove the bolt and roller stud sleeve
securing the roller bearing to the
respective mast or telescopic.
6. Remove the bearing.
NOTE: It may be necessary to drive a wedge
between the respective telescopics to
provide clearance for removal and Figure 7-203. Inner Race
installation.
14. Install the bearing assembly into its
7. Remove the socket head cap screw and respective mast or telescopic. Make sure
washer retaining the bearing on the stud. that the flat spot of the bearing stud aligns
NOTE: Shim the main frame top bearing and with the welded stop on the mast or
the outer telescopic lower bearing set to telescopic.
a 0.000 ±0.010 in. overall interference. 15. Install the roller stud sleeve.
8. Shim the outer telescopic upper bearing 16. Apply thread-locking compound
set to 0.000 ±0.010 in. overall (P/N 1013829) to the threads of the
interference with the inner telescopic after mounting bolt and torque to 260 ft. lb.
the top main frame bearings have been (352.5 Nm).
correctly shimmed. 17. Reconnect the battery connector and turn
9. Shim the inner telescopic lower bearing set the key switch ON.
to 0.000 ±0.010 in. overall interference 18. Remove the block from between the outer
with the outer telescopic after the outer telescopic and the main frame.
telescopic lower bearings have been set.
19. Test the operation of the elevating
10. Install or remove the required amount of assembly.
shims.
11. Install the bearing on the shaft.
12. Apply thread-locking compound
(P/N 990-536) to the socket head cap
screw and fasten the screw and washer in
place.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Upper Mast Bearing Replacement

Upper Mast Bearing roller bearing. Put a strap suitable to

handle the weight of the carriage around
Replacement the uppermost crosstie. Once the
carriage is raised in place, block it in
position.
5. Turn the key switch OFF and disconnect
the battery connector.
Use extreme care when blocking the
mast for any reason. Never remove the
block when it is supporting the mast.
Do not damage the telescopic when
1. Use the hydraulic system to slightly prying with the screwdriver.
elevate the carriage to gain access to the
bearings or use an appropriately rated NOTE: For the upper mast bearings, wedge a
rigging device to pull the carriage upward screwdriver between the roller bearing
to gain access to the roller bearing. and the mast to prevent the bearing
from falling.
NOTE: Refer to “Jacking” on page 2-9 for hoist
requirements. NOTE: When removing the roller bearing, use
caution not to let the bearing fall down
2. Put a strap suitable to handle the weight into the mast assembly.
of the carriage around the uppermost
crosstie. 6. Remove the bolt securing the roller
bearing to the respective mast or
3. Block the carriage once it is raised in telescopic.
place.
NOTE: If the bearings are worn or damaged,
4. Block the carriage with a suitable support replace them.
stand before you attempt to remove the
7. Install the same number of shims that
roller bearing. See Figure 7-204.
were removed from under the bearing.
8. Make sure the roller bearing mounting
bolts are clean before you install them.
9. Apply thread-locking compound
(P/N 1013829) on the threads. Torque the
bolts per Table 7-8.
10. Reconnect the battery connector and turn
the key switch ON.
11. Lift the carriage and mast and unblock the
mast.
12. Test the operation of the telescopics.
13. Return the lift truck to service.

Table 7-8. Mast Bearing Stud Retaining Bolt Torque Values

Location *Torque

Main Frame 300 ft. lb. (406.7 Nm)

709G6S001.TIF

Figure 7-204. Blocking Carriage Outer Tele Upper 250 ft. lb. (339 Nm)

NOTE: You may also use a lift hoist to pull the *After torquing, back bolt off 1/4 to 1/2 turn.
carriage upward to gain access to the

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Upper Mast Bearing Replacement

Mast Disassembly and 13. Remove the upper roller bearing bosses
and roller bearings from the outer
Shimming telescopic.
This section describes procedures for: 14. Remove the telescopics and main frame
stops.
• Disassembling the three-stage mast
15. Slide the inner telescopic out of the top of
• Shimming main frame to outer telescopic
the outer telescopic. Attach the hoist to
• Shimming outer telescopic to inner the outer telescopic.
telescopic
16. Remove the upper roller bearing bosses
• Shimming inner telescopic to carriage and roller bearings from the main frame.
17. Slide the inner telescopic out of the top of
Mast Disassembly the main frame.
1. Remove the forks and mast guard.
2. Fully lower the carriage and make sure the
Shimming Main Frame to Outer
pressure is out of the cylinders. Telescopic
3. Turn the key switch OFF and disconnect 1. Install the mast roller bearings at the
the battery connector. Remove the battery. bottom of the outer telescopic.
4. Disconnect the over-the-mast cables and 2. Use a suitable lifting device and insert the
hoses inside the tractor compartment and outer telescopic into the main frame all the
plug the hoses. Disconnect the lift hose to way to the bottom.
the side cylinders inside the tractor 3. Using a pry bar, move the outer telescopic
compartment and plug. Disconnect all and roller bearing to one side.
other cables that run from the tractor to
the mast. 4. Use spare shim(s) as a gauge to determine
the amount required to move the roller
5. Secure the main carriage and telescopics bearings outward to make contact with the
so they cannot move. main frame.
6. Remove the tractor from the mast and 5. Remove the outer telescopic from the main
block each securely. frame.
7. Disconnect and remove the lift chains 6. Remove the roller bearings from both roller
from the center lift cylinder. Remove the bearing bosses at the bottom of the outer
over-pulley-cables and hoses. Remove the telescopic.
center cylinder end cap assembly.
7. Install half of the total shim thickness
8. With a suitable hoist, carefully lay the required to each roller bearing boss at the
mast assembly down and block securely in bottom of the outer telescopic. (Applying
place. Remove the carriage stops from the one half of the total shim thickness to each
inner telescopic. side of the telescopic maintains the center
9. Remove the main carriage by sliding it out line of the mast assembly.)
the top of the inner telescopic. Set it aside 8. Reinstall the roller bearings. Torque the
for later reassembly. bolts per Table 7-8 on page 7-117.
10. Remove the lift chains, chain pulleys, hose 9. Use a suitable lifting device and reinstall
pulleys, and cable pulleys. the outer telescopic into the main frame.
11. Disconnect and remove the lift cylinders Check for tightness while moving the outer
from the telescopics. telescopic to the bottom of the main frame.
12. Attach the hoist to the inner telescopic. Add or remove shims as necessary to
maintain a snug, but free-running, fit.
NOTE: If the outer telescopic hangs up, a pry
bar may be used to move the telescopic.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Upper Mast Bearing Replacement

10. Assemble the two top main frame roller outward to make contact with the outer
bearings and bosses without shims. telescopic.
11. Install the roller bearing assemblies, 5. Remove the inner telescopic from the outer
attach with a retaining bolt, and snug up telescopic.
to the main frame. 6. Remove the bearings from both roller
NOTE: Failure to snug the assemblies to the bosses at the bottom of the inner
main frame will result in the wrong telescopic.
amount of shims, since the studs are 7. Install half the total shim thickness
canted. required to each roller boss at the bottom
12. With the outer telescopic fully nested, use of the inner telescopic.
a pry bar and carefully move the outer 8. Reinstall the roller bearings. Torque the
telescopic to the opposite side. Using spare bolts per Table 7-8 on page 7-117.
shims between the bearing and outer 9. Use a suitable lifting device and reinstall
telescopic, determine the amount of shims the inner telescopic into the outer
required to remove side play. telescopic. Check for tightness while
13. Remove the roller bearing assemblies. moving the inner telescopic to the bottom
14. Install half of the total shim thickness to of the outer telescopic.
each roller bearing assembly. NOTE: If the inner telescopic hangs up, a pry
15. Install the roller bearing assemblies and bar may be used to move the telescopic.
attach with the mounting bolts and Do not apply excessive pressure to the
tighten. bearings with the pry bar.
16. With the outer telescopic fully nested, use 10. With the inner telescopic fully nested, use
a pry bar to check for bearing tightness. If a pry bar to check for bearing tightness. If
more shims can be inserted between the a thin shim can be inserted between the
bearing and the outer telescopic, remove bearing and the outer telescopic, remove
the roller bearing assembly and install the the inner telescopic and install the shim
shim(s). Reinstall the bearing assembly. between the bearing and the roller boss.
17. Check for correct shimming by pulling the Torque the bearing stud retaining bolt per
outer telescopic out and then pushing it in Table 7-8 on page 7-117. Leave the lifting
all the way. The outer telescopic should device connected to the outer telescopic.
not hang up while moving it in and out. 11. Assemble the two roller bearings and
Torque the bearing stud retaining bolts bosses for the top inner telescopic without
per Table 7-8 on page 7-117. shims.
18. Install the stops in the main frame. 12. Insert the bearing/boss assemblies and
attach with the retaining bolts. Draw the
Shimming Outer Telescopic to Inner bearing bosses up snug to the outer
telescopic.
Telescopic
NOTE: Failure to snug the assemblies to the
1. Install the mast roller bearings at the
main frame will result in the wrong
bottom of the inner telescopic.
amount of shims, since the studs are
2. Use a suitable lifting device and insert the canted.
inner telescopic into the outer telescopic
all the way to the bottom. 13. Use a pry bar and carefully move the inner
telescopic to the other side. Using spare
3. Use a pry bar and carefully move the inner shims between the bearing and inner
telescopic and bearings to one side. telescopic, determine the number of shims
4. Use spare shim(s) as a gauge to determine required to remove side play.
the amount required to move the bearings 14. Remove the bearing/boss assemblies.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Upper Mast Bearing Replacement

15. Install half the total shim thickness to 9. Use a suitable lifting device and reinstall
each bearing/boss assembly. the carriage into the inner telescopic.
16. Install the bearing/boss assemblies into Check for tightness while moving the
the outer telescopic/inner telescopic. carriage to the bottom of the inner
Attach with a mounting bolt and tighten. telescopic.

17. With the inner telescopic fully nested, use 10. Use a pry bar to check for bearing
a pry bar to check for bearing tightness. If tightness. If a thin shim can be inserted
more shims can be inserted between the between the bearing and the inner
bearing and the inner telescopic, remove telescopic, remove the carriage and install
the bearing/boss assembly and install the the shim between the bearing and the
shim(s). Reinstall the bearing/boss roller boss.
assembly. Torque the bearing stud NOTE: Do not apply excessive pressure to the
retaining bolt per Table 7-8 on page 7-117. bearings with the pry bar.
18. Check for correct shimming by pulling the 11. Use a suitable lifting device and reinstall
inner telescopic out and then pushing it in the carriage, checking for tightness. Make
all the way. The inner telescopic should sure the carriage can be moved in and out
not hang up while moving it in and out. by hand.
19. Install the stops at the upper crosstie. 12. When the correct fit is obtained, measure
20. Install the outer lift cylinders. the gap between the top of the platform
21. Install the chain rollers and lift chains. and the inner telescopic on both sides. If
the gap between the platform and the
22. Install the center lift cylinders inner telescopic is not within 1/16 in.
(1.59 mm) of each other, remove the
Shimming Inner Telescopic to platform.
Carriage 13. Take shims from the top roller on the side
1. Install the mast roller bearings on the that is farthest away and install them on
carriage roller bosses. the opposite side. Repeat this procedure
until 1/16 in. (1.59 mm) is obtained. If all
2. Use a suitable lifting device and insert the shims are on one side of the top rollers,
carriage into the inner telescopic all the remove shims from the bottom roller on
way to the bottom. the side that is farthest away and install
NOTE: The carriage may have to be removed them on the opposite side.
several times to obtain the correct fit. 14. Repeat this procedure until the required
3. Using a pry bar, move the bottom carriage clearance at the top of the platform is
bearings to one side. obtained.

4. Use spare shim(s) as a gauge to determine 15. Install the carriage and the carriage stops.
the amount required to move the bearings 16. Install the pulleys for the over-mast-hoses
outward to make contact with the inner and cables.
telescopic. 17. Secure the main carriage and telescopics
5. Move the carriage to the top of the inner in place so that they do not move while
telescopic and repeat the process for the standing the assembly back up.
top set of bearings. 18. Install all the other items removed during
6. Remove the carriage from the inner the disassembly process after laying the
telescopic. assembly down.
7. Install half of the total shim thickness 19. Attach the hoist to the mast assembly and
required to each roller boss. stand the mast back up. Install all the
other items removed during the
8. Reinstall the roller bearings.
disassembly process prior to laying the
assembly down.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Upper Mast Bearing Replacement

20. Attach the tractor to the mast.

21. Install the remaining components.
22. Connect the hoses and cables inside the
tractor compartment.

Make sure all mast stops are installed

and securely tightened before operating
the lift truck.

23. Reinstall the battery.

24. Reconnect the battery connector and turn
the key switch ON.
25. Adjust the main lift chain so the top of the
inner telescopic is even with the outer
telescopic +/- 0.125 in. (3.2 mm) and both
chains have equal tension.
26. Adjust the free lift chains so the top of the
fork just in front of the platform is at a
minimum of 2.75 in. (70 mm) from the
floor and the tips are at a maximum of 3.5
in. (89 mm) from the floor.
27. Install the forks and mast guard.
28. Check for correct operation.
29. Grease the channels.
30. Bleed the lift cylinders. See “Bleeding Lift
Cylinders” on page 7-101.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Lift Chains, Three-Stage

Lift Chains, Three-Stage

Side Chain
Cylinder Anchor

Use extreme care when the lift truck is Anchor

jacked up. Never block the lift truck Block
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an
overhead hoist to stabilize the mast if
jacking higher than described in the
Jacking Safety section. Keep hands and
7
feet clear while jacking the lift truck. Figure 7-205. Lower Anchor Block
After the lift truck is jacked, place solid
blocks or jack stands beneath it to
support it. Lower the lift truck onto the Side Cylinder Chains
blocks or jack stands. Do not rely on the
jack or jack stand alone to support the Replace
lift truck. See Jacking on page 2-9.
1. Inspect the lift chain for wear or broken
links. See Chain Maintenance on
Center Cylinder Chain page 4-11.
2. Lift the carriage enough to block between
Replace the carriage and inner telescopic.
1. Turn the key switch OFF and disconnect 3. Place blocking between the carriage and
the battery connector. the inner telescopic.
2. Inspect the lift chain for wear or broken 4. Turn the key switch OFF and disconnect
links. See Chain Maintenance on the battery connector.
page 4-11. 5. Disconnect the chain from chain anchors.
3. Attach a suitable hoist. Lift the carriage Feed the chain off the pulley. See
approximately 3 ft. (0.9 m) and block. Figure 7-205 and Figure 7-206 on
4. Disconnect the chain from the chain page 7-123.
anchor and feed out of the lift truck. 6. Replace the chain as necessary.
5. Replace the chain as necessary. Figure 7-207 on page 7-123

6. Feed the chain over the pulley. Connect 7. Refer to “Lift Chain” on page 7-129 for lift
the chain to the chain anchor. chain adjustment.

7. Remove the block and hoist.

8. Reconnect the battery connector and turn
the key switch ON.
9. Test the lift function for smooth and
correct operation before returning the lift
truck to service.
10. Refer to “Lift Chain” on page 7-129 for lift
chain adjustment.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Side Cylinder Chains

8. Feed the chain over the pulley. Connect

the chain to the anchors. See Figure 7-205
and Figure 7-206.

Chain
Pulley

Chain
Anchor
7

Figure 7-208. Inside Chain Anchor, View from Operator

Platform

7
9. Remove the block and hoist.
Figure 7-206. Upper Chain Anchor and Pulley 10. Reconnect the battery connector and turn
the key switch ON.
11. Test the lift function for smooth and
correct operation before returning the lift
truck to service.

Figure 7-207. Master Link of Lift Chain

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Side Cylinder Chains

Center Cylinder Ride

Spring Chain Anchors
Inspect the chain anchors and pivot rocker any
time that the chains are lubricated and
adjusted.

Inspection
1. Remove the operator compartment console
cover and tractor cover.
2. Lift the operator platform just high enough Chain Anchor
to have the chain anchor/pivot rocker
visible through the opening under the
operator control panel.
3. Place blocking under the operator
platform. Lower the platform onto the
support.
4. Turn the key switch OFF and disconnect
the battery connector. Open the
7
emergency lower valve.
Figure 7-209: Chain Anchors
The center cylinder moves down and the
chains go slack. If the center cylinder does 5. Inspect the chain anchor and pivot rocker
not go down far enough to slacken the for wear and replace if necessary.
chains, push down on the top of the 6. Close the emergency lower valve.
cylinder. This allows the chain anchor to Reconnect the battery connector and turn
be visible for inspection. See Figure 7-209. the key switch ON.
7. Lift the platform slowly to take slack out of
the chains and to clear the support from
beneath it.
8. Remove the support and lower the
platform.
9. Reinstall all covers.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Forks

Forks 6. Drive out the pivot pin. The fork, washers,

or shim will drop.
7. Replace the damaged fork.
Removal
1. Raise operator platform high enough to Installation
reach the bottom of the forks.
1. Hold the new fork in place under the
2. Block the operator platform. See Operator operator platform.
Platform on page 2-10.
2. Install the pivot pin through the fork.
3. Secure the fork to a hoist using a suitable
strap or chain. See Figure 7-210. NOTE: Always use new snap rings when
assembling components.
4. Remove the cap screw from underneath
the fork at the tractor end of the fork. 3. Install a new snap ring on the pivot pin
using snap ring pliers.
4. Install the correct amount of washers or
Socket Head Fork shims at the tractor end of the fork to
Cap Screw maintain a level fork. See Figure 7-212.

Shims

Figure 7-210. Fork Removal

5. Remove the snap ring from the pivot pin in

the fork mounting block using snap ring 7
pliers. See Figure 7-211. Figure 7-212. Installing Forks and Shims

5. Install the socket head cap screw through

the fork and shims at the tractor end of
the fork.
6. Remove blocking from the operator
platform.
7. Lower the operator platform to the floor
Snap and make sure forks are level. The top
Ring surface of the forks should be within 0.25
in. (6.3 mm) of each other (31 in. and
longer) or 0.125 in. (3.2 mm) of each other
7
(under 31 in.) at the tips. If the forks are
Figure 7-211. Snap Ring, Pivot Pin, and Mounting Block not level, add more shims to the fork.
8. Check the fork up tilt. It must be between
level and 0.5 in. (12.7 mm) maximum.

The fork will drop in step 6. It weighs

approx 150 lb. (68 kg).

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Pallet Clamp

Pallet Clamp 8. Adjust the hex nut closest to the pedal

mounting until there is a 90-degree angle
between the pallet clamp and the left-hand
pallet support. Torque the remaining hex
Tension Spring nut to 21 ft. lbs. (29 Nm).
Pallet Clamp

Pedal Weld

Pivot Bracket

Figure 7-213. Pallet Clamp Assembly, Underside

Installation
1. Install the pallet clamp assembly on the
platform front plate. Secure it with four (4)
M10 x 20 screws. Torque to 30 ft. lbs.
(41 Nm).
2. Install the pedal assembly to the platform
main support plate. Secure it with two (2)
M8 x 20 screws. Torque to 15 ft. lbs.
(20 Nm).
3. Hook the tension spring into the 1/4-inch
holes in the pivot bracket and pedal weld
in the pedal assembly. See Figure 7-213.
4. To extend the spring so you can connect
the cable assembly, slide a two inch-wide
block between the left-hand pallet support
and the pallet clamp on the pallet clamp
assembly.
5. Install the cable bracket on the pedal
assembly. Secure it with the M8 x 10
shoulder bolt and M8 hex nut. Torque to
15 ft. lbs. (20 Nm).
6. Place the cable assembly in the cable
bracket and secure with the M6 hex nuts.
Finger-tighten the hex nut closest to the
pedal mounting and leave the other nut
loose.
7. Remove the two inch block you used in
step 4.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Load Wheels

Load Wheels 6. Remove the snap ring from the axle using
snap ring pliers. See Figure 7-214.
7. Drive the axle out of the wheel and
baseleg.
8. Remove the load wheel from the baseleg.
Use extreme care when the lift truck is 9. If the lift truck is equipped with dual load
jacked up. Never block the lift truck wheels, lift the second load wheel out the
between the telescopic and the floor. top of the baseleg. See Figure 7-214.
Attach an appropriately rated rigging
10. Replace the load wheel assembly.
device to the top of the mast, and an
overhead hoist to stabilize the mast if 11. Drive the axle in through the wheel and
jacking higher than described in the baseleg.
Jacking Safety section. Keep hands and 12. Install the snap ring using snap ring
feet clear while jacking the lift truck. pliers.
After the lift truck is jacked, place solid
13. Remove the block from under the baseleg
blocks or jack stands beneath it to
and lower the truck to the floor.
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the 14. Connect the battery connector and turn
jack or jack stand alone to support the the key switch ON.
lift truck. See Jacking on page 2-9. 15. Raise the operator platform and remove
the block between the platform and the
Installation baseleg.

Snap Ring

Axle

Figure 7-214. Load Wheel

1. Raise the operator platform approximately

1 ft. (0.3 m) from the floor and place a 4 x
4 in. (100 x 100 mm) block across the top
of baselegs underneath the platform.
2. Lower the platform onto the block.
3. Turn the key switch OFF and disconnect
the battery connector.
4. Jack up and block the baseleg high
enough to remove the load wheel axle.
5. Lower the baseleg onto the block.

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Skid Pads

Skid Pads
Location
There are two skid pads on each lift truck.

Inspection
1. Check the clearance between each skid
pad and the floor.
2. If clearance is more than 3/4 inch
(19.1 mm) on either side, replace the skid
pad. See procedure below.

Use extreme care when the lift truck is

jacked up. Never block the lift truck
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an
overhead hoist to stabilize the mast if
jacking higher than described in the
Jacking Safety section. Keep hands and
feet clear while jacking the lift truck.
After the lift truck is jacked, place solid
blocks or jack stands beneath it to
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the
jack or jack stand alone to support the
lift truck. See Jacking on page 2-9..

Replacement
Weld a new skid pad inside the worn skid pad.
Clearance from the floor should be 3/4 inch
(19.1 mm). See Welding Safety on page 2-14.

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Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures

Lift Chain

Lift Chain 5. Tighten the adjusting nut until the chain

is free of any twist and that the tension is
correct.
Lift chains are important components of the lift
6. Re tighten the locking nut on the chain
truck. The chain system on the mast is
anchor.
designed for efficient, reliable transmission of
lifting force from the hydraulic cylinder to the
forks. Safe, uninterrupted use of the lift truck Lift Chain Maintenance
depends on correct care and maintenance of the
lift chain. Unsatisfactory chain performance is traced
directly to inadequate maintenance. Highly
stressed precision chains require periodic
Lift Chain Adjustment maintenance to deliver maximum service life.
1. Adjust the free lift chains so the top of the Refer to “Lift Chains” on page 4-7.
fork near the platform is at a minimum of
2.75 in. (70 mm) and the tips are at a
maximum of 3.5 in. (89 mm) from the
floor.
2. Adjust the main lift chains so the top of
the inner telescopic is even with the outer
telescopic +/- 0.125 in. (3.2 mm) and both
chains have equal tension.
3. Check that the lift chain tension is correct.
by forcing the chain sideways
approximately 1/2 to 1 inch (13 to 25.4
mm) before the lift frame raises slightly.
4. If any of the chains need to be adjusted,
loosen the locking nut on the chain
anchor, See Figure 7-215.

Locking Nut

Figure 7-215. Lift Chain Locking Nut

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Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual

Lift Chain Maintenance

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Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

Section 8. Theory of Operation

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Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

System Architecture

System Architecture
Section 8. Theory of Operation

The following table identifies the various

electronic components found on this lift truck
and their function.

Ident Component Function

Controlling manager for the lift truck. See Vehicle Manager on

VM Vehicle Manager
page 8-3.

Powers the traction motor. See Traction Power Amplifier on

TPA Traction Power Amplifier
page 8-4.

Powers the lift motor on AC lift systems. See Lift Power

LPA Lift Power Amplifier
Amplifier on page 8-4.

Distributes B+/– throughout the lift truck. Houses the B+/–

FRC Fuse/Relay Card
control fuses. See Fuse/Relay Card on page 8-5.

Interfaces with the operator and various components on the

CCC Carriage Control Card
carriage. See Carriage Control Card on page 8-3.

Interfaces with the guidance coils and VM. See Guidance

GM Guidance Manager
Manager on page 8-4.

The filter card is only used with GM card P/N 1183339. If

applicable, it is located within the GM. Filters and conditions
Filter Card
the voltage from the guidance coils. See Filter Card on
page 8-4.

Receives and conditions the output from the guide wire. See
Antenna Cards
Antenna Cards on page 8-4.

Contactor/Fuse Panel Contactors and power fuses are located on this panel.

Provides for the connection of the electrical devices required for

Auxiliary Card
the optional Auxiliary Mast. See Auxiliary Card on page 8-5.

Processes inputs used for height calculation. See intellispeed

intellispeed Module and Sensor
Module and Sensor on page 8-5.

Displays information and fault codes to the operator. Also

Operator Interface Card contains the push button entry keys. See Operator Interface
Card on page 8-4.

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Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

Systems Overview

Systems Overview control of the brake release circuitry. The VM

directly monitors and controls the steering
The orderpicker control system uses five system of the lift truck in both Auto and
“intelligent” devices working together to control Manual modes of operation, but does not
the lift truck and respond to operator current limit the steering motor. The VM
commands. These devices pass information to calculates and maintains the platform height
each other via the communications (CAN) Bus. count based on direct inputs from the
The devices are: intellispeed Flow Module. The VM reduces the
travel speed of the lift truck as necessary, based
• Vehicle Manager
on the platform height and load weight as well
• Carriage Control Card as traction motor temperature. When in the
• Traction Power Amplifier guided mode, the VM receives information
regarding the lift truck’s position relative to the
• Lift Power Amplifier (AC Lift only)
wire from the Guidance Manager (GM). During
• Guidance Manager (Wire Guidance Option guided operation, the VM receives steering
only) correction requests from the GM. It is the VM
that slows or stops the lift truck as Heading
The system utilizes up to six other Angle (HA) and Distance From Wire (DFW)
“non-intelligent” devices, depending on options. limits are reached or exceeded. The VM
The following devices may also be installed on contains a power supply that provides a
the lift truck: regulated +12V and +5V. It provides +12V to the
• Filter Card (Wire Guidance Option only - CCC. The VM calculates the Battery
located within GM P/N 1183339). Not State-of-Charge (BSOC) from the voltage
used with GM P/N 1268588/001 measured at Battery Sense In.
• Antenna Cards (Wire Guidance Option
Carriage Control Card
only)
• Operator Interface Card Although the Carriage Control Card (CCC)
• Fuse/Relay Card contains a microprocessor, a communications
chip, and a firmware chip, it has very limited
• Steering Amplifier
decision making ability and communicates only
• intellispeed Module with the VM. The CCC and the VM share
control of the brake release circuitry. The CCC
Intelligent Devices functions primarily as an Input/Output (I/O)
board for the devices connected to it, such as:
Vehicle Manager • deadman switches, sidegate switches, and
lower limit switches
The Vehicle Manager (VM) controls the
• steering tiller encoder
orderpicker control system. It communicates
with all other devices that are on the • travel and lift potentiometers
communications Bus. It receives, via the CAN
Bus, all requests for travel and lift. The VM also The CCC converts the voltages it reads from
receives information on the status of all these inputs into a message that it sends to the
carriage switches such as the deadman, VM that takes any action required. The CCC
sidegate, and height switches. It also receives also drives the display and is the only manager
traction motor speed, direction, and that can put codes on the display. The only
temperature information from the Traction code that the CCC can actually precipitate is
Power Amplifier (TPA) and lift motor speed and Code 50 (no VM communications received by
temperature information from the Lift Power the CCC). The VM commands all other codes,
Amplifier (LPA). The VM determines allowable but must go to the CCC that causes the codes
vehicle operation based on those inputs and to be placed on the display. The CCC receives
operator requests. The VM and CCC share +12V from the VM. The CCC then regulates that

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Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

Systems Overview

voltage to +5.3V for the various devices that it Guidance Manager

powers.
The Guidance Manager (GM) communicates
Traction Power Amplifier with the VM only. The learned values for wire
guidance are stored in the GM. It determines
The Traction Power Amplifier (TPA) the position of the lift truck relative to the wire
communicates only with the VM, from where it when in the guided mode. GM P/N 1183339
receives all commands regarding travel uses inputs from the Filter Card to calculate the
direction and speed. The TPA monitors both the position of the lift truck relative to the wire.
traction motor encoder and temperature sensor. GM1268588/001 no longer uses a Filter Card.
It determines, based on the encoder feedback It uses inputs from the Antenna Card to
and the travel request, if the lift truck should be calculate the position of the lift truck relative to
in travel, plugging, or regenerative braking, and the wire. It then reports the lift truck position
determines if the performance has achieved the along with a command for steering direction to
travel command from the VM. If it has not, the the VM over the CAN Bus.
TPA adjusts the motor control voltage or sends
a fault code to the VM, as appropriate. The TPA Non-intelligent Devices
is solely responsible for controlling traction
motor current. The TPA sends the traction Filter Card
motor temperature to the VM. The VM then
alters the travel request if necessary depending Filter Cards are only applicable with the older
on the traction motor temperature. The TPA GM P/N 1183339. The Filter Card, attached
monitors its internal temperature and limits both physically and electrically to the GM,
current or travel speed as required by its provides voltages from the guide wire to the
internal programming. The TPA also checks the Guidance Manager. The Filter Card contains
operation of the TPC, the charging of the circuitry that provides the GM with the
amplifiers, and various internal operating guidance voltage levels required for correct
parameters. It also sends fault codes to the VM operation of the guidance system. It is also
if anything is operating incorrectly. connected electrically to the Antenna Cards
that are located under the tractor and platform
Lift Power Amplifier of the lift truck.

The Lift Power Amplifier (LPA) is used on AC lift Antenna Cards

models only. The LPA only communicates with
the VM, from where it receives all commands The two Antenna Cards are located along the
regarding lift speed. The LPA monitors both the center line of the lift truck. The Tractor Antenna
lift motor encoder and temperature sensor. It Card is attached behind the center bumper
determines from the encoder feedback if the plate in front of the drive tire. The Load End
motor has achieved the commanded speed Antenna Card is located under the operator
request. The LPA is solely responsible for platform between the baselegs. The Antenna
controlling lift motor current. It sends the lift Cards contain circuitry that receives the signal
motor temperature to the VM. The VM then from the floor wire and passes it to the GM or
determines if the motor must be shut down due Filter Card if installed.
to motor temperature. The LPA monitors its
internal temperature and limits current or lift Operator Interface Card
speed as required by its internal programming.
The LPA also checks the operation of the LPC, The Operator Interface Card is mounted on the
the charging of the amplifiers, and various carriage and connected to the CCC. It contains
internal operating parameters. It also sends the data entry push buttons and the character
fault codes to the VM if anything is operating display that messages and codes are displayed
incorrectly. on. It is driven by the CCC from where it
receives all its inputs.

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Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

sPort

Fuse/Relay Card
Value Location

The Fuse/Relay Card is a control power Date and Time Date and time are calculated
distribution board. It contains the B+ and B– and stored in the VM. There is
control fuses and the K1 through K4 relays. It no clock chip on the CCC.
provides B+ and B– to the VM, TPC, LPC, and
Hour Meters The hour meters (Hours
CCC. Deadman, Hours Lifting, Key
Hours, and Traction Miles) are
Steer Amplifier stored in the CCC.

The Steer Amplifier is an amplifier only. It takes

a low level steering input from the VM and sPort
amplifies it to drive the steering motor. Steer
motor current is limited by the Steer Amplifier. The sPort enables the to truck communicate
The Steer Amplifier also provides a steer motor with the Simulation PC in the Raymond Virtual
current feedback voltage and a voltage called Reality Simulator. While in Simulator Mode, all
neutral pulse, which confirms amplifier truck operation is disabled but any control
operation, back to the VM. inputs an operator makes are displayed as part
of a computer-generated simulation.
intellispeed Module and Sensor

The intellispeed module amplifies the inputs

from the flow sensor and passes them on to the
VM.

Auxiliary Card

The Auxiliary Card acts as an interface between

all switches for the optional aux mast and the
Carriage Control Card.

Stored Value Locations

Value Location

Primary Memory The Primary Memory in this lift

truck is stored in the CCC.
There is a backup copy in the
VM. If the CCC is blank or has
garbled memory, the VM will
send a copy up if the cards can
communicate. If both cards are
valid, but different, then the
CCC will overwrite the VM.

Configure Mode Configure Mode settings are

Settings stored in both the CCC and the
VM.

Learn Mode Learn Mode values are stored

Values in the VM.

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Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

Traction System

Traction System Travel

When the deadman is pressed, the brake is
Deadman Pedal Pressed released. During Learn Mode, the VM learns the
neutral position for the travel (VR1) and lift
When the deadman pedal is pressed, switches (VR2) potentiometers and stores those values in
S2 (Brake Deadman) and S23 (Carriage memory. During normal use, the VM learns the
Deadman) are closed. These switches are extreme values for full forward/reverse and full
connected to the Carriage Control Card (CCC). lift/lower. These values are also stored in
The output of S2 is hard wired through the CCC memory in the VM. Refer to page 3-9 for a
and over the mast at JPC11-5 to JPT22-8 as an complete description of Learn Mode. The CCC is
input to the VM processor. The Carriage in constant communication with the VM
Deadman voltage is not used by the CCC. It is through messages that report the status of the
only used by the VM. When S2 closes, it control potentiometers and carriage switches to
switches Carriage Deadman voltage from a high the VM. When the VM receives the message, it
state (>4.5VDC) to a low state (<0.7VDC). When compares the pot position information to the
the VM processor detects a low state at S2, it values that it stored when it learned the pots.
also needs to receive information that S23 is
closed. When the control handle is moved from neutral,
the CCC detects a different voltage at JPC9-9
When S23 closes, it activates a circuit on the from VR1. The CCC updates the VR1 position
CCC that provides a high input (>4.5VDC) value in the next message sent to the VM. When
through the connect detect jumper (steering the VM receives the new position value, it
request encoder connector JPC1-8 and 9) to the compares that position value to the learned
processor on the CCC. The purpose of this value for VR1 to determine the direction and
connect detect jumper is to make sure that the magnitude of the travel request. The VM then
steering card is connected before the brake is looks at all speed limiting inputs such as motor
released. When the processor receives that temperature, height, weight, steering angle, and
voltage, it performs two operations fault codes to determine if the requested speed
simultaneously. It sends a message over the is allowable. The VM then initiates a command
communications bus telling the VM that the for the appropriate direction and speed to the
Brake Deadman is pressed. When the VM TPA over the communications Bus. The CCC is
receives that message, it acknowledges to the constantly monitoring the travel request at VR1
CCC that the message was received. The CCC and updating the VR1 position value to the VM.
also activates a circuit on the CCC that The VM therefore, constantly updates the travel
switches the output Brake Deadman (JPC11-4) command to the TPA.
from a high state (>4.5VDC) to a low state
(<0.7VDC). The output Brake Deadman is hard When the TPA receives a travel command from
wired from the CCC at JPC11-4 to the VM at the VM, it produces a control output to the
JPT22-7 through the over-the-mast cable. traction motor. All operational parameters that
affect travel motor torque and speed are
To release the brake, the VM must know that all controlled exclusively by the TPA. It monitors
deadman switches are operational and that the motor current, voltage, and RPM, and from
steering encoder is connected. When the VM them, can determine motor performance. The
receives the communication message that S23 TPA will alter its control output to the traction
is closed, and detects low inputs at both motor to match the motor performance to the
JPT22-7 (Brake Deadman) and JPT22-8 travel command from the VM. As the travel
(Carriage Deadman), it knows that all the request from the CCC to the VM changes, so
required conditions are met. The VM then does the travel command from the VM to the
provides B– to JPT20-14 (Brake) that energizes TPA that, in turn, alters motor operation to
the brake coil and releases the brake. track the travel request from the operator. The
TPA also monitors drive motor temperature and

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Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

Tractor-First/Forks-First (TF/FF)

the internal temperature of the amplifier and

can alter travel based on the TPA temperature.
The TPA sends motor temperature to the VM,
and the VM alters the travel command based on
traction motor temperature.

When the lift truck is moving and the travel

control handle is moved to request the opposite
direction, the same sequence of events takes
place. The VM does not request plugging or
regeneration. It just requests travel in the
opposite direction at whatever speed the CCC
communicated. The TPA, that calculates both
direction and speed, determines whether the
travel command from the VM must be met with
a travel, a plug, or a regeneration control
output to the traction motor.

Tractor-First/Forks-First (TF/FF)
Tractor-First and Forks-First travel settings
allow independent configurations for the
maximum speed that the truck can travel while
moving in the tractor-first direction and the
forks-first direction.

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Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

Steering System

Steering System the steering motor to obtain the movement that

was requested from the tiller.

This section contains a description of the Both steering encoders in the dual encoder
steering system. For wire guided steering must be operational for full travel speed. If only
information, refer to page 8-13. one steering encoder is operational, travel speed
is limited to 2.5 mph (4.0 km/h).
System Components
The VM monitors steer current (JPT6-3), the
• Steering Request Encoder – a dual Steer Motor Encoder, and Neutral Pulse to
encoder located behind the steer wheel on determine that the steering system is operating
the carriage converts the operator request correctly. The VM supplies +12VDC to the Steer
into electronic pulses Amplifier at JPT6-6 to power the circuits inside
• Carriage Control Card - converts the the Steer Amplifier. When the deadman pedal is
inputs from the steering request encoder pressed, the VM energizes the TPC contactor,
into a message sent to the Vehicle providing B+ to TP2 on the Steer Amplifier to
Manager power the steer motor.
• Vehicle Manager - the controlling
manager of the steering system. Generates Functional Description
commands to the steer amplifier based on
the message from the Carriage Control The dual steering encoder is connected to the
Card CCC at JPC1 (encoder 1) and JPC21
(encoder 2). Each encoder has a +5.3V supply,
• Steer Amplifier - amplifies the steering
a DGND, two quadrature phased channels
commands from the Vehicle Manager and
(CHA and CHB), and a jumper that is used as a
drives the steer motor
connect detect to make sure that the steering
• Electric Steer Motor/Gear Reducer - encoder is connected to the CCC before normal
positions the drive unit operation of the lift truck is allowed by the VM.
• Steer Motor Encoder - located inside the
steer motor and used to determine if the When the tiller is moved, each encoder
motor is responding to the commands of produces an output pair (CHA and CHB from
the VM encoder 1 and CHA-E2 and CHB-E2 from
encoder 2). If the tiller is turned faster, the
• Home Sensor Prox - used by the steering
frequency of the output from the encoder
system to position the drive unit straight
increases. Each pair is converted into a positive
ahead during Auto Steer Center
or negative steering count that contains
information on the direction and speed of the
System Overview steering request from the tiller. This is sent over
the communications bus to the VM. If either of
The Steering Request Encoder is attached to the the steering counts are missing, the VM will
steer tiller on the carriage. The Steering Request cause a steering code to be displayed;
Encoder is a dual encoder. It contains two
• Code G0 if CHA/CHB is missing
encoders in a single package.
• Code G7 if CHA-E2/ CHB-E2 is missing
Each encoder produces two channels that are
quadrature phased and are used by the CCC to When the VM receives the steering count from
produce a steering request (steering count) that the CCC, it produces the appropriate steering
is sent to the VM over the communications bus. command for the Steer Amplifier. This steering
The VM, in turn, sends steering commands for command is sent to the Steer Amplifier at
either clockwise or counterclockwise rotation to JPT6-5 (CCW-PWM for CCW rotation) or JPT6-2
the Steer Amplifier. The Steer Amplifier drives (CW-PWM for CW rotation). Although these
commands are a PWM voltage, either can be

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Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

Functional Description

measured as a DC voltage with a Digital Multi that the encoder is not connected and the VM
Meter. The voltage will vary from approx. causes a Code G7. If the jumper is intact and
11VDC when the steering tiller is stationary, encoder 2 fails, the CCC will send a count for
and decreases as the steer tiller is moved faster. encoder 1 and not encoder 2, to the VM, and
A slow request is represented by a voltage of the VM will still cause a Code G7. Either failure
about 9VDC and a fast request is represented will cause the same code.
by a voltage of approx. 5VDC measured with
respect to (wrt) B–. Because the VM is
monitoring both the steer motor current and
the output from the Steer Motor Encoder, it
knows that the steer motor moves when
requested.

When the steer motor is not moving, there is no

input to the VM from either the steer motor
current or the steer motor encoder. This
situation can occur when driving in a straight
line. The VM needs a way to make sure the
steer system is operational. This is
accomplished through the Neutral Pulse. When
the Steer Amplifier has an input at the
CW-PWM line, it drives the Neutral Pulse
output low (<0.5VDC). When the Steer Amplifier
has an input on the CCW-PWM, it drives the
Neutral Pulse high (>4VDC). When the
deadman pedal is pressed and there is no input
on either the CW-PWM or the CCW-PWM lines,
the VM dithers the CW-PWM and CCW-PWM
control lines, causing the Neutral Pulse line to
toggle between high and low states. The VM
detects the Neutral Pulse is toggling as the
CW-PWM and CCW-PWM lines vary, thereby
informing the VM that the steering system is
operational.

The connect detect jumper for encoder 1 is

JPC1-8 and 9 and is called BRKDMAN/
DEADMAN. If that jumper is open or JPC1 is
disconnected, the hard wired voltage, BRAKE
DEADMAN, from the CCC to the VM is
interrupted and the VM will cause a Code 8C. If
the jumper is intact and the encoder fails, the
VM will lose steering encoder one and the VM
will cause a Code G0.

The connect detect jumper for encoder 2 is

JPC21-5 and 6 and is called CD SUPPLY/CD.
This jumper connects a 5VDC supply to an
input on the CCC processor. When the voltage
is present, the CCC sends a message to the VM
that the steering encoder is connected. If the
voltage is not present, the message to the VM is

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Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

Lift/Lower System

Lift/Lower System enough to start elevating the side cylinders. Oil

flow spins the turbine in the flow sensor. As the
turbine spins, the vanes pass by the magnetic
Emergency Lower pickups screwed into the flow sensor housing.
This creates a series of high and low pulses (or
Provisions are made to lower the carriage from counts) that go into the flow sensor module. The
the ground. When the Emergency Lower Valve pickups are 90 degrees out of phase. This
is opened, hydraulic fluid is allowed to pass allows the system to determine if the carriage is
through the emergency lower valve at a elevating or lowering, based on the direction the
constant rate. vanes are spinning. The flow sensor module
passes these counts to the VM. The VM
determines the direction of travel and the
Variable Speed DC Lift with number of counts. The VM uses this
intellispeed information to calculate fork height, which it
uses to determine speed reductions at elevated
NOTE: For lift trucks without intellispeed, all height.
functions are the same excluding
references to the flow sensor, When the VM first commands the activation of
intellispeed Manager, and height counts. the lift system, it is looking for the feedback
from the flow sensor. If the lift is commanded to
The CCC is constantly monitoring the output activate and no counts from the flow sensor are
voltage of VR2 and sending it to the VM over the present, the VM will flag an error condition and
BUS. The VM compares this voltage to the assume it is at maximum elevated height for
voltages stored during the Learn process. The speed limiting. Travel speed is reduced linearly
VM checks the battery voltage (for lift cutout), by about 0.5 mph (0.8 km/h) for every
all enabled options and switches that could 18 in. (45.7 cm) from full speed down to 1 mph
prevent the activation of the lift system. When (1.6 km/h), between the lower reference switch
satisfied that no criteria are present to prevent and 240 inches (610 cm). A low volume of fluid
lift, it then determines the requested percentage flow will not cause the turbine to spin. Because
of full speed lift. It then activates the lift/lower of this, if the lift system is feathered often, an
proportional valve fully open and closes the lift error is registered. If the intellispeed option is
pump contactor by taking the coils to B–. not on the lift truck, the travel is reduced each
time a mast limit switch is opened while
Opening the lift/lower valve fully prevents elevating.
sudden movement of the platform when the lift
pump is first activated by allowing the fluid to The VM monitors the P Sense line to determine
return to the tank. As soon as the command to the condition of the P contactor and verify the
close the P contactor is activated, the VM looks lift motor is spinning. When a lift request has
at the P Sense input, verifying the contactor finished (VR2 has either returned to neutral or
closed as commanded. It then slowly reduces through neutral to a lower request), the VM
the PWM output to the coil for the lift/lower monitors the P Sense line for back
proportional valve to match the percentage of ElectroMotive Force (EMF) from the motor to
full speed lift requested. As the lift/lower determine that the lift motor has stopped
proportional valve closes, hydraulic fluid passes spinning. As long as the VM senses voltage on
through the 5 psi (34 kPa) check valve, the the P Sense line, it will provide voltage to the
normally closed check valve in the load holding lift/lower proportional coil, keeping the valve
valve, through the flow sensor to the flow open to allow the fluid from the pump to return
controls at the bottom of the lift cylinders. The to tank. This makes sure that the cylinders do
flow control in the center cylinder allows not continue lifting after the request has ended.
unrestricted fluid flow to the center lift ram. The Once the lift motor has completely stopped
center ram elevates first because less pressure spinning, the VM removes voltage to the
is required. Once the platform hits the stops on
the inner telescopic, the pressure increases

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Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

24V Lift Trucks With Hi-Pro Option

lift/lower coil, closing the lift/lower RPM requested. As the voltage is increased to
proportional valve. the lift motor, the motor and pump spin faster,
increasing the output of oil to the lift system.
24V Lift Trucks With Hi-Pro The LPA monitors the input from the bearing
Option encoder in the lift motor and determines the
RPM of the motor. It adjusts the output to the
24V lift trucks with the Hi-Pro Option have a motor to maintain the requested RPM. The
two stage lift pump. This lift pump has a 2nd hydraulic fluid passes through the 5 psi
stage select solenoid on the bottom of the (34 kPa) check valve, the normally closed check
pump. This solenoid is activated whenever valve in the load holding valve, through the flow
there is less than 1000 lb. (454 kg) on the forks. sensor to the flow controls at the bottom of the
When activated, the fluid from the second pump lift cylinders. The flow control in the center
is ported to the lift system to increase lift speed. cylinder allows unrestricted oil flow to the
The weight calculation is done with either a center lift ram. The center ram elevates first
pressure transducer or a pressure switch (lift because less pressure is required. Once the
trucks without intellispeed) located on the platform hits the stops on the inner telescopic,
hydraulic manifold. The input from the the pressure increases enough to start elevating
pressure switch goes directly to the VM and the side cylinders. As the lift cylinders start to
activates a circuit to turn off the 2nd stage elevate, the fluid flow starts to spin the turbine
select solenoid. On lift trucks with the pressure in the flow sensor once the volume is large
transducer, the VM calculates the weight and enough. As the turbine spins, the vanes pass by
turns off the solenoid when a reading of 1000 the magnetic pickups screwed into the flow
lb. (454 kg) or more is registered. sensor housing. This creates a series of high
and low pulses (or counts) that go into the flow
Variable Speed AC Lift with sensor module. The pickups are 90 degrees out
of phase. This allows the system to determine if
intellispeed the carriage is elevating or lowering, based on
NOTE: For lift trucks without intellispeed, all the direction the vanes are spinning. The flow
functions are the same excluding sensor module passes these counts to the VM.
references to the flow sensor, The VM determines the direction of travel and
intellispeed Manager, and height counts. the number of counts. The VM uses this
information to calculate the fork height that it
The CCC is constantly monitoring the output uses to determine speed reductions at elevated
voltage of VR2 and sending it to the VM over the height. When the VM first commands the
BUS. The VM compares this voltage to the activation of the lift system, it is looking for the
voltages stored during the Learn process. The feedback from the flow sensor. If the lift is
VM checks the battery voltage (for lift cutout), commanded to activate and no counts from the
all enabled options, and all switches that could flow sensor are present, the VM flags an error
prevent the activation of the lift system. condition and assumes it is at maximum
elevated height for speed limiting. Travel speed
When satisfied that no criteria are present to is reduced linearly, about 0.5 mph (0.8 km/h)
prevent lift, the VM then determines the every 18 in. (45.7 cm), from full speed down to
requested percentage of full speed lift. It then 1 mph (1.6 km/h), between 60 (152 cm) and
sends an RPM command over the BUS to the 240 inches (610 cm). A low volume of fluid flow
Lift Power Amplifier. The LPA activates the LPC will not cause the turbine to spin. Because of
contactor by taking the coil to B– internally in this, if the lift system is feathered often, an
the LPA. As soon as the command to close the P error is registered. If the intellispeed option is
contactor is activated, the LPA looks at the (+) not on the lift truck, the travel is reduced each
input from the LPC verifying the contactor time a mast limit switch is opened.
closed as commanded. It then slowly increases
the voltage output to the lift motor to match the

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Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

Variable Speed Lower Activation

Variable Speed Lower the forks get hung up while lowering, there is a
180 psi (1241 kPa) check valve in series with
Activation the side lift cylinders and a 100 psi (689 kPa)
check valve in the manifold for the center
The following is based on a lower request from a
cylinder. If the pressure on these valves is
full-speed lift situation.
reduced below their rated pressure, the check
valve closes, stopping the lower function. This
VR2 passes through neutral to a full speed
keeps fluid from draining out of the cylinders
lower request. The CCC sends the voltage to the
and keeps the over the pulley hoses, cables,
VM over the BUS. The VM recognizes the
and lift chains from falling off the pulleys.
change and realizes full speed lower is required.
All enabled options and switches that can
prohibit lower are checked.

Once the VM is satisfied that lower can be

allowed, it monitors the back EMF of the lift
motor through the P Sense line. The VM
monitors the P Sense line to determine the
condition of the P contactor and verifies the lift
motor is spinning. When a lift request has
finished (VR2 has either returned to neutral or
through neutral to a lower request), the VM
monitors the P Sense line for back EMF from
the motor to determine that the lift motor has
stopped spinning. As long as the VM senses
voltage on the P Sense line, it provides voltage
to the lift/lower proportional coil, keeping the
valve open to allow the fluid from the pump to
return to tank. This makes sure that the
cylinders do not continue lifting after the
request has ended.

Once the lift motor has completely stopped

spinning, the VM removes voltage to the
lift/lower coil, closing the lift/lower
proportional valve. The Load Holding solenoid is
activated by the VM, opening the valve. The VM
then gradually opens the lift/lower solenoid to
the percentage of requested lower. This allows
the oil to flow from the side lift cylinders
through the flow controls at the bottom of the
cylinders, the 180 psi (1241 kPa) telescopic
hang up valve, the flow sensor, the load holding
valve, the lift/lower prop valve, the 100 psi
(689 kPa) platform hang up valve, the filter, and
back to the reservoir. The telescopics lower first
due to the greater amount of pressure on the
hydraulic fluid in the side cylinders. Once the
telescopics fully lower, the center cylinder
begins to lower. Lowering causes the turbine in
the flow sensor to spin in the opposite direction
of lift and reverses the counts to the VM. The
VM counts down, lowering the height count. If

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Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

Wire Guidance System

Wire Guidance System signal conditioning inputs to the

Antenna Cards as dictated by the
frequency selection in Configure Mode
This section contains a description of the wire and other program constraints. This
guidance system. For manual steering Filter Card is not present with the
information, refer to page 8-8. replacement GM 1268588/001.
Guidance Card - calculates the
System Components position of the lift truck relative to the
guide wire using the voltages received
• Auto/Manual Switch (S4) – located on the
from the Filter Card or the Antenna
dashboard near the speed control handle.
Card if the filter card is not present.
This switch is used by the operator to
The Guidance Card informs the VM of
select manual steering or wire guided
the necessary steering corrections to
operation.
keep the lift truck over the wire,
• Carriage Control Card - located behind guidance system error codes, distance
the console cover and below the steer tiller from wire, and heading angle
assembly. It monitors the state of the information.
Auto/Manual switch and advises the VM if
• Antenna Cards - there are two of these
it is open (Auto) or closed (Manual). Also
antenna assemblies. The Tractor Sensor is
operates the wire guidance icon LEDs on
located behind the center bumper plate in
the Carriage Light Display card.
front of the Drive Unit. The Load Sensor is
• Vehicle Manager - located in the tractor located on a bracket between the baselegs
compartment. It is the controlling manager beneath the operator platform. Each
for the steering and travel systems. When sensor card has 4 coils mounted on it. The
it is advised that the Auto/Manual switch center pair are the Nearwire Coils and the
is in the Auto position, it uses the lift truck outer coils are the Guidance Coils. These
position information supplied by the sensor coils have an AC voltage induced
Guidance Manager to provide steering into them by the magnetic field being
control for the lift truck. The VM also radiated from the guide wire. These AC
provides direction and speed information voltages are then amplified and sent to the
to the Guidance Manager that enables it to GM, or the Filter Card if present.
provide correctly oriented steering
• Steer Motor Encoder - when the steer
commands for either forward or reverse
motor armature is rotating, the steer
directions of travel.
motor encoder produces a pair of
• Steer Amplifier - located at the rear wall quadrature phased square waves that are
on the top deck of the tractor used by the VM to determine steer motor
compartment. It amplifies the steering speed and direction of rotation. The VM
commands from the VM and provides the then checks this information against the
high power drive necessary to control the steering commands from the GM to verify
steer motor. correct operation.
• Guidance Manager (GM) - located on the • Home Reference Prox Sensor - used by
right side of the drive tire wheel well the VM to determine “Home” or straight
housing in the tractor compartment. The ahead position of the drive unit.
older GM P/N 1183339 is comprised of
• Guide Wire - a wire that is buried in the
two physically and electrically connected
facility floor that radiates a magnetic field
printed circuit cards:
when an AC current flows through it.
Filter Card - conditions and amplifies
the AC guidance voltages received from
the Antenna Cards and converts them
into DC voltages usable by the
Guidance Card. It also supplies digital

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Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

System Overview

System Overview The GM then tells the VM to put the lift truck
into Seeking Mode and try to acquire the wire.
When the lift truck is in the wire guided mode, Travel speed is limited to 1 mph (1.6 km/h) in
the lift truck steering functions the same way as the forks-first direction and limited to the
when in the manual steering mode with one Acquire speed that is set in Configure Mode for
exception. Steering requests do not come from tractor-first travel. If the Wire Sense Creep
the CCC when in wire guided mode as they do (WrSnCrp) option is enabled in Configure Mode,
in manual steering. In the wire guided mode, lift truck speed is limited to 1 mph (1.6 km/h)
steering requests originate in the GM. To switch whenever S4 is detected closed (Manual
from manual steering to the wire guided mode, position) and the GM reports that a guide wire
several events need to occur. is detected. During Seeking Mode, an audible
tone is generated and the green LED triangles of
First, the CCC needs to detect that the the wire guidance icon (on the Carriage Light
Auto/Manual switch (S4) is open (Auto Display card) will blink. Steering at this time
position). Next, the CCC needs to advise the VM will still be in manual control because the lift
that S4 is open. When the VM is advised that truck has not acquired the wire. The operator
S4 is in the Auto position, it transfers steering must be steering the lift truck toward the guide
control from the Steering Encoder to the GM. wire location to help the lift truck acquire the
The GM calculates the position of the lift truck wire.
relative to the wire and advises the VM in what
direction and how far to steer the drive unit. As either the tractor end or the load end center
During wire guided operation, the GM is pair of sensor coils (Nearwire coils) approach
constantly updating the VM with corrections the guide wire, they begin to detect the
since the lift trucks position relative to the magnetic field around the guide wire. If the
guide wire is constantly changing. If the lift Nearwire coils do not detect this magnetic field
truck exceeds the deviation values for Distance for any reason, the lift truck will not acquire the
from Wire (DFW) or Heading Angle (HA) that are wire, even if the outer coils (guidance coils)
set in Configure, the GM informs the VM to detect the magnetic field. The magnetic field
either slow or stop the lift truck depending on around the guide wire causes an AC voltage to
the magnitude of the deviation. be induced into the sensor coils that is sent to
the Filter Card (GM P/N 1183339) or GM (GM
P/N 1268588/001) for conditioning. The Filter
Functional Description Card or GM removes any noise that was picked
up by the antenna coils and also converts this
During normal manual steering operation, the
AC voltage into a DC voltage to be used by the
CCC is in constant communication with the
Guidance Card. As either the tractor end or the
VM, updating the VM with the status of the
load end Nearwire coils get closer to the wire,
components connected to it such as switches,
the value of the DC voltage to the Guidance
the control handle, and the Steering Encoder.
Card increases. When the Nearwire coils get
Likewise, the GM is constantly attempting to
close enough (to the wire), and the voltage is
calculate the position of the lift truck relative to
high enough, the Guidance Card tells the VM to
the guide wire. The VM is constantly being
release full control of issuing the steering
updated as to the position of the drive unit
commands to the Guidance Card.
relative to home position as well as travel speed
and direction that it in turn communicates to
When the Guidance Card takes over issuing
the GM. When the CCC detects that S4 is
steer commands, the lift truck is in an Aligning
opened (Auto position), it advises the VM that
Mode. While in Aligning Mode, the VM ignores
S4 is open. The VM determines that the lift
the steering request from the CCC and all the
truck is ready for wire guided operation and
wire guidance icon LEDs on the Carriage Light
transfers the steering control from the Steering
Display Card will blink. The lift truck is now
Encoder to the GM.
auto steering and no longer responds to
operator steer tiller inputs.

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Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

System Overview

The Guidance Card also monitors the DC mm), the VM recognizes this as In-Aisle-State.
voltages from the Filter Card (GM P/N 1183339) This information is stored in Non Volatile
or the Antenna Card (GM P/N 1268588/001) Memory (NVM). NVM cannot be changed by a
representing the AC voltages being picked up by loss of power to the system. The only way to
the outer coils (Guidance Coils) on both the change it is by another input. This input can
tractor end and the load end sensors as the lift only be initiated by crossing another set of
truck begins to align over the wire. magnets or by traveling and turning the
steering more than 10 degrees. This allows the
When the voltages that the lift truck detects lift truck to be powered down inside the aisle
from the load end and tractor end guidance and remember that it is in an In-Aisle-State
coils begin to balance out and match the when powered back up. System operation is not
Learned Offset values for those coils, the changed upon aisle entry.
Guidance Card will switch from Aligning Mode When the lift truck is exiting an aisle and each
to Locked on Wire or Guided Mode. At that time, sensor is activated by magnets within 10 in.
all of the wire guidance icon LEDs on the (254 mm) of each other, the lift truck will plug
Carriage Light Display Card will illuminate solid to reduce speed until the speed is reached that
and full travel speed is allowed in either is stored in the Configuration Menu. Once this
direction. speed is reached, travel speed is limited by the
VM to the speed programmed in the
The Guidance Card constantly monitors the Configuration Menu until the control handle is
voltages from each of the four guidance coils via returned to neutral and travel is requested
the Filter Card (GM P/N 1183339) or the again. During the plugging sequence, the
Antenna Card (GM P/N 1268588/001). It operator can override the plugging strength
compares the voltage from each coil to the value with a request for a more aggressive plug from
for each coil that was obtained through the the control handle. When the sensors are
Learn procedure. By comparing the actual activated by magnets that are more than 11 in.
values for all four guidance coils with the (279 mm) but less than 30 in. (762 mm) apart,
learned values stored in the memory, the the VM plugs the lift truck to a complete stop.
Guidance Card can issue the appropriate The operator must then return the control
steering commands to the VM to keep the lift handle to neutral and request travel again.
truck centered over the guide wire. Also, using
these values, the Guidance Card calculates the End-of-Aisle Configurations
Heading Angle (HA - angle of the lift truck to the
wire) and the Distance From Wire (DFW - how Figure 8-1 shows the various EOA
far the lift truck is from the wire) and issues the configurations possible within a system.
appropriate Slow or Stop commands to the VM
when DFW or HA values set in Configure Mode
are exceeded. See Table 3-2, “Configure Mode End-of-Aisle Magnet Installation
Menu,” on page 3-14. Information

If there are consistent, repetitive problems with

End-of-Aisle Control
end-of-aisle operation, and the lift truck
appears to be OK, the magnets may have been
The End-of-Aisle system consists of lift truck
installed out of tolerance. Figure 8-2 and
mounted components and magnets embedded
Figure 8-3 depict the correct location of the
in the floor inside of the aisle. The lift truck
magnets.
mounted hardware consists of four magnet
sensors mounted between the baselegs under
the operator's platform. They are connected
directly to the VM. When the system is
activated, the VM monitors the inputs from the
sensors. When entering the aisle and both
sensors cross a magnet in less than 24 in. (610

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Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

System Overview

Vehicle will slow to configured end-of-aisle

speed when parallel magnets are crossed.

Magnets Parallel

Vehicle will plug to a stop when

staggered magnets are crossed
(or just one magnet is sensed).
Magnets Staggered

Vehicle will slow to configured end-of-aisle speed when

parallel magnets are crossed.

Vehicle will plug to a stop when staggered magnets are

crossed (or just one magnet is sensed). Magnets parallel at one end
and staggered at the other.

Magnets parallel in one aisle and staggered in the next.

Vehicle will slow to configured speed in aisle that has parallel magnets and plug to a stop
in aisle that has staggered magnets.

8
Figure 8-1. End-of-Aisle Configurations

20 ft. ±3 in. (6.1 m ±7.6 cm) 4.5 in. ±1/2 in.

Both Ends (114 mm ±13 mm)
Both Ends
Guide Wire*

4.5 in. ±1/2 in.

(114 mm ±13 mm)
Magnet
Both Ends
Magnet Position for Deceleration

* In rail guided applications, use the center of the aisle as the reference point for the dimensions.

8
Figure 8-2. End-of-Aisle Magnet Position (Deceleration)

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Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

End-of-Aisle Slow Down

20 ft. ±3 in. (6.1 m ±7.6 cm)

Both Ends
4.5 in. ±1/2 in.
(114 mm ±13 mm)
Both Ends
Guide Wire*

4.5 in. ±1/2 in.

(114 mm ±13 mm)
Magnet
Both Ends
24 in. ±1 in.
(610 mm ±26 mm) Both Ends

Magnet Position for Auto Stop

*In rail guided applications, use the center of the aisle as the reference point for the dimensions.
8
Figure 8-3. End-of-Aisle Magnet Position (Auto Stop)

20 ft (6.1 m) 20 ft
(6.1 m)

4.50 in.
4.50 in. (11.4 cm)
(11.4 cm)
Center of Aisle Magnet

8
Figure 8-4. End of Aisle Magnet Location

End-of-Aisle Slow Down the system is configured for. If the Auto/Manual

switch is moved to the Manual position prior to
crossing the magnets, the system will not look
With Wire Guidance for the magnets. Steering is reverted to the
operator and normal operation is resumed.
When the lift truck is locked on the guide wire,
Once out of the aisle and the steering is turned
the VM will start looking for the input from the
more than 10 degrees while traveling, the aisle
magnet sensors. When a set of magnets is
state is reset to out-of-aisle.
crossed entering the aisle, the system functions
as described in End-of-Aisle Control. If the
magnets are crossed while exiting the aisle with
the Auto/Manual switch in the Auto position,
the lift truck will slow down or stop; whichever

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Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

End-of-Aisle Slow Down

With auto steer center in a rail

guided system with a rail switch
installed on one guide roller
assembly.

When the lift truck enters the rails, the switch

mounted on the guide roller assembly is closed.
When the switch is activated, a tone will sound
and the lift truck is until the Auto/Manual
switch is placed in the Auto position. When the
switch is placed in the Auto position, the drive
unit auto steer centers and steering control is
taken away from the operator. The speed
restriction is removed and full speed travel is
allowed. The VM then starts looking for floor
magnet inputs. When exiting the aisle, if the
magnets are crossed with the Auto/Manual
switch in the Auto position, the lift truck will
slow down or stop, depending on system
configuration. If the Auto/Manual switch is
moved to the Manual position prior to crossing
the magnets, the system will not look for the
magnets. Steering is reverted to the operator
and normal operation is resumed. An audible
tone sounds until either the Auto/Manual
switch is turned back to Auto or the rail switch
on the guide roller opens. Once out of the aisle
and the steering is turned more than
10 degrees while traveling, the aisle state is
reset to out-of-aisle.

With auto steer center in a rail

guided system without a rail switch
installed on the guide roller
assembly.

When the lift truck is in the aisle and the

Auto/Manual switch is in Auto, the VM will
start looking for the input from the magnet
sensors. When a set of magnets is crossed
entering the aisle, the system functions as
described in “End-of-Aisle Control” on
page 8-15. When exiting the aisle, if the
magnets are crossed with the Auto/Manual
switch in either position, the lift truck will slow
down or stop, depending on how the system is
configured.

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Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

Pin-Out Matrix

Pin-Out Matrix • Normal Level: the approximate voltage

Section 8. Theory of Operation

that must be seen on that wire for the

state indicated. Unless otherwise
The pinout matrix chart lists functions and indicated, voltages are measured with
normal voltages of terminals and harness respect to (wrt) B– at TP4.
connector pins. The matrix columns have the • Signal Source: the device or connection
following meanings: that supplies the signal directly to the
• Item: sequential number to aid in wire.
reference. • Signal User: the device or connection
• Connection: the actual wire numbers or where the wire directly delivers the signal.
component abbreviations on the electrical
schematic.
• Function Description: brief definition of
the signal carried on the wire.
• Theory of Operation:
• A detailed description of the signal
carried on the wire. If the signal can be
variable, the state of a related
component that will cause the signal to
vary is indicated.
• Identifies possible causes for lack of
correct signal.

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

1 JPC1-1 +5.3V Supplies +5.3V to the Steering Request >5V CCC Steering
Encoder. It is dependent on the +12VP Request
from the VM and JPC11-1. Encoder

2 JPC1-2 DGND B– for the circuits of the Steering Request <0.3V wrt TP4 CCC Steering
Encoder. Request
Encoder

3 JPC1-3 CHA One part of the steering request from 0-5V nominal Steering CCC
the Steering Request Encoder when the w/tiller moving; Request
steering tiller is moved. It is a square >4.5V or <0.5V Encoder
wave signal (0V and 5V) identical to w/tiller
CHB but different phase. The CCC uses stationary
the phase relationship of CHA/CHB to
determine the direction and speed of the
steering request.

4 JPC1-4 CHB One part of the steering request from 0-5V nominal Steering CCC
the Steering Request Encoder when the w/tiller moving; Request
steering tiller is moved. It is a square >4.5V or <0.5V Encoder
wave signal (0V and 5V) identical to w/tiller
CHA but different phase. The CCC uses stationary
the phase relationship of CHA/CHB to
determine the direction and speed of the
steering request.

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Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

5 JPC1-8 BRAKE Output of the Brake Deadman switch >5V w/pedal CCC VM
DEADMAN (S2 at JPC7-1) that is looped back to the pressed; <0.5V
CCC at JPC1-9 and sent to the VM to w/pedal
inform the VM of the status of S2. If the released
Steering Request Encoder Cable
becomes unplugged, the VM will not
release the brake.

6 JPC1-9 BRAKE Receives output from JPC1-8 and sends >5V w/pedal CCC VM
DEADMAN the VM the status of S2. If the Steering pressed; <0.5V
Request Encoder Cable becomes w/pedal
unplugged, the VM will not release the released
brake.

7 JPC2-1 DGND B– for the Operator Interface Card. <0.3V wrt TP4 Fuse/Relay Operator
Card Interface

8 JPC2-2 UP ARROW The CCC monitors this input to >5V w/switch Operator CCC
determine when the up arrow on the open; Interface
Operator Interface is pressed. <0.5V w/switch
closed

9 JPC2-3 DN ARROW The CCC monitors this input to >5V w/switch Operator CCC
determine when the down arrow on the open; Interface
Operator Interface is pressed. <0.5V w/switch
closed

10 JPC2-4 ETR/SHFT The CCC monitors this input to >5V w/switch Operator CCC
determine when the Enter/Shift button open; Interface
on the Operator Interface is pressed. <0.5V w/switch
closed

11 JPC2-17 Not Used

12 JPC3-1 60” LIMIT The voltage on this line changes when <1V w/switch CCC CCC
the platform crosses S28 (60” Limit closed;
Non-intellispeed Switch). This change in voltage is used >9V w/switch
lift trucks by the CCC to limit travel speed. S28 open
opens when the platform is above the
60 in. switch and speed is limited to
1 mph (1.6 km/h) maximum. When the
platform is below 60 in. (1524 mm),
S28 is closed and the speed is
configurable from 0.5 to 2.5 mph (0.8
to 4.0 km/h).

Intellispeed Lift There is a jumper on the CCC at JPC3.

Trucks Travel speed above S28 is determined
by height. The lift truck will have full
configured speed to 60 in.

13 JPC3-2 6-12VF 12V supply to S28 (60” Limit Switch). 6-8.8V VM S28
w/switch
connected;
>8.8V w/switch
disconnected

14 JPC3-3 PGND B– for S28 (60” Limit Switch). <0.3V wrt TP4 VM S28

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Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

15 JPC4-1 LOWER INHIBIT Output from S25 used by the CCC to <1V w/platform S25 CCC
detect the location of the operator below switch;
platform. approx. 10V
with platform
above switch

16 JPC4-2 +12VF 12V supply to S25 (Lower Inhibit 10.8-13V VM S25

Switch). w/key switch
ON

17 JPC4-3 PGND B– for S25. <0.3V wrt TP4 VM S25

18 JPC5-1 B+KEY B+ that is switched by the key switch B+ w/key CCC Light and
and powers the optional light and fan. switch ON Fan
package

19 JPC5-2 B–F B– for the optional light and fan. <0.3V wrt TP4 CCC Light and
Fan
package

20 JPC5-3 B–F B– for the CCC power option (Control <0.3V wrt TP4 CCC Handle
Handle Heater). Heater

21 JPC5-4 B+KEY B+ that is switched by the key switch B+ w/key CCC Handle
and powers the CCC power option switch ON Heater
(Control Handle Heater).

22 JPC6-1 B+F B+F to S1 (Key Switch). If B+ is not B+ wrt TP4 Fuse/Relay S1

present, check for B+ at JPC16-3. w/battery Card
connected and
FU5 good

23 JPC6-2 B+KEY B+ switched by the key switch. If B+ is B+ w/key Fuse/Relay All

missing, check for B+ at JPC6-1. switch ON and Card
FU5 good

24 JPC6-2 B+KEY B+ for Security Start Switch Relay. B+ CCC K2 Relay

for
Security
Start
Switch

25 JPC6-3 B+EPO B+ after going through S21 (EPO B+ when EPO CCC Fuse/
switch). If B+ is missing, the CCC will switch is up Relay
display EPO depressed. Check for B+ at (closed) Card
JPC6-4.

26 JPC6-4 B+KEY B+ Key from JPC6-2 to supply B+ EPO B+ from JPC6-1 S1 S21
when S21 is out (closed).

27 JPC6-5 DGND B– for S7. <0.3V wrt TP4 VM S7

28 JPC6-6 L/L INHIBIT Determines whether the CCC will allow >5V w/S7 CCC CCC
BYPASS lift or lower when either lift or lower limit closed (up);
is reached. When S7 is closed, <0.5V w/S7
lift/lower is prevented when the cutout open (down)
switch is activated. When S7 is open,
lift/lower is allowed.

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Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

29 JPC7-1 BRAKE The CCC monitors the state of S2 (Brake >4V up CCC VM and
DEADMAN Deadman) directly. The VM detects the (released); CCC
state of S2 at JPT22-8. The CCC and the <0.5V down
VM communicate S2 status and must (pressed)
agree that it is pressed before the brake
is released.

30 JPC7-2 +12VF 12V supply to S2 (Brake Switch). 10.8-13V VM S2

w/key switch
ON

31 JPC7-3 DGND B– for S2. <0.3V wrt TP4 VM S2

32 JPC7-4 CARRIAGE The CCC monitors the voltage on this >10V w/S2 up; CCC VM and
DEADMAN line to determine the state of S23. This <0.5V w/S2 CCC
signal is looped through the Steering down
Request Encoder at JPC1-8 and 9 and
sent to the VM at JPT22-7.

33 JPC7-5 +12VF 12V supply to S23 (Carriage Deadman 10.8-13V VM S23

Switch). w/key switch
ON

34 JPC7-6 DGND B– for S23. <0.3V wrt TP4 VM S23

35 JPC8-1 24 IN. LIMIT The voltage on this line changes when <1V w/S11 CCC CCC
the platform crosses S11. The change in closed;
voltage is used by the VM to reset the >9V w/S11
height counter and enable correct open
speed. S11 opens when the platform is
above 24 in. and speed is determined
by height. When the platform is below
24 in., S11 is closed and full speed is
allowed.

36 JPC8-2 6-12VF 12V supply to S11 (24 in. Limit Switch). 6-8.8V w/S11 VM S11
connected;
>9.0V w/S11
disconnected

37 JPC8-3 DGND B– for S11. <0.3V wrt TP4 VM S11

38 JPC9-1 AUTO/MANUAL The CCC monitors the state of the S4 <1V in manual; CCC VM
(Auto/Manual Switch) to determine if >5V on wire/in
the lift truck is in manual steering or rail
Wire Guidance/Rail Guidance mode.

39 JPC9-2 DGND B– for S4. <0.3V wrt TP4 VM S4

40 JPC9-3 HORN This input is monitored by the CCC. >5V Open; CCC CCC
When S3 (Horn Switch) is pressed, the <0.5V Closed
CCC tells the VM to blow the horn.

41 JPC9-4 DGND B– for S3 and VR2 (Lift/Lower Pot). If <0.3V wrt TP4 VM S3
missing, Code 81 is displayed.

42 JPC9-5 +5.3V Supply voltage for VR2 (Lift/Lower Pot). >5V CCC VR2

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Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

43 JPC9-6 L/L Variable voltage from VR2 wiper. The 1.3V Neutral; CCC VM
CCC monitors this voltage and sends it 0.4V Full Lift;
to the VM. Voltage must be between 0.4 2.1V Full Lower
and 4.6V. If not, Code 81 is displayed.

44 JPC9-7 DGND B– for VR1. <0.3V wrt TP4 VM VR1

45 JPC9-8 +5.3V Supply voltage for VR1 (Travel Pot). >5V CCC VR1

46 JPC9-9 TRAVEL Variable voltage from VR1 wiper. The 1.3V Neutral; CCC VM
CCC monitors this voltage and sends it 0.8V Full Fwd;
to the VM. Voltage must be between 0.4 2.6V Full Rev
and 4.6V. If not, Code 80 is displayed.

47 JPC9-10 Not Used

48 JPC11-1 +12VF Supplies working voltage to the CCC. 10.8-13V VM CCC

w/key switch
ON

49 JPC11-2 BUS– Carries the negative component of the 2.0V CCC LPA, TPA
digital communications between the and VM
CCC and the managers on the tractor
side of the communications bus.

50 JPC11-3 BUS+ Carries the positive component of the 3.0V CCC LPA, TPA
digital communications between the and VM
CCC and the managers on the tractor
side of the communications bus.

51 JPC11-4 BRAKE Sent by the CCC to the VM to energize >6V with CCC VM
DEADMAN the brake when all other conditions are deadman up
met. This output is sent when S2 is and brake
closed. applied;
<0.5V with
deadman down
and brake
released

52 JPC11-5 CARRIAGE Sent by the CCC to the VM to energize >6V with CCC VM
DEADMAN the brake when all other conditions are deadman up
met. This output is sent when S23 is and brake
closed. applied;
<0.5V with
deadman down
and brake
released

53 JPC11-6 DGND Reference and negative for the circuits <0.3V wrt TP4 VM CCC
on the CCC. Although it eventually
connects to B–, it is kept separate from
the other grounds to help reduce the
effects of noise on system operation.

54 JPC12-2 B–F SPARE B– for Security Start Switch Relay. B– CCC K2 Relay
for
Security
Start
Switch

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

55 JPC13-1 SIDEGATE LEFT Output from S61 used by the CCC to 10.8-13V VM CCC
detect the position of the left sidegate. w/key switch
The VM will prohibit travel if the ON
sidegate is up or the switch is open.

56 JPC13-2 +12VF 12V supply to S61 (Left Sidegate 10.8-13V VM CCC

Switch). w/key switch
ON

57 JPC13-3 PGND B– for S61. <0.3V wrt TP4 VM CCC

58 JPC14-1 SIDEGATE RIGHT Output from S60 used by the CCC to <1V with S60 CCC
detect the position of the right sidegate. sidegate down;
The VM will prohibit travel if the approx. 10V
sidegate is up or the switch is open. w/sidegate up

59 JPC14-2 +12VF 12V supply to S60 (Right Sidegate 10.8-13V VM S60

Switch). w/key switch
ON

60 JPC14-3 PGND B– for S60. <0.3V wrt TP4 VM CCC

61 JPC15-1 Not Used

62 JPC15-15 DGND B– for the Carriage Control Light <0.3V wrt TP4 VM Light
Display Card. Display
Card

63 JPC15-16 5.3V Supply voltage for the Carriage Control >5V CCC Light
Light Display Card. Display
Card

64 JPC15-24 Not Used

65 JPC16-1 B+EPO Present when both the Key Switch and B+ CCC Fuse/
EPO switch are closed. Supplies B+ Relay
EPO to the Fuse/Relay Card where it is Card
used by the K1, K2, and K3 relays.

66 JPC16-2 B–FUSEDS B– for the Spare Power Connector <0.3V wrt TP4 Fuse/Relay CCC
(JPC12-2) on the CCC. Supplies B– for Card (FU8)
the optional lights, fan, and RF unit.

67 JPC16-3 B+FUSEDS B+ for the Spare Power Connector B+ wrt TP4 Fuse/Relay CCC
(JPC12-1) on the CCC. Supplies B+ for w/battery Card (FU7)
the optional lights, fan, and RF unit. connected

68 JPC16-4 B–FUSED B– for the CCC from the Fuse/Relay <0.3V wrt TP4 Fuse/Relay CCC
Card. Card (FU6)

69 JPC16-5 B+EPO B+EPO Spare. B+ CCC Spare

70 JPC16-6 B+KEY B+ that is switched by the Key Switch B+ w/S1 closed CCC Fuse/
(S1) and sent from the CCC to supply Relay
B+ Key to the Fuse/Relay Card. Card

71 JPC16-7 B+FUSEDS B+ Fused Spare. B+ CCC Spare

72 JPC16-8 B+FUSED Main B+ supply to the CCC and is fused B+ wrt TP4 Fuse/Relay CCC
through FU5 on the Fuse/Relay Card. Card (FU5)

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

73 JPC21-1 +5.3V Supplies +5.3V to the E2 Steering >5V CCC E2

Request Encoder. It is dependent on the Steering
+12VP from the VM at JPC11-1. Request
Encoder

74 JPC21-2 DGND B– for the circuits of the E2 Steering <0.3V wrt TP4 CCC E2
Request Encoder. Steering
Request
Encoder

75 JPC21-3 CHA–E2 One part of the steering request from 0-5V nominal E2 Steering CCC and
the E2 Steering Request Encoder when w/tiller moving; Request VM
the steering tiller is moved. It is a square >4.5V or <0.5V Encoder
wave signal (0V and 5V) identical to w/tiller
CHB-E2 but different phase. The CCC stationary
sends this information to the VM.

76 JPC21-4 CHB-E2 One part of the steering request from 0-5V nominal E2 Steering CCC and
the E2 Steering Request Encoder when w/tiller moving; Request VM
the steering tiller is moved. It is a square >4.5V or <0.5V Encoder
wave signal (0V and 5V) identical to w/tiller
CHA-E2 but different phase. The CCC stationary
sends this information to the VM.

77 JPC21-5 CD SUPPLY 5.3V output from the CCC power >4V CCC CCC
supply. This voltage is dependent on
+12VP from the VM at JPC11-1. This
voltage goes back to the CCC
microprocessor to let the CCC know that
JPC21 is connected. If not connected,
Code G0 is displayed.

78 JPC21-6 CD +5.3V output from the CCC power >5V CCC CCC
supply. This voltage is dependent on
+12VP from the VM at JPC11-1. This
voltage goes back to the CCC
microprocessor to let the CCC know that
JPC21 is connected. If not connected,
Code G0 is displayed.

79 JPF1-1 B– B– for FU8 (15A/5A) Fuse for optional <0.5V TP4 Aux
Aux power. Power

80 JPF1-2 B– B– for FU8 (15A/5A) Fuse for optional <0.5V TP4 Aux
Aux power. Power

81 JPF1-3 Not Used

82 JPF1-4 B–F B–F from FU8 for optional Aux Power. <0.5V FU8 to B– Aux
Power

83 JPF1-5 Not Used

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

84 JPF1-6 B+F or B–F Provides either B+F or B–F to B+K3 on B– w/K3 FU5 when LPA and
the Lift and Travel Power Amplifiers. At De-energized; K3 is TPA
Startup the K3 coil is energized, B+ w/K3 energized;
providing B+ to the precharge circuit Energized FU6 when
and logic circuits in the power K3 is
amplifiers. With the K3 coil de-energized
de-energized, JPF1-6 is at B– to
discharge the amplifier precharge
circuits.

85 JPF2-1 B+K2 B+ that is present when the K2 relay tips B+ w/K2 closed Fuse/Relay LPC Coil
close (DC lift only). Card

86 JPF2-2 B+K2 B+K2 to power the horn. B+ with K2 K2 tips Horn

energized

87 JPF2-3 B+K2 B+K2 when the K2 relay tips are closed. B+ K2 tips VM

88 JPF2-3 B+K2 B+ supplied to the Aux Mast solenoids. B+ Fuse/Relay Aux Mast
Card Solenoids

89 JPF2-4 N/A

90 JPF2-5 B+K2 B+K2 to power Load Holding Solenoid. B+ with K2 K2 tips L/H Sol.
energized.

91 JPF2-6 B+K2 B+K2 when the K2 relay tips are closed. B+ K2 tips VM

92 JPF2-7 B+K2 B+K2 when the K2 relay tips are closed. B+ K2 tips VM

93 JPF2-8 Not Used

94 JPF2-8 B+K2 B+ supplied to the 2 Stage Select B+ Fuse/Relay 2 Stage

Solenoid. Card Select
Sol.

95 JPF2-9 B+KEY B+ Key for warning light when K1 tips B+ CCC Warning
are closed. Light

96 JPF3-1 B– B– for FU6 (15A) that provides B– to the <0.5V TP4 VM

Vehicle Manager.

97 JPF3-2 B– B– for FU6 (15A) that provides B– to the <0.5V TP4 VM

Vehicle Manager.

98 JPF3-3 B–F B–F for DGND on the VM. <0.5V FU6 VM

99 JPF3-4 B–F B–F for DGND on the VM. <0.5V FU6 VM

100 JPF3-5 B–F B–F for the VM. <0.5V FU6 VM

101 JPF3-6 B–F B–F for the VM. <0.5V FU6 VM

102 JPF3-7 B–F B–F for the VM. <0.5V FU6 VM

103 JPF3-8 B–F B–F for S10 (150 or 120 in. Limit <0.5V FU6 S10
Switch) on the mast.

104 JPF3-9 B–F B–F for wire guidance. <0.5V Fuse/Relay Guidance
Card (FU6) Manager

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

105 JPF3-11 B–F B–F for the warning light/motor fan. <0.5V FU6 Warning
Light/
Motor
Van

106 JPF3-12 B–F B–F for the CCC. <0.5V FU6 CCC

107 JPF4-1 B+ B+ from TP1 to FU5 (15A) to supply K2, B+ TP1 VM

K4 relay tips. This also supplies
Battery_Sense_In on the VM.

108 JPF4-2 B+ B+ from TP1 to FU5 (15A) to supply K2, B+ TP1 FU5 and
K4 relay tips. This also supplies VM
Battery_Sense_In to the VM.

109 JPF4-3 B+ B+ from TP1 to FU7 (15A/5A) to supply B+ TP1 FU7 and
Aux power option. Aux
Power

110 JPF4-4 B+ B+ from TP1 to FU7 (15A/5A) to supply B+ TP1 FU7 and
Aux power option. Aux
Power

111 JPF4-5 B+EPO B+ supply from EPO to K1, K2 and K3. EPO EPO K1, K2,
All functions associated with these Closed: B+; K3
relays are inoperable when the EPO is Open: 0.05V
open.

112 JPF4-6 B+EPO B+ to the EPO_Sense on the VM. Tells EPO EPO VM, EPO
the VM if the EPO is open or closed. Closed: B+; Sense
Open: 0.05V

113 JPF4-7 B+ B+ present when the battery is plugged B+ (there should TP1 VM
in. It is supplied through a thermistor on be no voltage
the Relay Control Fuse Panel. This is drop)
used by the VM to determine that the
correct battery is connected. It will
accept between 28 and 45V (36V
Battery) or 18 and 30V (24V Battery). If
the correct battery is sensed,
Relay_Enable is energized during
startup. After startup, this voltage is used
to determine BSOC.

114 JPF4-8 B+KEY B+ Key from the CCC. B+ CCC VM

115 JPF4-10 B+ B+ Fused to the CCC. B+ FU5 CCC

116 JPF4-11 B+KEY B+ Key for VM. B+ CCC VM

117 JPF4-12 Not Used

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

118 JPF4-13 RELAY ENABLE Return path for relays K1, K2, K3, and B+ w/Key VM K1, K2,
K4. This is dependent on Switch ON and K3 and
Battery_Sense_In being between 28 all relays K4
and 45V (36V Battery). de-energized;
<0.5V w/Key
Switch OFF or
ON and any
relay energized

119 JPF4-14 RELAY ENABLE Return path for relays K1, K2, K3, and B+ w/Key VM K1, K2,
K4. This is dependent on Switch ON and K3 and
Battery_Sense_In being between 18 all relays K4
and 30V (24V Battery). de-energized;
<0.5V w/Key
Switch OFF or
ON and any
relay energized

120 JPF4-15 B+ B+ for battery connected Aux Power. B+ FU7 Aux

Power

121 JPLA1-1 B+K3 B+ present when K3 is energized. This B+ w/K3 K3 LPA

is used to power the control circuits of energized
the LPA.

122 JPLA1-6 TPC Control path for the LPC. The LPA LPC LPA LPC
CONTACTOR supplies a path for B– for the contactor de-energized;
by way of the B– terminal. B+
energized:
14.7V

123 JPLA1-7 DGND Return path for the bearing encoder in <0.5V LPA Lift
the lift motor. Velocity
Sensor

124 JPLA1-8 L TEMP+ Analog voltage that varies with the lift 75°F (24°C) Lift Motor LPA
motor temperature. Used by the LPA to approx. 1V Temp.
adjust motor performance. Sensor

125 JPLA1-11 ID0 B+ present at the LPA with K3 tips B+ w/K3 K3 LPA
energized. It is used as an identifier to energized
determine correct connection.

126 JPLA1-11 ID0 ID0 on the LPA has B+ applied. This B+ Fuse/Relay LPA
voltage tells the amplifier what amp it is. Card

127 JPLA1-12 ID1 Not Used by the Lift Power Amp.

128 JPLA1-13 B+K3 B+ for the LPC. The LPA supplies B+ for B+ LPA LPC
the LPC.

129 JPLA1-23 BUS+ Carries the positive component of 3.0V CCC LPA, VM
digital communications between the
LPA, VM, and CCC.

130 JPLA1-25 Not Used

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

131 JPLA1-26 L VEL SENSOR + 5V supply to the bearing encoder on the 4.98V LPA Lift
lift motor. This voltage is produced by Velocity
the Lift Power Amp from B+K3. Sensor

132 JPLA1-28 Not Used

133 JPLA1-29 Not Used

134 JPLA1-31 L VEL PHASE A Generated when there is movement of Motor Lift Velocity LPA
the bearing encoder in the lift motor. It is Stationary: Sensor
a square wave that is either high (>3V) 4.06 or 0.03V;
or low (<1V). The frequency varies Motor Turning:
directly with motor speed. Identical to 2.3V
L VEL Phase B except for phase. The LPA
uses the relationship between phases to
determine lift speed.

135 JPLA1-32 L VEL PHASE B Generated when there is movement of Motor Lift Velocity LPA
the bearing encoder in the lift motor. It is Stationary: Sensor
a square wave that is either high (>3V) 4.06 or 0.03V;
or low (<1V). The frequency varies Motor Turning:
directly with motor speed. Identical to 2.3V
L VEL Phase A except for phase. The LPA
uses the relationship between phases to
determine lift speed.

136 JPLA1-35 BUS– The wire that carries the negative 2.3V CCC LPA, VM
component of the digital
communications between the LPA, VM,
and the CCC.

137 JPS2-11 B+EPO B+EPO is present when both the key B+ with S1 and VM Guidance
switch and EPO switch are closed. It is EPO closed. Manager
supplied to the Guidance Manager from
B+K2 on the VM. If the key switch or
EPO are open, K2 is de-energized.

138 JPS2-24 B–F B– for the Guidance Manager. It is <0.5V wrt TP4 Guidance VM
fused through FU6 on the Fuse/Relay Manager
Card.

139 JPS4-6 BUS+ Carries the positive component of the Not Usable VM Guidance
digital communications between the VM Manager
and the Guidance Manager.

140 JPT4-2 Not Used

141 JPT4-3 LIFT DECEL Voltage from S124 (Lift Decel Switch) Open: 4.8V; S124 VM
that indicates the open or closed state of Closed: <0.3V
the switch. Used to reduce the lift speed
as the vehicle approaches full elevation.
Only on AC lift trucks.

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

142 JPT6-1 NEUTRAL_PULSE This input tells the VM that the Steer Deadman up: Steer Power VM
Power Amplifier is connected and 4.8V; Amplifier
functioning. CCW steer:
0.2V;
CW steer:
4.8V;
No steering:
voltage varies

143 JPT6-2 CW_PWM This is a control voltage used to rotate At rest: 11.9V; VM Steer
the drive unit in the CW direction. The CW fast: 4V; Power
average DC value will vary depending CW slow: Amplifier
on the amount and speed of steering 11.8V
requested.

144 JPT6-3 STEER_CURRENT Analog voltage that varies with the steer Steering Steer Power VM
motor current and is sent from the Steer CW: 2.9V; Amplifier
Power Amplifier to the VM. This voltage At rest: 2.5V;
is used by the VM to establish current Steering
reading for current limit. CCW: 2.1V

145 JPT6-4 DGND Reference for the control circuits in the <0.5V VM Steer
Steer Power Amplifier. If missing, the Power
Steer Power Amplifier will not be Amplifier
powered up.

146 JPT6-5 CCW_PWM This is a control voltage used to rotate At rest: 11.9V; VM Steer
the drive unit in the CCW direction. The CCW fast: 4V; Power
average DC value will vary depending CCW slow: Amplifier
on the amount and speed of steering 11.8V
requested.

147 JPT6-6 +12VP Operating voltage from the VM for the 10.7-13V VM Steer
control circuits in the Steer Power Power
Amplifier. If missing, steering is Amplifier
inoperable.

148 JPT10-2 SENSOR 1 Voltage from the S46A and S46B aisle 10.8-13V when VM S46A/B
detect switches that indicates a magnet is not Aisle
transition over a Floor Magnet. sensed; Detect
<1V for Sensors
0.1 sec. after
magnet is
sensed, then
10.8-13V

149 JPT10-6 +12VP 12V supply to S46A and S46B (Aisle 10.8-13V VM S46A and
Detect Sensors). B

150 JPT10-7 +12VP 12V supply to S47A and S47B (Aisle 10.8-13V VM S47A and
Detect Sensors). B

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

151 JPT10-8 SENSOR 2 Voltage from S47A and S47B (Aisle 10.8-13V when VM S46A/B
Detect Sensors) that indicates a magnet is not Aisle
transition over a floor magnet. sensed; Detect
<1V for Sensors
0.1 sec. after
magnet is
sensed, then
10.8-13V

152 JPT10-9 DGND Reference for the steer motor encoder. <0.5V VM Steer
Motor
Encoder

153 JPT12-5 LIFT Emergency L/L for pendant and MVP VM S112
option (down)

154 JPT12-6 LOWER Emergency L/L for pendant and MVP VM S111 (up)
option

155 JPT12-12 DGND Emergency L/L for pendant and MVP VM VM

option

156 JPT14-1 B–F This connects B–F on the VM to TP4(B–) <0.5V Fuse/Relay VM
through FU6 on the Fuse/Relay Card. Card
These B– provide the return for
everything not using DGND or AGND
as reference.

157 JPT14-2 DGND This connects DGND on the VM to TP4 <0.5V Fuse/Relay VM
(B–) through FU6 on the Fuse/Relay Card
Card. This is the reference for all circuits
on the lift truck that reference DGND.

158 JPT14-3 DGND This is the negative path for the 12V <0.5V VM CCC
supply to the CCC. If this is not present,
the CCC will not function. 5V is made
from the 12V on the CCC.

159 JPT14-4 BUS_I– The wire that carries the negative 2.3V VM LPA, TPA
component of the digital and CCC
communications between the VM, TPA,
LPA, and CCC.

160 JPT14-5 +12VP This is the positive path for the 12V 10.8-13V VM CCC
supply to the CCC. If this is not present,
the CCC will not function. 5V is made
from the 12V on the CCC.

161 JPT14-6 RELAY_ENABLE Control path for K1, K2, K3 and K4 on Relays VM K1, K2,
the Fuse/Relay Card. After S1 is closed, OFF: B+, K3, K4
all relays are energized simultaneously Relays
during SelfTest if the voltage at ON: <0.5V
Battery_Sense_In is between 28 and
45V (36V Battery) or 18 and 30V (24V
Battery).

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

162 JPT14-7 B+K2 B+ provided to the VM when the K2 B+ K2 Relay VM,

relay tips are closed. They are Brake
de-energized when the EPO is open. Coil
Note: Also used by the VM for Brake
Coil Suppression.

163 JPT14-8 B–F This connects B–F on the VM to TP4 (B–) <0.5V Fuse/Relay VM
through FU6 on the Fuse/Relay Card. Card
These B– provide the return for
everything not using DGND or AGND
as reference.

164 JPT14-9 B–F This connects B–F on the VM to TP4 (B–) <0.5V Fuse/Relay VM
through FU6 on the Fuse/Relay Card. Card
These B– provide the return for
everything not using DGND or AGND
as reference.

165 JPT14-10 DGND This connects DGND on the VM to TP4 <0.5V Fuse/Relay VM
(B–) through FU6 on the Fuse/Relay Card
Card. This is the reference for all circuits
on the lift truck that reference DGND.

166 JPT14-11 BUS_I+ The wire that carries the positive 3.0V VM LPA, TPA
component of the digital and CCC
communications between the VM, TPA,
LPA, and CCC.

167 JPT14-12 B+KEY B+ that is switched by S1 (Key Switch) S1 closed: B+; S1 VM

and used to power functions on the VM S1 open: 0.3V
that are initiated after S1 is closed and
are not affected by the EPO. This
includes the VM power supplies, the
operation of the microprocessor, and
execution of the firmware.

168 JPT14-13 B+K2 B+ provided to the VM when the K2 B+ K2 Relay VM

relay tips are closed. They are
de-energized when the EPO is open.

169 JPT14-14 B+K2 B+ provided to the VM when the K2 B+ K2 Relay VM

relay tips are closed. They are
de-energized when the EPO is open.

170 JPT18-1 2 STAGE SOL Negative path for the 2nd Stage Select <0.1V Fuse/Relay 2 Stage
Solenoid 24V High Performance Lift. Card Select
Sol.

171 JPT18-4 +12VP 12V supply for S15 (Rail Sense Switch). 10.8-13V VM S15

172 JPT18-5 DGND Negative path for the Pressure Switch <1V Pressure VM
24V High Performance Lift. Switch

173 JPT18-16 HORN Control path for the horn that is B+ VM Horn
switched to B– by the VM. de-energized;
<0V energized

174 JPT18-7 DGND Return path for S124 (Lift Decel Switch). <0.5V S124 VM

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

175 JPT18-9 LIFT_ B– for the LPC coil (DC lift only). 24V Lift Truck: VM LPC Coil
CONTACTOR B+ w/coil
de-energized;
1V w/coil
energized
36V Lift Truck:
B+ w/coil
de-energized;
11-12V w/coil
energized

176 JPT18-10 L/H Control path for the load holding B+ VM L/H Sol.
solenoid that is switched to B– by the de-energized;
VM to energize the L/H solenoid coil. 12.7V
energized

177 JPT18-12 AUX L/H Negative path for the Aux Mast L/H <1V Aux. L/H VM
Solenoid. Sol.

178 JPT18-15 AUX SEL Negative path for the Aux Mast Select <1V Aux. Select VM
Solenoid. Solenoid

179 JPT18-14 MAIN SEL Negative path for the Aux Mast Main <1V Aux.Main VM
Select Solenoid. Select Sol.

180 JPT18-18 ALARM_TRAVEL Return path for Travel Alarm. B+ Travel Alarm VM
de-energized;
<0V energized

181 JPT20-1 +12VF 12V supply to S10 (120/150 in. +10.7 -13V VM S10
Switch).

182 JPT20-2 +12VP 12V supply for the Flow Sensor. 10.8-13V Flow Sensor VM

183 JPT20-3 Not Used

184 JPT20-4 Not Used

185 JPT20-5 +12VP 12V supply to the Pressure Transducer. 10.8-13V VM Pressure
Trans-
ducer

186 JPT20-6 +12VP 12V supply to S27 (Travel Cutout 10.8-13V VM S27
Switch).

187 JPT20-7 +12VP 12V supply for the steer motor encoder. 10.8-13V VM Steer
Motor
Encoder

188 JPT20-8 +12VP 12V supply to S124 (Lift Decel). 10.8-13V VM S124

189 JPT20-9 +12VP 12V supply to the Home Sensor Prox by +10.7-13V VM Home
the VM. Sensor
Prox

190 JPT20-10 +12VP 12V supply to the S24 (Lift Inhibit 10.8-13V VM S24
Switch).

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

191 JPT20-14 BRAKE Control path for the electrically released B+ VM Brake
brake on the traction motor. de-energized:
26V energized

192 JPT20-15 B+L/L B+ supplied to lift/lower solenoid when B+ VM L/L

K2 tips are closed.

193 JPT20-16 L/L Control path for the lift/lower De-energized: VM L/L
proportional solenoid. B+;
Full Lift: 28V;
Full Lower:11V;
Feather Lift:
34V;
Decel: 27.7V

194 JPT20-17 B+ALARM B+ supplied to the lift/lower alarm when B+ VM Alarm

K2 tips are closed. Travel/Lift

195 JPT20-18 ALARM_LIFT Control path for the lift/lower alarm. B+ Alarm_Lift VM
de-energized;
<0.0V
energized

196 JPT20-19 B+K2 B+ supplied to the Guidance Manager B+ VM Guidance

when the K2 tips are closed. Manager

197 JPT22-1 120/150 IN. Input to the VM from S10. Open: 4.8V; S10 VM
LIMIT Closed: <0.03V

198 JPT22-2 LIFT INHIB Voltage from S24 that indicates the Open: 4.8V; S24 VM
open/closed state of the switch. S24 is Closed: <0.03V
for lift limit when lift limit is selected in
FlashWare. The truck will not be able to
lift above this switch. If lift limit with
bypass is selected, S24 limits the height,
and S7, the Bypass Switch, will allow
further lifting.

199 JPT22-3 HOMESENSE Voltage that the VM uses to determine Off Metal: Home VM
on or off metal. 5.2V; Sensor Prox
On Metal:
0.03V

200 JPT22-4 180_LIM Voltage from S100 (180 in. Limit Open: 4.8V; S100 VM
Switch) that indicates the open/closed Closed: <0.03V
state of the switch.

201 JPT22-5 PRESS_SW 5V supply for the Pressure Switch 4.7V VM PRESS
(PRESS SW1). SW1

202 JPT22-6 TRVL CUTOUT Voltage from S27 that indicates the Open: 4.8V; S27 VM
open/closed state of the switch. Closed: <0.03V

203 JPT22-7 BRAKE Voltage from CCC to VM that indicates 6.1V released; S2 VM
DEADMAN the open/closed state of switch S2. 0.1V pressed

204 JPT22-8 CARRIAGE Voltage from CCC to VM that indicates 4.8V released; S23 VM
DEADMAN the open/closed state of switch S23. 0.1V pressed

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

205 JPT22-9 CHANNELA_4 Part of the steering position feedback Not Turning: Steer Motor VM
from the steer motor encoder when the either 0V or 5V; Encoder
drive unit is rotated. It is a square wave Turning either
signal identical to Channel B_4 but direction: 2.4V
different phase. The VM uses the phase
relationship of the two channels to
determine that the direction and speed
of the steering response is the same as
that requested.

206 JPT22-10 CHANNELB_4 Part of the steering position feedback Not Turning: Steer Motor VM
from the steer motor encoder when the either 0V or 5V; Encoder
drive unit is rotated. It is a square wave Turning either
signal identical to Channel A_4 but direction: 2.4V
different phase. The VM uses the phase
relationship of the two channels to
determine that the direction and speed
of the steering response is the same as
that requested.

207 JPT22-11 DGND B– for the Home Sensor Prox. <0.5V Home VM
Sensor Prox

208 JPT22-12 Not Used

209 JPT22-13 FLOW_A Square waves generated whenever Approx. 2.7V Flow Sensor VM
there is movement of the turbine in the during lift at
flow sensor. The frequency varies 1/3 speed or
directly with the speed of the turbine greater;
that is driven by fluid flowing through >5V or <0.5V
the sensor. The VM uses the quadrature when stopped
phase relationship between Flow_A
and_B to determine flow direction and
speed to calculate carriage height.

210 JPT22-14 FLOW_B Square waves generated whenever Approx. 2.7V Flow Sensor VM
there is movement of the turbine in the during lift at
flow sensor. The frequency varies 1/3 speed or
directly with the speed of the turbine greater;
that is driven by fluid flowing through >5V or <0.5V
the sensor. The VM uses the quadrature when stopped
phase relationship between Flow_A
and_B to determine flow direction and
speed to calculate carriage height.

211 JPT22-19 FU1_SENSE B+ when there is not an open between Closed: B+; PC1 VM
battery positive and PC1. This voltage is Open: voltage
used by the VM to determine the state of drops very
FU1 and the PC1 contactor tips. slowly

212 JPT22-20 FU3 SENSE B+ when there is not an open between Closed: B+; PC2 VM
B+ and PC2. This voltage is used by the Open: voltage
VM to determine the state of FU3 and drops slowly to
the LPC contactor tips (DC lift only). 0V

213 JPT22-21 EPO_SENSE Sense wire used by the VM to determine EPO closed: B+; EPO VM
when the EPO is open. This is used to EPO open:
initiate braking and display a message. <0.5V

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

214 JPT22-22 RAIL_SEN Read by the VM to determine if the lift closed:<1V; S15 VM
truck is in or out of the rail. The VM open: approx.
communicates lift truck position to the 10V
CCC, limiting travel speed based on lift
truck location and position of the
Auto/Manual switch. When the lift truck
is in the rail, S15 is closed.

215 JPT24-1 +12VP 12V supply for S100 (180 in. Limit 10.8-13V S100 VM
Switch).

216 JPT24-3 DGND Return path for S24 (Lift Inhibit Switch). <0.5V S24 VM

217 JPT24-5 DGND Return path for S15 (Rail Sense Switch). <0.5V S15 VM

218 JPT24-6 DGND Return path for S27 (Travel Cutout <0.5V S27 VM
Switch).

219 JPT24-7 DGND Return path for S100 (180 in. Limit <0.5V S100 VM
Switch).

220 JPT24-8 DGND Return path for S46A and S46B (Aisle <0.5V S46A and VM
Detect Sensors). S46B

221 JPT24-9 DGND Return path for S47A and S47B (Aisle <0.5V S47A and VM
Detect Sensors). S47B

222 JPT24-10 DGND Return path for Pressure Transducer A. <0.5V Pressure VM
transducer

223 JPT24-11 DGND Return path for the intellispeed Flow <0.5V Flow Sensor VM
Sensor.

224 JPT24-16 Not Used

225 JPT24-18 P/T_A Analog DC voltage that varies directly 1V with forks Pressure VM
with the weight on the carriage. fully lowered Transducer
Approx. 0.5V per 1000 lbs. (454 kg). It
is necessary to have the VM supply
approx. 12V as well as DGND in order
for the transducer to function correctly.

226 JPT24-19 FS_TEMP Variable voltage that is representative of 0.2-4.86V; Flow Sensor VM
the temperature of the fluid in the lift approx. 3.2V
system. @86°F

227 JPT24-24 BATTERY_ B+ present when the battery is plugged B+ (there should TP1 VM
SENSE_IN in. It is supplied through a thermistor on be no voltage
the Relay Control Fuse Panel. This is drop)
used by the VM to determine that the
correct battery is connected. It will
accept between 28 and 45V (36V
Battery) or 18 and 30V (24V Battery). If
the correct battery is sensed, Relay
Enable is energized during start-up.
After start-up, this voltage is used to
determine BSOC.

8-36 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

228 JPTA1-1 B+K3 B+ present when K3 is energized. This B+ w/K3 K3 TPA

is used to power the control circuits of energized
the TPA.

229 JPTA1-6 TPC Control path for the TPC. The TPA TPC TPA TPC
CONTACTOR supplies a path for B– for the contactor de-energized:
by way of the B– terminal. B+
energized:
14.7V

230 JPTA1-7 DGND Return path for the bearing encoder in <0.5V Travel TPA
the traction motor. Velocity
Sensor

231 JPTA1-8 T TEMP+ Analog voltage that varies with the Approx. 1V Traction TPA
traction motor temperature. Used by the @75°F (24°C) Motor Temp.
TPA to adjust motor performance. Sensor

232 JPTA1-11 ID0 Not Used by the Traction Power Amp.

233 JPTA1-12 ID1 B+ present at the TPA with K3 tips B+ w/K3 K3 TPA
energized. It is used as an identifier to energized
determine correct connection.

234 JPTA1-13 B+K3 B+ for the TPC. The TPA supplies B+ for B+ TPA TPC
the TPC.

235 JPTA1-14 Not Used

236 JPTA1-23 BUS+ The wire that carries the positive 3V CCC TPA, VM
component of the digital
communications between the TPA, VM,
and CCC.

237 JPTA1-25 Not Used

238 JPTA1-26 T VEL SENSOR + 5V supply to the bearing encoder on the 4.95V TPA Travel
traction motor. This voltage is produced Velocity
by the Traction Power Amp from B+K3. Sensor

239 JPTA1-28 Not Used

240 JPTA1-29 Not Used

241 JPTA1-31 T VEL PHASE A This is generated when there is Motor Travel TPA
movement of the bearing encoder in the Stationary: Velocity
traction motor. It is a square wave that is 4.06 or 0.03V; Sensor
either high (>3V) or low (<1V). The Turning: 2.3V
frequency varies directly with the speed
of the traction motor. Identical to T VEL
Phase B, except for phase. The TPA uses
the relationship between phase A and B
to determine travel speed and direction.

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Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

242 JPTA1-32 T VEL PHASE B This is generated when there is Motor Travel TPA
movement of the bearing encoder in the Stationary: Velocity
traction motor. It is a square wave that is 4.06 or 0.03V; Sensor
either high (>3V) or low (<1V). The Turning: 2.3V
frequency varies directly with the speed
of the traction motor. Identical to T VEL
Phase A, except for phase. The TPA uses
the relationship between phase A and B
to determine travel speed and direction.

243 JPTA1-35 BUS– The wire that carries the negative 2.3V CCC TPA, VM
component of the digital
communications between the TPA, VM,
and CCC.

244 JS27-2 OTM Cable Spare Over-The-Mast wire for future B– VM Option
option.

245 LPA (+) LPA B+ B+ to the LPA used to produce the AC B+ with LPC LPC LPA
phases U,V, and W when the LPC is closed
closed to power the lift motor.

246 LPA (–) LPA B– B– from TP4 on the power panel. It is <0.5V TP4 LPA
used for the power circuits on the LPA.
Without B–, U, V, and W cannot be
produced and the lift motor will not turn.

247 LPA (U) Lift Motor Phase One of three phases from the LPA to the VAC between LPA Lift Motor
U Lift Motor. This AC voltage is produced two phases:
by the LPA and is dependent on B+ at Stationary:
the + terminal and B– on the LPA. This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full RPM. Stall: approx.
4VAC

248 LPA (V) Lift Motor Phase One of three phases from the LPA to the VAC between LPA Lift Motor
V Lift Motor. This AC voltage is produced two phases:
by the LPA and is dependent on B+ at Stationary:
the + terminal and B– on the LPA. This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full RPM. Stall: approx.
4VAC

249 LPA (W) Lift Motor Phase One of three phases from the LPA to the VAC between LPA Lift Motor
W Lift Motor. This AC voltage is produced two phases:
by the LPA and is dependent on B+ at Stationary:
the + terminal and B– on the LPA. This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full RPM. Stall: approx.
4VAC

250 PC12-1 B+F (SPARE) B+ power for optional Work Lights or RF B+ wrt TP4 Fuse/Relay Work
Unit. Present when the battery is w/battery Card Lights and
connected. It is fused through FU5 on connected RF Unit
the Fuse/Relay Card.

8-38 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

251 PC12-2 B–F (SPARE) B– power for optional Work Lights or RF <0.3V wrt TP4 Fuse/Relay Work
Unit. Present when the battery is Card Lights and
connected. It is fused through FU6 on RF Unit
the Fuse/Relay Card.

252 TPA (+) TPA B+ B+ to the TPA used to produce the AC B+ w/TPC B+ from TPC TPA
phases U, V and W when the TPC is closed
closed to power the traction motor.

253 TPA (B–) TPA B– B– from TP4 on the power panel. It is <0.5V TP4 TPA
used for the power circuits on the TPA.
Without B–, U, V and W cannot be
produced and the traction motor will not
turn.

254 TPA (U) Traction Motor One of three phases from the TPA to the VAC between TPA Traction
Phase U traction motor. This AC voltage is two phases: Motor
produced by the TPA and is dependent Stationary:
on B+ at TPA (+) and B– at TPA (B–). This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full acceleration. Stall: approx.
4VAC

255 TPA (V) Traction Motor One of three phases from the TPA to the VAC between TPA Traction
Phase V traction motor. This AC voltage is two phases: Motor
produced by the TPA and is dependent Stationary:
on B+ at TPA (+) and B– at TPA (B–). This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full acceleration. Stall: approx.
4VAC

256 TPA (W) Traction Motor One of three phases from the TPA to the VAC between TPA Traction
Phase W traction motor. This AC voltage is two phases: Motor
produced by the TPA and is dependent Stationary:
on B+ at TPA (+) and B– at TPA (B–). This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full acceleration. Stall:
approx. 4VAC

Publication: 1031794/001E, Revised: 04 Dec 2019 8-39

Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual

Pin-Out Matrix

8-40 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section A. Appendix

Section A. Appendix

Publication: 1031794/001E, Revised: 04 Dec 2019 A-1

Section A. Appendix Models 5400/5500/5600 Maintenance Manual

Lubrication Specification Chart

Lubrication Specification Chart

Approved Raymond Lubricants

Where Used Type Specification Raymond Part Number

75W-90 Synthetic
Drive Unit Gear Case Gear 990-655/001 (1 qt./0.9 liters)
Gear Oil
(all applications) Lubricant 990-655/003 (1 gal./3.8 liters)
API Service GL-5

Hydraulic Reservoir 990-616/04 (1 qt./0.9 liter)

(Non-CS trucks) 990-616/01 (1 gal./3.8 liters)
Hydraulic Fluid ISO 46
+50° to +120°F 990-616/02 (2 gal./7.6 liters)
(+10° to +49°C) 990-616/03 (5 gal./18.9 liters)

Hydraulic Reservoir
(CS trucks - in and out of
1266010
freezer) Hydraulic Fluid ISO VG 32
Note: Do not add any additives.
0° to +80°F
(–18° to +27°C)

Hydraulic Reservoir
(Freezer trucks) 990-618/TX1 (1 gal./3.8 liters)
Hydraulic Fluid MIL-H-5606E
–20° to +32°F 990-618/01 (1 gal./3.8 liters)
(–29° to 0°C)

NOTE: For ambient temperature ranges of 0° to +32°F (-18° to 0°C) and +50° to +80°F (+10° to +27°C),
specific environmental, application, and operating conditions should be considered when selecting a
hydraulic fluid.

Mast Uprights, Bearings,

and so forth
(all-weather) Grease NLGI 2 1012992
–20° to +120°F
(–29° to +49°C)

High Performance/
1151877/001 (Rexoil)
Lift Chains High Load Chain Aerosol
1151877/002 (Rocol)
Spray

Steering Reducer Grease NLGI 2 1012992

A-2 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section A. Appendix

Thread Adhesives, Sealants, and Lubricants

Thread Adhesives, Sealants, and Lubricants

Loctite*
Raymond P/N Application
Number/Color

990-403 Thread-locking 1/4 in. and below 222/Purple

990-411 Anaerobic Gasket Maker 518

990-445 Cold Storage Silicone Sealing Compound

990-452 Anti-Seize Lubricant, Heavy Duty High Temperature

990-463 Thread-locking 1 in. and under, contamination tolerant 603/Green

990-533 Thread-locking Primer T7471

990-538 Thread-locking Cleaner 707

990-544 Thread-locking 1 in. and under 271/Red

990-552 Hydraulic Sealant 569

990-556 Gasket Sealant Compound

990-571 Thread-locking 1 in. and over 277/Red

990-638 Molybdenum Anti-Seize Compound (Molykote) /Silver

990-644 Corrosion Inhibitor Coating

990-659 RTV Silicone Sealant 5900/Black

990-666 Thread-locking Primer 7649 (19269)

990-669 Thread-locking, primerless high strength 2760

243 or 2440
1013829 Thread-locking 1/4 to 3/4 in. medium strength
7242 (Cyberbond)

Note: *Loctite is a registered trademark of the Loctite Corporation. Brand endorsement is not implied
here, but listed only as a commonly identified product.

Publication: 1031794/001E, Revised: 04 Dec 2019 A-3

Section A. Appendix Models 5400/5500/5600 Maintenance Manual

Component Specific Service/Torque Chart

Component Specific Service/Torque Chart

Thread-Locking Torque to:
Compound (use Dry values for hardware with
pre-applied thread-locking compound)
(not applicable if using
Component Sub-Component(s) hardware with
pre-applied Lubricated Dry
thread-locking
compound) ft. lb. (Nm) ft. lb. (Nm)

Adjust the switch so it is flush with outside

switch
Battery Gate edge.

bracket P/N 1013829 8 (11.3) 11 (15.1)

Brake traction motor P/N 1013829 12 (16)

Drive Unit - Standard mounting bolts P/N 1013829 180 (244)

N/A
250 to 275
Drive Unit - Heavy Duty mounting bolts P/N 1013829
(339 to 373)

Drive Unit Housing Cover mounting bolts P/N 1013829 16 (22) 17 (23)

Drive Wheels mounting bolts N/A 170 (230)

Finger tighten, then use socket to tighten an

EPO N/A
additional 1/4 turn.

Refer to “Torque Chart - Thread-Forming

Horn N/A
Screws” on page A-12
threaded end caps 200 (271)

Lift Cylinders bleed screws N/A 40 in. lb. (4.5)

staging screws 60 in. lb. (6.8)

mounting bolts P/N 1013829 20 (27) 27 (37)

Top Nut:
Lift Motor - AC - Apply anti-seize 17 to 18.4
compound (P/N 990-638) to pump (23 to 25)
spline and mating surfaces. power cables N/A
Bottom Nut:
10.7 to 11
(14.5 to 15)

mounting bolts P/N 1013829 20 (27) 27 (37)

Top Nut:
Lift Motor - DC - Apply anti-seize 8.3 to 10
compound (P/N 990-638) to pump (11.3 to 13.6)
spline and mating surfaces. power cables N/A
Bottom Nut:
11.7 to 13.3
(15.8 to 18.1)

Lift Pump - AC - Apply anti-seize

compound (P/N 990-638) to pump mounting bolts P/N 1013829 49 (67) 66 (90)
spline and mating surfaces.

A-4 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section A. Appendix

Component Specific Service/Torque Chart

Thread-Locking Torque to:

Compound (use Dry values for hardware with
pre-applied thread-locking compound)
(not applicable if using
Component Sub-Component(s) hardware with
pre-applied Lubricated Dry
thread-locking
compound) ft. lb. (Nm) ft. lb. (Nm)

Lift Pump - DC - Apply anti-seize

compound (P/N 990-638) to pump mounting bolts P/N 1013829 15 (20) 19 (26)
spline and mating surfaces.

mounting bolts P/N 1013829 8 (11.3) N/A

Manifold 35 - 40
valves N/A
(48 - 54)

mounting bolts, rear N/A N/A 22 (30)

Platform Extensions
mounting bolts, front N/A N/A 21 (28)

mounting bolts P/N 1013829 8 (11.3) 11 (15.1)

Power Amplifiers
power cables 8.3 (11.3)

Top Nut:
40 to 50 in.lb.
N/A (4.5 to 5.6)
power cable
Steer Motor Bottom Nut:
50 to 60 in.lb.
(5.6 to 6.8)

mounting bolts P/N 1013829 15 (20) N/A

Steer Reference (Home) Proximity bracket mounting

P/N 1013829 6 (8.2) N/A
Sensor screws (qty 2)

A minimum pressure of 5 tons (4536 kg) is required to press on a new

Tire Replacement
tire. If the minimum pressure is not met, replace the hub.

mounting bolts P/N 1013829 21 (28) 28 (38)

Top Nut:
12.5 to 18.4
Traction Motor (23 to 25)
power cables
Bottom Nut:
N/A 10.7 to 11
(14.5 to 15)

hex head bolts 170 (230)

Tractor-to-Mast
socket flathead bolts 130 (176)

Publication: 1031794/001E, Revised: 04 Dec 2019 A-5

Section A. Appendix Models 5400/5500/5600 Maintenance Manual

Torque Chart - Hydraulic Fittings

Torque Chart - Hydraulic

Fittings
JIC SAE Straight Thread Steel Plugs
SAE
Thread (37° Flare Thread)
Dash Hollow Hex Head Plug HP50N Hex Head Plug P50N
Size
Size
ft. lb. Nm ft. lb. Nm ft. lb. Nm

-2 5/16-24 3 ±1 4 ±1 3 ±0.5 4 ±0.6 7.5 ±0.5 10 ±0.6

-3 3/8-24 6 ±1 8 ±1 5 ±0.5 7 ±0.6 14 ±1 19 ±1

-4 7/16-20 12 ±1 16 ±1 11 ±1 15 ±1 18 ±1 24 ±1

-5 1/2-20 15 ±1 20 ±1 15 ±1 20 ±1 22 ±1 30 ±1

-6 9/16-18 21 ±1 28 ±1 18 ±1 24 ±1 27 ±2 37 ±3

-8 3/4-16 45 ±2 61 ±3 46 ±2 62 ±3 48 ±2 65 ±3

-10 7/8-14 60 ±5 81 ±7 75 ±5 102 ±7 90 ±5 122 ±7

-12 1 1/16-12 85 ±5 115 ±7 85 ±5 115 ±7 110 ±5 149 ±7

-14 1 3/16-12 105 ±5 142 ±7 130 ±6 176 ±8 145 ±6 197 ±8

-16 1 5/16-12 120 ±5 163 ±7 135 ±6 183 ±8 160 ±6 217 ±8

-20 1 5/8-12 170 ±10 230 ±14 225 ±12 305 ±16 225 ±12 305 ±16

-24 1 7/8-12 200 ±15 271 ±20 250 ±12 339 ±16 250 ±12 339 ±16

-32 2 1/2-12 270 ±20 366 ±27 325 ±15 441 ±20 325 ±15 441 ±20

A-6 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section A. Appendix

Torque Chart - Straight Thread Face Seal O-Rings

Torque Chart - Straight Thread Face Seal O-Rings

SAE Dash Tube Size
ft. lb. Nm
Size Thread Size

-4 9/16-18 18 ±1 24 ±1

-6 11/16-18 27 ±2 37 ±3

-8 13/16-16 40 ±2 54 ±3

-10 1-14 63 ±3 85 ±4

-12 1 3/16-12 90 ±4 122 ±5

-14 1 5/16-32 95 ±6 129 ±8

-16 1 7/16-12 120 ±8 163 ±11

-20 1 11/16-12 140 ±8 190 ±11

-24 2-12 165 ±8 224 ±11

-32 2 1/2-12 360 ±10 488 ±14

Publication: 1031794/001E, Revised: 04 Dec 2019 A-7

Section A. Appendix Models 5400/5500/5600 Maintenance Manual

Torque Chart - Standard (Ferrous)

Torque Chart - Standard (Ferrous)

Grade
None
Marking

SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 7 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque Tightening Torque
Size
Dry** Oiled* Dry** Oiled* Dry** Oiled* Dry** Oiled*
in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm
4-40 5 0.56 4 0.45 8 0.9 6 0.68 11 1.5 8 0.9 12 1.4 9 1.0
4-48 6 0.68 5 0.56 9 1.0 7 0.8 12 1.4 9 1.0 13 1.5 10 1.1
6-32 10 1.1 8 0.9 16 1.8 12 1.4 20 2.2 15 1.7 23 2.6 17 1.9
6-40 12 1.4 9 1.0 18 2.0 13 1.5 22 2.5 17 1.9 25 2.8 19 2.1
8-32 19 2.1 14 1.6 29 3.3 22 2.5 36 4.1 27 3.0 41 4.6 31 3.5
8-36 20 2.2 15 1.7 31 3.5 23 2.6 38 4.3 29 3.3 44 5.0 33 3.7
10-24 27 3.0 21 2.4 42 4.8 32 3.6 52 5.9 39 4.4 60 6.8 45 5.1
10-32 31 3.5 24 2.7 48 5.4 36 4.1 60 6.8 45 5.1 68 7.7 51 5.8
1/4-20 66 7.5 49 5.5 100 11.3 76 8.6 125 14.1 94 10.6 143 16.2 107 12.1
1/4-28 75 8.5 56 6.3 120 13.6 87 9.8 143 16.2 107 12.1 164 18.5 123 13.9
ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm
5/16-18 11 15.1 8 10.9 17 23.0 13 18 21 29 16 22 25 34 18 24
5/16-24 12 16.3 9 12.2 19 26 14 19 24 33 18 24 25 34 20 27
3/8-16 20 27 15 20 30 41 23 31 40 54 30 41 45 61 35 47
3/8-24 23 31 17 23 35 47 25 34 45 61 30 41 50 68 35 47
7/16-14 32 43 24 33 50 68 35 47 60 81 45 61 70 95 55 75
7/16-20 35 47 25 34 55 75 40 54 70 95 50 68 80 109 60 81
1/2-13 50 68 35 47 75 102 55 75 95 129 70 95 110 150 80 109
1/2-20 55 75 40 54 85 115 65 88 105 143 80 109 120 163 90 122
9/16-12 70 95 50 68 110 150 80 109 135 183 100 136 150 203 110 150
9/16-18 80 109 60 81 120 163 90 122 150 203 110 150 170 231 130 177
5/8-11 95 129 70 95 150 203 110 150 190 258 140 190 220 298 170 231
5/8-18 110 150 85 115 170 231 130 177 210 285 160 217 240 326 180 244
3/4-10 170 231 130 177 260 353 200 272 330 448 240 326 380 515 280 381
3/4-16 190 258 140 190 300 407 220 298 370 502 280 381 420 569 320 434
7/8-9 170 231 125 169 430 583 320 434 530 719 400 544 600 813 460 624
7/8-14 185 252 140 190 470 637 350 475 580 786 440 598 660 895 500 680
1-8 250 339 190 258 650 881 480 651 800 1085 600 813 900 1224 680 925
1-12 275 373 205 278 700 949 520 705 860 1166 660 895 1000 1360 740 1003
1 1/8-7 350 475 270 366 800 1085 600 813 1120 1519 840 1139 1280 1136 960 1302
1 1/8-12 400 544 300 407 880 1193 660 895 1260 1708 940 1274 1440 1952 1080 1464
1 1/4-7 500 680 375 509 1120 1523 840 1139 1580 2142 1200 1627 1820 2468 1360 1884
1 1/4-12 550 746 420 569 1240 1681 920 1247 1760 2386 1320 1790 2000 2720 1500 2034
1 3/8-6 650 881 490 664 1460 1980 1100 1491 2080 2820 1560 2115 2380 3227 1780 2413
1 3/8-12 750 1017 560 759 1680 2278 1260 1708 2380 3227 1780 2413 2720 3688 2040 2766
1 1/2-6 870 1180 650 881 1940 2630 1460 1980 2780 3769 2080 2820 3160 4298 2360 3200
1 1/2-12 980 1329 730 990 2200 2983 1640 2224 3100 4203 2340 3173 3560 4857 2660 3606
NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.
NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

A-8 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section A. Appendix

Torque Chart - Metric (Ferrous)

Torque Chart - Metric (Ferrous)

Ferrous Metric Bolts, Coarse Thread
(The grade rating is stamped on the head of the bolt.)
Grade 4.8 Grade 8.8 Grade 10.9 Grade 12.9
Size Dry** Oiled* Dry** Oiled* Dry** Oiled* Dry** Oiled*
in. in.
Nm Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm
lb. lb.

M1.6-0.35 0.8 0.09 0.6 0.07 1.6 0.18 1.2 0.14 2.2 0.25 1.7 0.19 2.6 0.30 2.0 0.22
M2-0.40 1.7 0.19 1.3 0.14 3.3 0.37 2.5 0.28 4.6 0.52 3.4 0.39 5.3 0.60 4.0 0.45
M2.5-0.45 3.5 0.40 2.6 0.30 6.7 0.76 5.1 0.57 9.3 1.1 7.0 0.79 11 1.2 8.2 0.93
M3-0.5 6.2 0.70 4.7 0.53 12 1.4 9 1.0 17 1.9 12 1.4 19 2.2 15 1.7
M3.5-0.6 9.8 1.1 7.3 0.83 19 2.1 14 1.6 26 3.0 20 2.2 31 3.5 23 2.6
M4-0.7 14 1.6 11 1.5 28 3.2 21 2.4 39 4.4 29 3.3 45 5.1 34 3.8
M5-0.8 29 3.3 22 2.5 57 6.4 42 4.8 78 8.9 59 6.6 91 10.4 69 7.8
ft. ft.
Nm Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm
lb. lb.

M6-1 – – – – 8 10.9 6 8.2 11 15.1 8 11.3 13 17.6 10 13.2

M8-1.25 – – – – 19 26 15 20 27 37 20 27 31 43 24 32
M8-1 – – – – 21 29 16 22 29 39 22 30 34 46 25 34
M10-1.5 – – – – 38 52 29 39 53 72 40 54 62 85 47 63
M10-1.25 – – – – 41 56 30 41 56 76 42 57 66 90 49 67
M12-1.75 – – – – 65 88 50 68 90 122 70 95 110 150 80 109
M12-1.25 – – – – 75 102 55 75 100 136 75 102 120 163 90 122
M14-2 – – – – 105 143 80 109 150 204 110 150 175 238 130 177
M14-1.5 – – – – 115 156 85 116 160 218 120 163 190 258 140 190
M16-2 – – – – 165 224 125 170 230 313 170 231 270 367 200 272
M16-1.5 – – – – 175 238 130 177 245 333 185 252 280 381 215 292
M20-2.5 – – – – 325 442 240 326 450 612 340 462 520 707 400 544
M20-1.5 – – – – 360 490 270 367 500 680 375 510 580 789 440 598
M24-3 – – – – 560 762 420 571 780 1061 580 789 900 1224 680 925
M24-2 – – – – 610 830 460 626 850 1156 640 870 1000 1360 740 1006
M30-3.5 – – – – 1120 1523 840 1142 1550 2108 1160 1578 1800 2448 1350 1836
M30-2 – – – – 1240 1686 920 1251 1700 2312 1280 1741 2000 2720 1500 2040
M36-4 – – – – 1950 2652 1460 1986 2700 3671 2000 2720 3160 4298 2350 3196
M36-2 – – – – 2200 2992 1640 2230 3000 4080 2250 3060 3500 4760 2650 3604
NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.
NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

Publication: 1031794/001E, Revised: 04 Dec 2019 A-9

Section A. Appendix Models 5400/5500/5600 Maintenance Manual

Torque Chart - Standard (Brass)

Torque Chart - Standard (Brass)

Brass MS63 Standard Bolts, Coarse Thread
Torque (with bolts oiled*)
Size
in. lb. Nm
0-80 0.5 0.05
1-64 0.9 0.10
1-72 1.0 0.11
2-56 1.5 0.17
2-64 1.6 0.18
3-48 2.3 0.26
3-56 2.5 0.28
4-40 3.3 0.37
4-48 3.6 0.40
5-40 4.8 0.54
5-44 5.3 0.60
6-32 6.1 0.69
6-40 6.8 0.77
8-32 11 1.24
8-36 11 1.24
10-24 14 1.58
10-32 17 1.92
12-24 23 2.59
12-28 25 2.82
1/4-20 35 3.96
1/4-28 40 4.52
5/16-18 73 8.25
5/16-24 81 9.15
3/8-16 130 14.69
3/8-24 147 16.61
NOTE: * Use “oiled” values for bolts with
thread-locking compound.

A-10 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section A. Appendix

Torque Chart - Metric (Brass)

Torque Chart - Metric (Brass)

Brass MS63 Metric Bolts, Coarse Thread

Diameter Torque (bolts oiled)

(in millimeters) in. lb. Nm

3 4.4 0.5

3.5 7.0 0.79

4 10 1.1

5 19 2.1

6 34 3.8

8 79 9

10 150 17

NOTE: * Use “oiled” values for bolts with

thread-locking compound.

Publication: 1031794/001E, Revised: 04 Dec 2019 A-11

Section A. Appendix Models 5400/5500/5600 Maintenance Manual

Torque Chart - Thread-Forming Screws

Torque Chart - Thread-Forming Screws

Standard Thread-Forming Screws
Torque
Size
in. lb. Nm
4-40 10 1.1
5-40 16 1.8
6-32 20 2.3
8-32 36 4
10-24 51 5.76
10-32 59 6.7
12-24 81 9.1
1/4-20 123 13.9
5/16-18 253 28.6
3/8-16 450 50.8
7/16-14 736 83.1
1/2-13 1000 113

Metric Thread-Forming Screws

Diameter Torque
(mm) in. lb. Nm
2.5 7 0.8
3 14 1.6
3.5 22 2.5
4 33 3.7
5 47 5.3
6 113 12.7
6.3 147 16.6
7 198 22.3
8 280 31.7
10 554 62.6
12 981 110.9

A-12 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section A. Appendix

Decimal Equivalent Chart

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 .397
1/32 .031 .03 .794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272

Publication: 1031794/001E, Revised: 04 Dec 2019 A-13

Section A. Appendix Models 5400/5500/5600 Maintenance Manual

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400

A-14 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section A. Appendix

Standard/Metric Conversions

Standard/Metric Conversions
To Convert... Multiply, Add, or Subtract...
Area
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Distance
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Mass
Ounces to Grams Ounces x 28.35
Grams to Ounces Ounces x 0.035
Ounces to Kilograms Ounces x 0.028
Kilograms to Ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to Pounds Kilograms x 2.2
Pressure
Pounds per Square Inch (PSI) to kiloPascals PSI x 6.894
kiloPascals to Pounds per Square Inch (PSI) kiloPascals x 0.145
Speed
Miles per hour to Kilometers per hour Miles per hour x 1.609
Kilometers per hour to Miles per hour Kilometers per hour x 0.6214
Temperature
Fahrenheit to Celsius (°F minus 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) plus 32
Torque
Inch Pounds (in. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lb.) Newton Meters x 0.737
Volume
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26

Publication: 1031794/001E, Revised: 04 Dec 2019 A-15

Section A. Appendix Models 5400/5500/5600 Maintenance Manual

Standard/Metric Conversions

A-16 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section I. Index

Index

Index 1K . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Section I. Index

2A . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
2E . . . . . . . . . . . . . . . . . . . . . . . . 6-21
A 2G . . . . . . . . . . . . . . . . . . . . . . . . 6-21
2H . . . . . . . . . . . . . . . . . . . . . . . . 6-21
2M . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Active Maintenance Mode . . . . . . 3-9, 3-27
2T . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
AMP Connectors . . . . . . . . . . . . . . . . 7-88
2U . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Analog Tests . . . . . . . . . . . . . 6-45 to 6-75
2V . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Antenna Cards . . . . . . . . . . . . . . . . . . 8-4
2W . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Audible Alarms . . . . . . . . . . . . . . . . . . 3-8
2X . . . . . . . . . . . . . . . . . . . . . . . . 6-23
2Y . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
B 42 . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
43 . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Battery 4C . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Cables . . . . . . . . . . . . . . . . . . . . . 7-70 4F . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Charging . . . . . . . . . . . . . . . . . . . 7-71 4G . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Checks . . . . . . . . . . . . . . . . . . . . . 4-6 4H . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Cleaning Exterior . . . . . . . . . . . . . 7-71 4K . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Maintenance . . . . . . . . . . . . . . . . 7-71 50 . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Safety . . . . . . . . . . . . . . . . . . . . . . 2-5 51 . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
State-of-Charge (BSOC) . . . . . 5-5, 7-71 56 . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Testing . . . . . . . . . . . . . . . . . . . . 7-71 59 . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Bearings 5A . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Mast, Shimming . . . . . .7-115 to 7-121 5B . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Bleeding Cylinders . . . . . . . . . . . . . .7-101 5E . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Brake 5G . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Adjustment . . . . . . . . . . . . . . . . . 7-63 5J . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Rotor Replacement . . . . . . . . . . . 7-64 5M . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Brushes . . . . . . . . . . . . . . . . . . . . . . 7-74 5P . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
BSOC (Battery State-of-Charge) . . 5-5, 7-71 61 . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Lift Cutout Adjustment . . . . . . . . . 5-5 63 . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Bulletins, Service . . . . . . . . . . . . . . . . 1-vi 64 . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
66 . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
C 67 . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6D . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6F . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Cables, Power . . . . . . . . . . . . . . . . . . 7-72
6K . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Carriage . . . . . . . . . . . . . . .7-112 to 7-114
6M . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Carriage Control Card Replacement . . 7-82
6N . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Caution, Definition . . . . . . . . . . . . . . . 2-2
6P . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Chains
7E . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Center Cylinder, 3-Stage . . . . . . .7-122
7F . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Inspection . . . . . . . . . . . . . . . . . . 4-11
7G . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Maintenance . . . . . . . . . . . . . . . . 4-11
7H . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Side Cylinders, 3-Stage . . . . . . . .7-122
7M . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Chains, Maintenance . . . . . . . . . . . . 4-11
7T . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Cleaning
7U . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Lift Truck . . . . . . . . . . . . . . . . . . . 2-4
7V . . . . . . . . . . . . . . . . . . . . . . . . 6-31
CODE . . . . . . . . . . . . . . . . . . . . . . . . 6-21
7W . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Code
7X . . . . . . . . . . . . . . . . . . . . . . . . 6-32
10 . . . . . . . . . . . . . . . . . . . . . . . . 6-20
7Y . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
1H . . . . . . . . . . . . . . . . . . . . . . . . 6-20

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Section I. Index Models 5400/5500/5600 Maintenance Manual

Index

80 . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Codes, Configuration . . . . . . . . . . . . . 3-32

81 . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Cold Storage . . . . . . . . . . . . . . . . . . . 3-31
83 . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Heater Assemblies . . . . . . . . . . . . 3-31
84 . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Communication Error Code
88 . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Troubleshooting . . . . . . . . . . . . . . 5-25
8C . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Commutator, Motor . . . . . . . . . . . . . . 5-10
8F . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Component Locator Photos . . . . 7-5 to 7-10
8L . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Configuration Codes . . . . . . . . . . . . . . 3-32
91 . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Configure Mode . . . . . . . . . . . . . . . . . . 3-9
92 . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Connector
93 . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Battery . . . . . . . . . . . . . . . . . . . . . 7-70
94 . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Connectors
9A . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 AMP . . . . . . . . . . . . . . . . . . .7-87, 7-88
9B . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 General . . . . . . . . . . . . . . . ..... 7-86
9E . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Molex . . . . . . . . . . . . . . . . . ..... 7-87
9F . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Power Amp . . . . . . . . . . . . . ..... 7-91
9G . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Repair . . . . . . . . . . . . . . . . ..... 7-86
9H . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Contactor Test
9J . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 PC . . . . . . . . . . . . . . . . . . . . . . . 6-128
9K . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Contactor Test, P . . . . . . . . . . . . . . . 6-129
A0 . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Contactor Tip Inspection . . . . . . . . . . 4-12
A2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Control Handle
A4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Cleaning . . . . . . . . . . . . . . . . . . . . 7-25
AH . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Inspection . . . . . . . . . . . . . . . . . . 7-25
AL . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Installation . . . . . . . . . . . . . . . . . . 7-26
AP . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Lift/Lower Knob . . . . . . . . . . . . . . 7-25
AT . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Removal . . . . . . . . . . . . . . . . . . . . 7-21
F8 . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Repair/Replacement
FE . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Procedures . . . . . . . . . 7-21 to 7-26
FG . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Soldering Procedures . . . . ...... 7-26
FH . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Travel Pot Repair/Replace ...... 7-23
FN . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Control Handle Assembly . . . . ...... 7-81
FP . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Conversion
FT . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Decimal to Fraction . . . . . . . . . . . A-13
G0 . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Fraction to Decimal . . . . . . . . . . . A-13
G2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Conversions, Standard/Metric . . . . . . A-15
G3 . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Cylinder
G4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Storage Preparation . . . . . . . . . . . 3-32
G5 . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Cylinders
G7 . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Bleeding . . . . . . . . . . . . . . . . . . . 7-101
GD . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Center . . . . . . . . . . . . . . . . . . . . 7-108
GE . . . . . . . . . . . . . . . . . . . . . . . . 6-42
GF . . . . . . . . . . . . . . . . . . . . . . . . 6-43 D
J2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
J4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
DC Motor
VC . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Brushes . . . . . . . . . . . . . . . . . . . . 7-74
X3 . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Troubleshooting . . . . . . . . . . . . . . 5-10
X4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
DC Motor Test . . . . . . . . . . . . . . . . . . 5-13
X5 . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
DC Motor Troubleshooting . . . . . . . . . 5-10
Codes
Deadman Pedal
Power Amplifier . . . . . . . . . . . . . . . .6-2
Pressed, Theory . . . . . . . . . . . . . . . 8-6
Codes and Messages . . . . . . . . . . . . . . .6-9
Rectangular . . . . . . . . . . . . . . . . . 7-27

I-2 Publication: 1031794/001E, Revised: 04 Dec 2019

Models 5400/5500/5600 Maintenance Manual Section I. Index

Index

Round . . . . . . . . . . . . . . . . . . . . . 7-27 G
Decals and Plates . . . . . . . . . . . . . . . 7-13
Decimal to Fraction Conversion . . . . . A-13 Ground Jack, ESD . . . . . . . . . . . . . . . . 2-8
Display Messages . . . . . . . . . . . . . . . . 3-7 Grounded DC Motor Test . . . . . . . . . . 5-13
Drive Tire . . . . . . . . . . . . . . . 7-67 to 7-68 Guidance Manager
Drive Unit Theory of Operation . . . . . . . . . . . . 8-4
Checks . . . . . . . . . . . . . . . . . . . . . 4-6 Guide Wire
Heavy Duty . . . . . . . . . . . . . . . . . 7-51 Learn Wirefreq . . . . . . . . . . . . . . . 3-21
Removal . . . . . . . . . . . . . . . 7-31, 7-51 Learning Wire Frequency . . . . . . . 3-21
Standard . . . . . . . . . . . . . . . . . . . 7-31
Troubleshooting . . . . . . . . . . . . . . 5-24
Drive Wheel . . . . . . . . . . . . . . 7-67 to 7-68 H

Harness
E
Connectors . . . . . . . . . . . . . . . . . . 7-86
Soldering Procedures . . . . . . . . . . 7-86
Electrostatic Discharge Heater Assemblies . . . . . . . . . . . . . . . 3-31
See Static Precautions High Pressure Relief Valve Adjustment 7-99
Emergency Lower Valve . . . . . . . . . . . 2-11 Home Proximity Sensor
Emergency Lower Valve, Theory . . . . 8-10 Adjustment . . . . . . . . . . . . . . . . . . 7-20
End-of-Aisle Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Code J2 . . . . . . . . . . . . . . . . . . . . 5-27 Hydraulic
EPROM Bleeding Cylinders . . . . . . . . . . . 7-101
Removal/Replacement . . . . . . . . . 7-84 Flow Sensor Service Notes . . . . . . . 7-96
Error Messages System Storage Preparation . . . . . 3-32
Power Amplifier . . . . . . . . . . . . . . . 6-2 Hydraulic Components
ESD Ground Jack . . . . . . . . . . . . . . . . 2-8 Center Cylinder . . . . . . . . . . . . . . 7-108

F I
Fault Codes IETM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Power Amplifier . . . . . . . . . . . . . . . 6-2 Input Tests . . . . . . . . . . . . . . 6-77 to 6-123
Filter Card Inspection
Theory of Operation . . . . . . . . . . . . 8-4 Battery Connector . . . . . . . . . . . . . 7-70
FlashWare Motor Brushes . . . . . . . . . . . . . . . 7-74
Starting . . . . . . . . . . . . . . . . . . . . 3-28 Wiring/Harness . . . . . . . . . . . . . . 7-86
FlashWare Program . . . . . . . . . . . . . . 3-28 Installation . . . . . . . . . . . . . . . . . . . . . . 3-7
Flow Sensor . . . . . . . . . . . . . . . . . . . 7-96 Interactive Electronic Technical Manuals 1-3
Assembly . . . . . . . . . . . . . . . . . . . 7-98
Disassembly . . . . . . . . . . . . . . . . 7-97
O-Ring Replacement . . . . . . . . . . 7-96 L
Forks
Checks . . . . . . . . . . . . . . . . . . . . . 4-7 L/L Pot Test . . . . . . . . . . . . . . . . . . . . 6-47
Installation . . . . . . . . . . . . . . . . .7-125 Learn
Removal . . . . . . . . . . . . . . . . . . .7-125 Controls . . . . . . . . . . . . . . . . . . . . 3-19
Fraction to Decimal Conversion . . . . . A-13 Guide Wire Offsets . . . . . . . . . . . . 3-21
Fuse Relay Card . . . . . . . . . . . . . . . . . 8-5 Ht/Wt . . . . . . . . . . . . . . . . . . . . . . 3-19
Fuse/Relay Card Mode . . . . . . . . . . . . . . . . . . . . . . . 3-9
Troubleshooting . . . . . . . . . . . . . . 5-21 When to Run . . . . . . . . . . . . . . . . 3-20
Wirefreq . . . . . . . . . . . . . . . . . . . . 3-21
LEDs
Wire Guidance . . . . . . . . . . . . . . . . 3-7

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Section I. Index Models 5400/5500/5600 Maintenance Manual

Index

Lift Microprocessor Removal/Replacement 7-84

Motor . . . . . . . . . . . . . . . . . . . . . 7-102 Modes of Operation
Pump . . . . . . . . . . . . . . . . . . . . . 7-102 Program Mode . . . . . . . . . . . . . . . . 3-9
Lift Chain Run Mode . . . . . . . . . . . . . . . . . . . . 3-8
Adjustment . . . . . . . . . . . . . . . . . 7-129 Motor
Maintenance . . . . . . . . . . . . . . . . 7-129 Checks . . . . . . . . . . . . . . . . . . . . . . 4-8
Lift Chain Storage Preparation . . . . . . 3-32 Lift . . . . . . . . . . . . . . . . . . . . . . . 7-102
Lift Chains Storage Preparation . . . . . . . . . . . 3-32
3-Stage . . . . . . . . . . . . . 7-122 to 7-123 Motors . . . . . . . . . . . . . . . . . . 7-74 to 7-79
Maintenance . . . . . . . . . . . . . . . . . 4-11 AC
Lift Cylinder Bearing Encoder . . . . . . . . . . . 7-78
Three-Stage Center With Cushions Open Winding . . . . . . . . . . . . . 5-14
Cushion Replacement . . . . . . 7-108 Service . . . . . . . . . . . . . . . . . . 7-77
Seal Replacement . . . . . . . . . 7-110 Shorted Winding . . . . . . . . . . . 5-14
Service . . . . . . . . . . . . . . . . . 7-108 Temperature Sensor . . . . . . . . 7-77
Lift Power Amplifier . . . . . . . . . . . . . . . 7-80 Commutator . . . . . . . . . . . . . . . . . 5-10
Theory of Operation . . . . . . . . . . . . .8-4 DC . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Lift/Lower Field Winding Test . . . . . . . . . 5-13
Knob Installation/Adjustment . . . . 7-25 Grounded Motor Test . . . . . . . 5-13
System Theory . . . . . . . . . . . . . . . 8-10 Open Circuit Test . . . . . . . . . . 5-13
Valve . . . . . . . . . . . . . . . . . . . . . . 7-100 Short Circuited Armature . . . . 5-13
Lights Tests . . . . . . . . . . . . . . . . . . . . 5-13
Steering Indicator . . . . . . . . . . . . . .3-7 winding . . . . . . . . . . . . . . . . . . 5-13
Wire Guidance LEDs . . . . . . . . . . . .3-7 Power Cable Terminals . . . . . . . . . 7-74
Load Holding Valve . . . . . . . . . . . . . . 7-100 Troubleshooting
Load Wheels . . . . . . . . . . . . . . . . . . . 7-127 DC . . . . . . . . . . . . . . . . . . . . . 5-10
Locator Photos . . . . . . . . . . . . .7-5 to 7-10
Loctite® O
See Thread Adhesives
Lubrication Specification Chart . . . . . . .A-2
Open Circuit DC Motor Test . . . . . . . . 5-13
Open Winding AC Motor . . . . . . . . . . . 5-14
M Operator Display . . . . . . . . . . . . . . . . . 3-7
Steering Indicator Lights . . . . . . . . . 3-7
Maintenance Minder . . . . . . . . . . . . . . .4-3 Output Tests . . . . . . . . . . . 6-127 to 6-145
Disabling . . . . . . . . . . . . . . . . . . . . .4-4
Enabling . . . . . . . . . . . . . . . . . . . . .4-3 P
Maintenance Mode . . . . . . . . . . . 3-9, 3-26
Active . . . . . . . . . . . . . . . . . . 3-9, 3-27
Pallet Clamp . . . . . . . . . . . . . . . . . . 7-126
Static . . . . . . . . . . . . . . . . . . 3-9, 3-26
Password . . . . . . . . . . . . . . . . . . . . . . . 3-8
Mast
How to Change . . . . . . . . . . . . . . . 3-13
Bearing
Photos, Locator . . . . . . . . . . . . 7-5 to 7-10
Shimming . . . . . . . . 7-115 to 7-121
Pin Extraction
Inner Tele to Carriage . . . . 7-120
AMP Connectors . . . . . . . . . . . . . . 7-88
Main Frame to
Pin Insertion
Outer Telescopic . . 7-118
AMP Connectors . . . . . . . . . . . . . . 7-89
Outer Tele to Inner Tele . . 7-119
Pin-Out Matrix . . . . . . . . . . . . 8-19 to 8-39
Bearing Replacement
Power Amplifier
Upper . . . . . . . . . . . . . . . . . . 7-117
Connectors . . . . . . . . . . . . . .7-87, 7-91
Checks . . . . . . . . . . . . . . . . . . . . . .4-8
LED Diagnostics . . . . . . . . . . . . . . . 6-2
Disassembly . . . . . . . . . . . . . . . . 7-118
Replacement . . . . . . . . . . . . . . . . . 7-80
Messages and Codes . . . . . . . . . . . . . . .6-9
Power Amplifier Replacement . . . . . . . 7-80
Power Amplifier . . . . . . . . . . . . . . . .6-2

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Models 5400/5500/5600 Maintenance Manual Section I. Index

Index

Power Cables . . . . . . . . . . . . . . . . . . . 7-72 Special Tools . . . . . . . . . . . . . . . . . . . 7-12

Power Cables, Motor . . . . . . . . . . . . . 7-74 Specification Tag . . . . . . . . . . . . . . . . . 3-3
Pressure Switch Adjustment . . . . . . .7-103 Specifications, Vehicle . . . . . . . . . . . . . 3-3
Program Mode . . . . . . . . . . . . . . . . . . . 3-9 Standard/Metric Conversions . . . . . . . A-15
Configure Mode . . . . . . . . . . . . . . . 3-9 Static
LEARN . . . . . . . . . . . . . . . . . . . . . . 3-9 Precautions . . . . . . . . . . . . . . . . . . . 2-8
Maintenance . . . . . . . . . . . . . . . . . 3-9 Static Maintenance Mode . . . . . . 3-9, 3-26
Pump Steer Motor/Gearbox . . . . . . . . . . . . . 7-18
Lift . . . . . . . . . . . . . . . . . . . . . . .7-102 Encoder Bearing Replacement . . . . 7-18
Steering
R Indicator Lights . . . . . . . . . . . . . . . 3-7
Steering and Controls . . . . . . . . . . . . . 7-17
Storage
Relief Valve
Hydraulic Cylinders . . . . . . . . . . . 3-32
Adjustment . . . . . . . . . . . . . . . . . 7-99
Hydraulic System . . . . . . . . . . . . . 3-32
Run Mode . . . . . . . . . . . . . . . . . . . . . . 3-8
Lift Chains . . . . . . . . . . . . . . . . . . 3-32
Motors . . . . . . . . . . . . . . . . . . . . . 3-32
S Warranty Issues . . . . . . . . . . . . . . 3-32
SuperWord . . . . . . . . . . . . . . . . . . . . . . 3-8
Safety How to Change . . . . . . . . . . . . . . . 3-13
Battery . . . . . . . . . . . . . . . . . . . . . 2-5 Switch Adjustment . . . . . . . . . . . . . . . . A-4
Decals . . . . . . . . . . . . . . . . . . . . . 7-13 Switch Gap . . . . . . . . . . . . . . . . . . . . . . A-4
Definitions . . . . . . . . . . . . . . . . . . . 2-2 Switches
Emergency Lower Valve . . . . . . . . 2-11 Deadman Replacement . . . . . . . . . 7-27
ESD . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Pressure Switch Adjustment . . . . 7-103
General . . . . . . . . . . . . . . . . . . . . . 2-3 Tests
Static Precautions . . . . . . . . . . . . . 2-8 S10 . . . . . . . . . . . . . . . . . . . . 6-113
Welding . . . . . . . . . . . . . . . . . . . . 2-14 S11 . . . . . . . . . . . . . . . . . . . . . 6-80
Scheduled Maintenance S15 . . . . . . . . . . . . . . . . . . . . 6-109
360 Day . . . . . . . . . . . . . . . . . . . . 4-10 S2 . . . . . . . . . . . . . . . . . . . . . . 6-79
60 Day . . . . . . . . . . . . . . . . . . . . . 4-6 S21 . . . . . . . . . . . . . . . . . . . . . 6-95
Guidelines . . . . . . . . . . . . . 4-2 to 4-10 S23 . . . . . . . . . . . . . . . . . . . . . 6-78
Sealants, Specifications . . . . . . . . . . . . A-3 S24 . . . . . . . . . . . . . . . . . . . . . 6-83
Sensor S25 . . . . . . . . . . . . . . . . . . . . 6-121
Flow . . . . . . . . . . . . . . . . . . . . . . 7-96 S27 . . . . . . . . . . . . . . . . . . . . 6-112
Sensors S28 . . . . . . . . . . . . . . . . . . . . . 6-81
Home Prox Adjustment . . . . . . . . 7-20 S3 . . . . . . . . . . . . . . . . . . . . . . 6-84
Service Bulletins . . . . . . . . . . . . . . . . . 1-vi S4 . . . . . . . . . . . . . . . . . . . . . 6-110
Service/Torque Chart, S46 . . . . . . . . . . . . . . . . . . . . 6-117
Component Specific . . . . . . . . . . . . A-4 S47 . . . . . . . . . . . . . . . . . . . . 6-115
Shimming Mast Bearings . .7-115 to 7-121 S60 & 61 . . . . . . . . . . . . . . . . 6-111
Inner Tele to Carriage . . . . . . . . .7-120 S7 . . . . . . . . . . . . . . . . . . . . . . 6-82
Main Frame to Outer Telescopic . .7-118 System Architecture . . . . . . . . . . 8-2 to 8-5
Outer Tele to Inner Tele . . . . . . . .7-119 Systems
Shorted Winding AC Motor . . . . . . . . 5-14 Theory of Operation . . . . . . . . . . . . 8-3
Shorted Winding on AC Motor . . . . . . 5-14
Shorts to Frame Test . . . . . . . . . . . . . . 5-2 T
Skid Pads . . . . . . . . . . . . . . . . . . . . .7-128
Soldering Procedures . . . . . . . . . . . . . 7-86
Terminals, Motor Power Cable . . . . . . 7-74
Solenoid
Tests
Main Load Hold
A04 (VR1) . . . . . . . . . . . . . . . . . . . 6-46
Test . . . . . . . . . . . . . . . . . . . .6-130
A05 (VR2) . . . . . . . . . . . . . . . . . . . 6-47

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Section I. Index Models 5400/5500/5600 Maintenance Manual

Index

A08 (TM Temp) . . . . . . . . . . . . . . . 6-48 O40 (L/L Alarm) . . . . . . . . . . . . . 6-141

A09 (LM Temp) . . . . . . . . . . . . . . . 6-49 O41 (Aux Sel SOL) . . . . . . . . . . . 6-142
A10 (TPA Temp) . . . . . . . . . . . . . . . 6-50 O42 (Main Sel SOL) . . . . . . . . . . 6-143
A11 (TM Current) . . . . . . . . . . . . . 6-51 O43 (Aux Load Hold SOL) . . . . . . 6-144
A13 (Press Sensor) . . . . . . . . . . . . 6-52 Output . . . . . . . . . . . . . 6-127 to 6-145
A14 (VM +12V) . . . . . . . . . . . . . . . 6-53 Shorts to Frame . . . . . . . . . . . . . . . 5-2
A15 (Batt) . . . . . . . . . . . . . . . . . . . 6-54 Wire Guidance . . . . . . . . . . . . . . . 6-76
A19 (LPA Temp) . . . . . . . . . . . . . . . 6-55 Theory of Operation
A20 (LM Current) . . . . . . . . . . . . . 6-56 Antenna Cards . . . . . . . . . . . . . . . . 8-4
A22 (Traction Request) . . . . . . . . . 6-57 BSOC . . . . . . . . . . . . . . . . . . . . . . . 5-5
A23 (Lift Request) . . . . . . . . . . . . . 6-58 Carriage Control Card . . . . . . . . . . 8-3
A34 (L/L Current) . . . . . . . . . . . . . 6-59 Emergency Lower Valve . . . . . . . . 8-10
A35 (Brake) . . . . . . . . . . . . . . . . . . 6-60 Filter Card . . . . . . . . . . . . . . . . . . . 8-4
A37 (Steer PA Current) . . . . . . . . . 6-61 Fuse/Relay Card . . . . . . . . . . . . . . 8-5
A51 (Left Tractor Guidance Coil) . . 6-63 Guidance Manager . . . . . . . . . . . . . 8-4
A52 (Right Tractor Guidance Coil) . 6-65 Intellispeed . . . . . . . . . . . . . . . . . . . 8-5
A53 (Left Load Guidance Coil) . . . . 6-67 Lift Power Amplifier . . . . . . . . . . . . 8-4
A54 (Right Load Guidance Coil) . . . 6-69 Lift/Lower System . . . . . . . . . . . . 8-10
A55 (Tractor Near Wire Coil) . . . . . 6-71 Emergency Lower . . . . . . . . . . 8-10
A56 (Load Near Wire Coil) . . . . . . . 6-73 Hi-Pro . . . . . . . . . . . . . . . . . . . 8-11
Analog . . . . . . . . . . . . . . . . 6-45 to 6-75 Lower . . . . . . . . . . . . . . . . . . . 8-12
DC Motor . . . . . . . . . . . . . . . . . . . 5-13 Variable Speed DC Lift . . . . . . 8-10
I00 (S23) . . . . . . . . . . . . . . . . . . . . 6-78 Variable Speed with AC Lift . . . 8-11
I01 (S2) . . . . . . . . . . . . . . . . . . . . . 6-79 Operator Interface Card . . . . . . . . . 8-4
I02 (S11) . . . . . . . . . . . . . . . . . . . . 6-80 Pin-Out Matrix . . . . . . . . . 8-19 to 8-39
I03 (S28) . . . . . . . . . . . . . . . . . . . . 6-81 Steering . . . . . . . . . . . . . . . . . . . . . 8-8
I04 (S7) . . . . . . . . . . . . . . . . . . . . . 6-82 Systems Overview . . . . . . . . . . . 8-8
I05 (S24) . . . . . . . . . . . . . . . . . . . . 6-83 Systems Overview . . . . . . . . . . . . . . 8-3
I15 (S3) . . . . . . . . . . . . . . . . . . . . . 6-84 Traction Power Amplifier . . . . . . . . . 8-4
I38 (S21) . . . . . . . . . . . . . . . . . . . . 6-95 Vehicle Manager . . . . . . . . . . . . . . . 8-3
I65 (S15) . . . . . . . . . . . . . . . . . . . 6-109 Wire Guidance . . . . . . . . . . . . . . . 8-13
I66 (S4) . . . . . . . . . . . . . . . . . . . . 6-110 Systems Overview . . . . . . . . . . 8-14
I67 (S60 & 61) . . . . . . . . . . . . . . . 6-111 Thread Adhesives, Specifications . . . . . A-3
I68 (S27) . . . . . . . . . . . . . . . . . . . 6-112 Throttle Pot Test . . . . . . . . . . . . . . . . . 6-46
I69 (S10) . . . . . . . . . . . . . . . . . . . 6-113 Tie-Down for Transport . . . . . . . . . . . 2-12
I72 (S47) . . . . . . . . . . . . . . . . . . . 6-115 Tire, Drive . . . . . . . . . . . . . . . 7-67 to 7-68
I73 (S46) . . . . . . . . . . . . . . . . . . . 6-117 Tools, Special . . . . . . . . . . . . . . . . . . . 7-12
I74 (S25) . . . . . . . . . . . . . . . . . . . 6-121 Torque Chart
Input . . . . . . . . . . . . . . . . 6-77 to 6-123 Brass, Standard . . . . . . . . . . . . . . A-10
O00 (TPC) . . . . . . . . . . . . . . . . . . 6-128 Face Seal O-Rings . . . . . . . . . . . . . A-7
O02 (LPC) . . . . . . . . . . . . . . . . . . 6-129 Ferrous, Metric . . . . . . . . . . . . . . . . A-9
O11 (SOL1) . . . . . . . . . . . . . . . . . 6-130 Hydraulic Fittings . . . . . . . . . . . . . . A-6
O12 (Ramp L/L SOL) . . . . . . . . . . 6-131 Metric (Brass) . . . . . . . . . . . . . . . . A-11
O18 (Horn) . . . . . . . . . . . . . . . . . 6-132 Thread-Forming Screws . . . . . . . . A-12
O19 (Audible Alarm) . . . . . . . . . . 6-133 Towing . . . . . . . . . . . . . . . . . . . . . . . . 2-13
O20 (Travel Alarm) . . . . . . . . . . . 6-134 Traction Motor
O25 (2 Stage Select SOL) . . . . . . . 6-135 Power Cable Terminal Nuts . . . . . . 7-74
O28 (Ramp LM) . . . . . . . . . . . . . . 6-136 Traction Power Amplifier . . . . . . . . . . 7-80
O29 (Ramp TM) . . . . . . . . . . . . . . 6-137 LED Diagnostics . . . . . . . . . . . . . . . 6-2
O30 (Brake SOL) . . . . . . . . . . . . . 6-138 Theory of Operation . . . . . . . . . . . . 8-4
O32 - Toggle Relay Enable . . . . . . 6-139 Traction Power Amplifiers . . . . . . . . . . 7-80
O39 (OD Lights) . . . . . . . . . . . . . 6-140 Traction System

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Models 5400/5500/5600 Maintenance Manual Section I. Index

Index

Functional Operation . . . . . . . . 8-5, 8-6 LEDs . . . . . . . . . . . . . . . . . . . . . . . 3-7

Travel Pot (VR1) Replacement . . . . . . 7-23 Setup . . . . . . . . . . . . . . . . . . . . . . 3-30
Travel, Theory . . . . . . . . . . . . . . . . . . . 8-6 Tests . . . . . . . . . . . . . . . . . . . . . . . 6-76
Troubleshooting Wiring
Aisle Exit Error Code J2 . . . . . . . 5-27 Connectors . . . . . . . . . . . . . . . . . . 7-86
Chains . . . . . . . . . . . . . . . . . . . . . 4-11 Soldering Procedures . . . . . . . . . . 7-86
Communication Error Codes . . . . 5-25 Wrist strap, ESD . . . . . . . . . . . . . . . . . 2-8
DC motors
short-circuited winding . . . . . 5-13
Drive Unit . . . . . . . . . . . . . . . . . . 5-24
Electrical . . . . . . . . . . . . . . . . . . . . 5-2
Electrical Symptoms . . . . 5-33 to 5-34
Fuse/Relay Card . . . . . . . . . . . . . 5-21
Hydraulic Functions . . . . 5-29 to 5-31
Motors . . . . . . . . . . . . . . . 5-10 to 5-14
DC . . . . . . . . . . . . . . . . . . . . . 5-10
Pin-Out Matrix . . . . . . . . 8-19 to 8-39
Shorts to Frame Test . . . . . . . . . . . 5-2
Travel Functions . . . . . . . . . . . . . 5-32

Valve
High Pressure Relief
Adjustment . . . . . . . . . . . . . . 7-99
Valves
Emergency Lower . . . . . . . . . . . . 2-11
High Pressure Relief Adjustment . 7-99
Lift/Lower . . . . . . . . . . . . . . . . . .7-100
Load Holding . . . . . . . . . . . . . . . .7-100
Vehicle
Specifications . . . . . . . . . . . . . . . . 3-3
Vehicle Manager
Theory of Operation . . . . . . . . . . . . 8-3
VR1 Test . . . . . . . . . . . . . . . . . . . . . . 6-46
VR2 Test . . . . . . . . . . . . . . . . . . . . . . 6-47

Warning, Definition . . . . . . . . . . . . . . . 2-2

Warranty
Storage Issues . . . . . . . . . . . . . . . 3-32
Welding Safety . . . . . . . . . . . . . . . . . 2-14
Wheels
Drive . . . . . . . . . . . . . . . . 7-67 to 7-68
Load . . . . . . . . . . . . . . . . . . . . . .7-127
Wire Guidance . . . . . . . . . . . . . . . . . 3-30
End-of-Aisle Configurations . . . . . 8-15
End-of-Aisle Control, Theory . . . . 8-15
End-of-Aisle Magnet Installation . 8-16
End-of-Aisle Slow Down, Theory . 8-17

Publication: 1031794/001E, Revised: 04 Dec 2019 I-7

Section I. Index Models 5400/5500/5600 Maintenance Manual

Index

I-8 Publication: 1031794/001E, Revised: 04 Dec 2019

 1031794/001E
Printed by the Digital Print Center,
The Raymond Corporation, Greene, NY
 Schematics

Models Serial Numbers

5400 00100 and Up This publication applies to the all subsequent releases of this product until otherwise
indicated in new editions or bulletins. Changes occur periodically to the information in this
5500, 5600 00100 to 44000 publication.

If you need assistance with your lift truck, or to order additional copies of this document,
contact your local authorized Raymond Sales and Service Center. To locate your local
authorized Raymond Sales and Service Center, go to www.raymondcorp.com.

Publication: 1031794/001E Revised: 04 Dec 2019

©2019 The Raymond Corporation.

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Section A. Appendix

Figure 1. Power Distribution Diagram Sheet 1 (AC Lift)

Publication: 1031794/001E, Revised: 04 Dec 2019 2

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 2. Power Distribution Diagram Sheet 2 (DC Lift)

Publication: 1031794/001E, Revised: 04 Dec 2019 3

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 3. Electrical Schematic Sheet 1 (AC Lift)

A B C D E F G H
JPTA2 JPTA4 JPTA1 SEE SHEET 5, D6
MOTOR VELOCITY
JPTA1
NOTES: RED -1 -6 -26

JPS4-6
JPS4-5
TPC -6
T VEL SENSOR +
SEE PAGE 6. BLACK -4 -5 -7
CONTACTOR
TME T VEL SENSOR - -13

2 -31 TPC SUPPLY JPS25

WHITE -3 -4 (B+K3)
T VEL PHASE A -2
-2 -3 -32 -3
BLUE
T VEL PHASE B
CONTACTOR RED
JPTA3
-2 -8
-8
T TEMP+ -23
-6
-1
PANEL TMT RED/BLK -1 -7
BUS+
-35
-11 BUS-
TPC -1
MOTOR TEMPERATURE ID0
TP1 -2 -12
ID1
VEHICLE JPC11
2 1
SEE DETAIL D
MANAGER -1
+12V
B- -2 BUS-
SHEET 7 DETAIL A 11
-25

OVER THE MAST CABLE

-3 BUS+
1 +12V CURTIS TA
JPS25
LPC FU2 -28 AC TRACTION JPT22-7 -4 BRAKE DEADMAN -4
FU1 SEE SHEET 7 SERIAL Tx AMPLIFIER BRAKE DEADMAN BRAKE DEADMAN
2 (350A)
(100A) ZONE D4 -29 JPT22-8 -5 CARRIAGE DEADMAN -5
CARRIAGE DEADMAN CARRIAGE DEADMAN
SERIAL Rx JS27
TP2 FU3 TP5
JP U JS31-1 -1 -6
JPS1-2 (500A) U -1 DGND
B+
-1 X Y V B+K3 -2 -2
JPS1-8 TM
TP3 TPC V B+KEY +12V
-4
W +

3
-3 W -14 +5V
PROGRAM
DGND DGND CARRIAGE
JPS1-11 CONTROL
CARD
MOTOR VELOCITY JPLA2 JPLA4 JPLA1
JPLA1
RED -1 -6 -26
LPC -6
L VEL SENSOR + S124
CONTACTOR JPS57
+
-4 -5 -7 -3

LIFT DECEL
JPT20-8 -1
BLACK +12VP
LME L VEL SENSOR - -13 JPT4-3 -2 -2 0
WHITE -3 -4 -31 LPC SUPPLY
(B+K3)
LIFT DECEL S124
SEE SHEET 3
L VEL PHASE A DGND JPT18-7 -3 -1 -

JPSC2-2

JPSC1-2
-2 -3 -32 JPT14
BLUE
L VEL PHASE B -5
JPLA3 -8 +12VP
RED -2 -8
L TEMP+ -23 -11
LMT RED/BLK -1 -7 BUS+ BUS_I+
-35 -4
-11 BUS- BUS_I-
-1
MOTOR TEMPERATURE ID0 -3

JPSC1-1
JPSC2-1
-12 DGND
-2
ID1
DETAIL A 11
X Y JPS1-9
LPC B-
-25
+12V CURTIS LA
-28 AC LIFT

4 SERIAL Tx AMPLIFIER
-29 S10
JPS1-5 JPS1-10
SERIAL Rx SEE SHEET 7
JPT20-1 JPS8-1 -3
U ZONE G5 +12VF

120 IN. LIMIT

150 IN. LIMIT
U -1 JPT22-1 JPS8-2 -2
150_LIM S10
V B+K3
LM V 13
JPS8-3 -1
W +
JP W -14
B- PROGRAM

JPT6
TP4 TP2 -6
+12VP
MS+ -5
CCW_PWM JPT20
+ -2 -16
CW_PWM L/L L/L
MS SA -3
STEER_CURRENT -15
2 1
-4 (B+K2)B+L/L
DGND
- -1
MS- NEUTRAL_PULSE
TP4 JPT22
-19

5
FU1_SENSE
JPT14
-10
DGND
-2
DGND
-1
-8
-9 B-F

JPT22 JPA7

HOME SENSOR
-3 -1 0
HOMESENSE
JPF1-3

JPF1-5

JPF2-1

JPF1-6
JPF3-3

-11 -2 - HOME
DGND
-12
-11

SENSOR
-4
-5
-6
-7
-8

JPT20
+12VF -9 -3 + PROX

JPF3-1 T T HRN
FU6 (15A) -NEG JPT18
-2
-IN H-1 -16
1 2 H HORN
T K3 -POS H-2
JPF1-1
FU8 (15A/5A) JPF1-4
-2
1 2 JPF4-15
FU7 (15A/5A) K1 JPBR-2
JPF4-3 JPT20-7 JPE4-1 RED
JPF2-9 JPT20 +12VP

6 -4 1 2
JPF2-2
BRAKE
-1

11
-14
BRAKE CHANNELA_4
JPT22-9

-10
-3

-2
WHT
BLU
STEER
MOTOR
ENCODER
-3 DETAIL B CHANNELB_4
JPT18
-5 JPT10-9 -4 BLK JPC16
-10 DGND
L/H L/H -1 B+EPO
1 2 JPT14
JPF4-13 8 -6
-2 B-FU8
RELAY_ENABLE

OVER THE MAST CABLE

-3 B+FU7
-14 JPT22

FLASHWARE
JPT9 -4 B-FU6
-6 -21
EPO_SENSE TXD -2
K4 K3 K2 K1 JP10-1
-5 WARNING LIGHT RXD -3
-6 B+KEY
DGND -5
-12 -2
JPT14
-12 -8 B+FU5
-11
B+KEY

COMMUNICATIONS
JPT2
-8 VBUS -1
FU5 (15A)
-1 -10 D+ -2

USB
1 2 -3
JPT14 D-
K2 K4

AC LIFT
-2 JPF2-4 -7 DGND -4
B+K2
-6 -13 9
B+K2
-7 -14
B+K2
T JPF4-7 JPT24-24
BATTERY_SENSE_IN
JPF2-8

7 FUSE/ JPS26
-4
RELAY -2
CARD -3
-1
-6
-8
JPS30-1 JPS29-1

Publication: 1031794/001E, Revised: 04 Dec 2019 4

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 4. Electrical Schematic Sheet 2 (DC Lift)

A B C D E F G H
MOTOR VELOCITY JPTA2 JPTA4 JPTA1 SEE SHEET 5, D6
JPTA1
RED -1 -6 -26
TPC -6

JPS4-6
JPS4-5
T VEL SENSOR +
CONTACTOR
BLACK -4 -5 -7
TME T VEL SENSOR - -13

2 -31 TPC SUPPLY JPS25

WHITE -3 -4 (B+K3)
T VEL PHASE A -2
-2 -3 -32 -3
BLUE
T VEL PHASE B
CONTACTOR RED
JPTA3
-2 -8
-8
T TEMP+ -23
-6
-1
PANEL TMT RED/BLK -1 -7
BUS+
-35
-11 BUS-
TPC -1
MOTOR TEMPERATURE ID0
TP1 -2 -12 VEHICLE JPC11

JPSC1-1

JPSC1-2
ID1
1 2 MANAGER -1
+12V
B- -2 BUS-
DETAIL A 11
-25 -3 BUS+

OVER THE MAST CABLE

1 +12V CURTIS TA
JPS25
LPC FU2 -28 AC TRACTION JPT22-7 -4 -4
FU1 SERIAL Tx AMPLIFIER BRAKE DEADMAN BRAKE DEADMAN
2 (350A)
(100A) -29 JPT22-8 -5 -5
CARRIAGE DEADMAN CARRIAGE DEADMAN
SERIAL Rx JS27
TP2 FU3 TP5
JP 2 U JS31-1 -1 -6
JPS1-2 (500A) U -1 DGND
B+
-1 X Y V B+K3 -2 -2
JPS1-8 TM
TP3 TPC V B+KEY +12V
-4
W +
-3

3
W -14 +5V
PROGRAM
DGND DGND CARRIAGE
JPS1-11 CONTROL
CARD
A1 +

A2

LM
SEE SHEET 3
JPT14
-5
S1 - +12VP
-11
BUS_I+
-4
BUS_I-
-3
DGND

X Y JPS1-9
LPC

4 JPS1-5 JPS1-6 JPS1-10

JPT20-1 JPS8-1
S10
-3
+12VF

120 IN. LIMIT

150 IN. LIMIT
JPT22-1 JPS8-2 -2
150_LIM S10
13
JPS8-3 -1
JP
B-

JPT18
-9
LIFT_CONTACTOR

JPT6
TP4 TP2 -6
+12VP
MS+ -5
CCW_PWM JPT20
+ -2 -16
CW_PWM L/L L/L
MS SA -3
STEER_CURRENT -15
2 1
-4 (B+K2)B+L/L
DGND
- -1
MS- NEUTRAL_PULSE
TP4 JPT22
-19 FU1_SENSE

5 JPT14
-10
-2
DGND
DGND
-1
-8
-9 B-F

JPT22 JPA7

HOME SENSOR
-3 -1 0
HOMESENSE
JPF1-3

JPF1-5

JPF2-1

JPF1-6
JPF3-3

-11 -2 - HOME
DGND SENSOR
-12
-11
-4
-5
-6
-7
-8

JPT20
+12VF -9 -3 + PROX
JPT22
-20
JPF3-1 T T HRN FU3_SENSE
FU6 (15A) -NEG JPT18
-2
-IN H-1 -16 HORN
1 2 H
T K3 -POS H-2
JPF1-1
FU8 (15A/5A) JPF1-4
-2
1 2 JPF4-15
FU7 (15A/5A) K1 JPBR-2
JPF4-3 JPT20-7 JPE4-1 RED
JPF2-9 JPT20 +12VP

6 -4 1 2 -1 -14 JPT22-9
BRAKE BRAKE -3 WHT STEER
JPF2-2 CHANNELA_4
MOTOR
11 -10 -2 BLU ENCODER
-3 DETAIL B CHANNELB_4
JPT18
JPT10-9 -4 BLK JPC16
-5 -10 DGND -1
L/H L/H B+EPO
JPF4 1 2 JPT14 -2 B-FU8
-13 -6
RELAY_ENABLE -3 B+FU7

OVER THE MAST CABLE

-14 JPT9

FLASHWARE
-6 JPT22-21 -4 B-FU6
EPO_SENSE TXD -2
K4 K3 K2 K1 JP10-1
-5 WARNING LIGHT RXD -3
-6 B+KEY
DGND -5
-12 -2
JPT14
-12 -8 B+FU5
-11
B+KEY

COMMUNICATIONS
JPT2
-8 VBUS -1
FU5 (15A)
-1 -10 D+ -2

USB
1 2 -3
JPT14 D-
K2 K4

DC LIFT
-2 JPF2-4 -7 DGND -4
B+K2
-6 -13 9
B+K2
-7 -14
B+K2
T JPF4-7 JPT24-24
BATTERY_SENSE_IN
JPF2-8

7 FUSE/
JPS26
-4
RELAY -2
CARD -3
-1
-6
-8
JPS30-1 JPS29-1
-2 -2

Publication: 1031794/001E, Revised: 04 Dec 2019 5

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 5. Electrical Schematic Sheet 3

A B C D E F G H

JPTA4-1 JPLA4-1
JPTA1-11 JPLA1-11

2 JPTA4-2
JPTA1-12 JPLA4-2
JPLA1-12

JPLA1-1
JPC1

JPF1-6
-1
VEHICLE +5.3V

JPTA1-1
-2

JPF1-6
MANAGER DGND
-3
CHA
-4

INPUT STEER ENCODER

(SEE SHEET 1 & 2) JPS4 JPS25 JPC11 CHB
-5 -2 -2 -8
BUS- BRKDMAN
JPT14 ( SEE
SHEET 5 ) -6 -3 -3 BUS+ DEADMAN
-9
STEERING
ENCODER
DETAIL A1 11 -5 -1 -1

OVER THE MAST CABLE

+12V +12V JPC21

-3 -6 -6 -1
+5.3V
DGND DGND -2
JPT22 DGND
-3
-7 -4 -4 CHA-E2
BRAKE DEADMAN BRAKE DEADMAN -4
CHB-E2
-8 -5 -5 CARRIAGE DEADMAN -5
SPL2 SPL1 CARRIAGE DEADMAN CD SUPPLY
-2 JPTA1-12 -1 -2 JPLA1-11 -6
-1 CD

3
JPTA1-1 JPLA1-1

CARRIAGE

JPF1-6
JPF1-6

CONTROL
FOR LIFT CONTROLLER
FOR TRACTION CONTROLLER
CARD

OPTIONS
DETAIL A2 11

VEHICLE MANAGER
JPS53 JPS53 S15
JPT18-4 -2 -2 -3
+12VP

*INCLUDES CPU, CAN & ROM

JPT22-22 -1 -1 -2

RAIL SENSE
RAIL_SEN S15
H-2

13
JPT24-5 -3 -3 -1
JPXBR-2
DGND
JPBR-2 JPC6
-1 1 2

4 JPBR-1 JPT20-14
JPXBR-1 JPS53B S16
B+F
B+KEY
-2
-3
S1

EPO/ KEY
-2 -3 NC
B+ESTOP
1
-1 -2 S21
S16
13
-4 2
B+ KEY NO
-3 -1
DETAIL B1 11 DETAIL B2 11

DUAL ASC SWITCHES

JPC8 S11
-2 -3
6-12VF
-2

24" LIMIT
24" LIMIT -1
S46A RIGHT S11
-1 JPC15 13
DGND -3 -1
-1 -1
-2

CARRIAGE CONTROL
CARRIAGE CONTROL

LIGHT DISPLAY CARD

LIGHT DISPLAY

ALL PINS USED

-3 JPC7
-15 -15 DGND

CARD
S2
5 -4
-6
-16 -16 +5.3V +12VF
BRK DEADMAN
-2
-1 -2 NO C
S2

DEADMAN SWITCHES
13
-8 -24 -24 -3 -1
DGND

S47A RIGHT -5 S23

JPC2 +12VF
-1 -1 -1 DGND -4 -2 NO C

INTERFACE CARD
CARRIAGE DEADMAN S23

OPERATOR
-2 -2 -2 UP ARROW

ALL PINS USED

13

OPERATOR
INTERFACE
-3 -3 DN ARROW -6 -1
-3 DGND
-4 -4 ETR/SHFT
OPTIONS -4
-6 -17 -17 JPC3 S28
-8 6-12VF -2 -3
VEHICLE MANAGER -1 -2 S28

60" LIMIT
60" LIMIT
5

-3 -1 13
PGND

JPT10 JPS54
-6 -1
+12VP

6
-2 -2
SENSOR 1 CONTROL HANDLE
JPC9
-8
AISLE DETECT

JPT24-8 -3 +5.3V
DGND
-9 TRAVEL
S47B LEFT TRAVEL

CONTROL HANDLE/ AUTO MANUAL SW

VR1
JPS55 -1 DGND
-7
JPT10
-7 -1 -3
+12VP -5
-8 -5 +5.3V
SENSOR 2
-2 FUSE/RELAY -6
-7 LIFT/LOWER
CARD L/L
VR2
JPT24-9 -3 -8 -4
DGND DGND
(SEE SHEET 1 & 2) S3
-3 + +VS

JPS26 JPC16 -3 -2 0
S46B LEFT JPF4-5 -1 -1 HORN
OUT S3
B+EPO B+EPO
-1 JPF1-4 -2 -2
B-FU8
-1 - GND HORN
B-FU8
-3 JPF4-15 -3 -3

OVER THE MAST CABLE

B+FU7 B+FU7
JPF3-12 -4 -4
-5 B-FU6 B-FU6

-7 -6 -6 -1 1
JPF4-8 2
7 B+KEY B+KEY AUTO/MAN
-8 S4 (OPTION)
-2
-8 -8 DGND
B+FU5 JPF4-10 B+FU5

ALTERNATE END OF AISLE

9

Publication: 1031794/001E, Revised: 04 Dec 2019 6

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 6. Electrical Schematic Sheet 4

A B C D E F G H

OTM CABLE SUPPRESSOR

NETWORK

2
FAN
IN S43
PC5-1 +1 4 1 2 + - 171205 JQ
WHITE
JPS30 JPS29 FAN
S81 HTR3
HTRDM FUDM
-2 1 2
-1 -1 JPC12
TS12-1 HTRC
2
1 2
IN -1 1 2 1
PC5-2 -2 3,5,6 B+FU7 5A
BLACK 1
1

6A SPARE
TP1 1
S40
2
FL-L FL-L FU21 10A S80
B+ FU30 FU11
(15A) (10A) WORKING
LIGHTS -2
2 2
B-FU8 HTR3
TS12-2 -1
-2 -2
FL-R FL-R
TP4
HTR3
-1 COLD STORAGE OPTION
B- FU31 FU12 DEADMAN HEATER
3 (15A) (10A)
-2

COLD STORAGE OPTION

KEYED ON BLUE LIGHTS 1 & OR 2 LIGHTS
1
S41
2
SLL-1 SLL-2 CARRIAGE CONTROL CARD HEATER
10 AMP POWER HOOKUP OPTION DOME JP10-1 JPBL10-1 SPL22 JPBL11-1 JPBL12-1
LIGHTS
SLR-1 SLR-2 JP10-1 FU50 (2A) -2 -2
JP10-2 -2
1 2
JP10-2 -4 -3 -1 BLUE LIGHTS
FU51 (2A) JPBL13-2 JPBL14-2
1 2

COLD STORAGE / INCANDESCENT SUP6 -1 -1

SUPPRESSOR
NETWORK
FAN
S43
+6 1 1 2 + - VEHICLE
CONNECTOR TO CONNECTOR TO PC5-1

4
THIRD PARTY DEVICE RAYMOND TM FAN
MANAGER JPS16 JPBGS2 S15B
RXD TXD JP1-6
JRDP1-1 PT9-2 BLUE JPT20-6 -1 -1 +
PC5-2 -5 2,3,4
-2
TXD RXD
-3 BLUE JP1-4 -2
S41
JP1-1 FU1
-4 JPT22-6 -2 0
SHLD 1 2 RED -4
-5
JPT24-6 -3 -3 -

BALLAST
DOME 5 AMP

BULB
DGND LGHT 1

BULB
-3 LIGHTS LGHT 2
JP1-2
WHITE
BATT-
-5
JP1-3 -1 JPBGS1 S15A
-1
-6
BATT+ -1 +
FU35
BLACK
JP1-5 -2 0
TP1

TP4

2 AMP
125VDC
BATT+ BATT-
-3 -
iPORT SUPPLIER WIRELESS MODULE
BLACK JP2-3 JP1-7

BATTERY GATE SENSOR (OPTION)

-4
S40
5 1 2
JP2-1 FU2
RED -4
OTM CABLE

BALLAST

BULB
WORKING 5 AMP

BULB
LIGHTS JPS26 JPSI26 JPS16 JPC16
JP2-2 -1 -1 -1 -1
WHITE
B+EPO
-1 -1
JPX1 JPC16 BLUE -2 -2 -2 -2
-1 -1 B-FU8
JP1-8 -3 -3 -3 -3
JP2-4
-2 -2 BLUE B+FU7

CARRIAGE GARD
MAIN HARNESS
-4 -4 -4 -4
-3 -3 B-FU6
-4 -4 -5 -5
STANDARD / FLUORESCENT B+EPO
-5 -5 -6 -6 -6 -6
B+KEY
-6 -6
-7 -7
-7 -7 B+FUSEDS
-8 -8 -8 -8
-8 -8 S22 B+FU5
1 2
TS12 CARRIAGE JPC14 680? EPO JC5-2 OF LIGHT & FAN PACKAGE

6 -2 TS13
+12VF JPS26
CONTROL -4 -4 JC5-1 OF LIGHT & FAN PACKAGE
SIDEGATE RIGHT -1
B-FU13 1
CARD -2 -2
1 2
SIDEGATE SWITCHES

-3 -3
-3 TP4 FU13 B+FU12
PGND -1 -1 B- (15A) 2
-6 -6 JC5-3 OF CONTROL HANDLE HEATER
FU12
10 AMP
JPC13 -8 -8
+12VF -2 0 JC5-4 OF CONTROL HANDLE HEATER
FU11 SIDEGATE LEFT
10 AMP -1 - SENSOR TP1 FU12
PROX B+ (15A)
PGND -3 + VM
JP1MPV
ORIGINAL 10 AMP POWER LIFT -5
JPT12
-4 9 FUSE RELAY CARD HARNESS (P/N 1057487 AND 1057488)
S112 (UP)
HOOKUP OPTION 1 2
-6 -3
LOWER S111 (DOWN)
1 2
-12 -9
GND

7
MPV OPTION

Publication: 1031794/001E, Revised: 04 Dec 2019 7

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 7. Electrical Schematic Sheet 5

A B C D E F G H
S46A
-1 RIGHT

-2
-3

2
-4
-6
-8
S31 JPC19 OPTIONS
S46B -2 -1 -2 -3
-1 DGND JPC14 S60
-3 -2
CARRIAGE -3
+12VF -2
-5
S33
AUX LIFT JPC17 CONTROL -2
S32 -1 -1 SIDEGATE RIGHT -1
OPTIONS -7 & LOWER CARD S60

SIDEGATE SWITCHES
-8 LOWER LIFT -2 -2
13
-1 -1 -1 -3 -3 -3 -1
LIFT PGND
VEHICLE MANAGER S47A
-4 -4
LEFT -2
-1 LOWER -5 -5
JPC13 S61
-2 S34 JPC20 -6 -6
-2 -3

6
-3 -2 -7 -7 +12VF
+12VP JPT10 JPS54 -3 +12VF
-6 -1 -1 -2

TRANSDUCER A
-4 -2 -1 -8 -8 SIDEGATE LEFT

PRESSURE
P/T A +12VP S34 AUX LIMIT S61
DETAIL C (PAGE 6) -2 -2 -9 -9

4
DGND SENSOR 1 -6
13 -1 -3 13
-8 DGND -3 -1

AISLE DETECT
DGND JPT24-8 JPC18 PGND
-3

3
DGND -1 -1
PGND

AUX CARD
S47B -2 -2 JPC4 S25
-1
JPT10 JPS55 -3 -3 -2 -3

LOWER BYP INHIB

-1 -3 DGND +12VF
-7 -4 -4

AUX MAST
+12VP
LOWER INHIBIT -1 -2
FLOW A -8 -2 -5
SENSOR 2 -5 -5 S25
FLOW B -7 +5.3V
-6 -6

FLOW SENSOR
13
DGND JPT24-9 -3 -8 -7 -7 -3 -1
DETAIL C (PAGE 6) DGND PGND
JPC21 +12VF
FS TEMP S36 -8 -8
-3 -2 B+KEY
+12VP JPS53 S15 +12VF -9 -9
JPT18-4 -2 -3 -2 -1 JPC6
+12VP S36 SLACK CHAIN

RAIL SENSE
JPT22-22 -1 -2
RAIL_SEN S15 -6
-1 -3 L/L INHIBIT BYP
13 4 DGND
1

/L/ BYP INHIB

JPT24-5 -3 -1
DGND S7
13 S37 JPC22 S7
-3 -2
JPS10 S24 +12VF DGND -5 2
JPT20-10 -1 -3
-2 -1
S37 SLACK CHAIN

LIFT INHIBIT
+12VP
JPT22-2 -2 -2
J1 JPT12 LIFT INHIB S24 -1 -3
-4 -5 DGND
LIFT
JPT24-3 -1
13
-3 S90

LIFT PENDANT
DGND
-3 -6
LOWER

4 JPS16 S27
4 3

TRAVEL CUTOUT
-9 -12 JPT20-6 -1 -3
DGND +12VP
JPT22-6 -2 -2
TRVL CUTOUT S27 4 6
7 A
13
JPT24-6 -3 -1
DGND DA60 K12
S124 1
JPS57 K12

OPTIONAL FOR 5400

ALL OTHER 54/55/56

B

W/ EH<315 STD ON
-3 -1 JPT20-8

LIFT DECEL
+12VP JPS28 S100 1
S1-2
-2 -2 JPT4-3 JPT24-1 -1 -3
LIFT DECEL +12VP (SHEET 3)
-2 180 IN. LIMIT JPC12
13

180 IN. LIMIT

180_LIM
JPT22-4 -2
2 FU9 1 TS12-1
-1 -3 JPT18-7 S100 -1

SPARE
DGND

POWER
B+FU7 JPC12-2
13 RF B-FU8

SWITCH
-1

HIDDEN
DGND
JPT24-7 -3 TERMINAL -2 B-FU8 JPC6-2
2

KEY
FU10 1 TS12-2 B+KEY
JPS15
TRAVEL
ALARM

JPT20-17 -2 AL+
S29 B+ALARM (B+K2) TRAVEL
JPS58 JPT20 JPT18-18 -1 AL- A
ALARM_TRAVEL ALARM
-3 -1 -3 +12VP
-2 -2 JPT22-12
SLACK SW1

SPL2-B+
+
SLACK CHAIN

-1 -3 JPT4-2 DGND JPS52-1

4
LIFT/LOWER

JPT20
ALARM

5
S30
JPS59 -18 -2 B+KEY

SPL1-B-
13 JPT20-4
ALARM_LIFT
-3 -1 +12VP -
-2 -2 JPT24-16 WORK LTS B-F DETAIL B (PAGE 6)

OPTION
SLACK SW2

POWER
ELECTRONIC

-1 -3 B-F
HORN

JPT18-16 H-2(-) -
HORN
B+KEY
H1
H-1(+) HRES
+
1 2
1
FSUP-
X X X -6
AUX AUX MAIN -4 JPC9
L/H SEL SEL
SOL SOL SOL WIRE GUIDANCE FSUP -3 -3 iPORT

RS-232
JPT18 TP1 -2 TRUCK
Y Y Y -1
JPW2 JP1T B+ VM
-14 JPS2 -5
AUX MAST

MAIN SEL -1 -1 RIGHT

SEE INSTALLATION MANUAL FOR DETAILS

-15 JPT20-19 -11
AUX SEL 6 B+WG (B+K2) B+ESTOP -2 -2 NEAR WIRE
-12
AUX L/H -3 -3 LEFT B- 1

iWAREHOUSE-RED SYSTEM
-5 -5 T0

6 PRESS SW1 -6 -6 T1

TRACTOR
PERFORMANCE LIFT

SENSOR
JPT22-5 -7 -7 T2
PRESS_SW JPS4 B+ 2
NC -5 -8 -8 T3
24V HIGH

JPT18-5 BUS- FAN

-14 -14 AGRD
DGND
-15 -15 +12VF
-13
JPT18-1 SEE SHEET 1
2 NO
2 STAGE SOL
GUIDANCE MANAGER

S56
NO
1
JPW1 JP1L
-1 -1 RIGHT
2 STAGE -6 -2 -2 NEAR WIRE B-
SELECT BUS+
-3 -3 LEFT

LOAD SENSOR
SOL
-5 -5 T0
FUSE/RELAY CARD -6 -6 T1 TP4
-7 -7 T2
JPF2-8 -8 -8 T3
B+K2
-14 -14 AGRD
JPS2
-24 -15 -15 +12VF
B-FU6 JPF3-9
B-F -13
( )
JPF2-3 SEE
B+K2
SHEET 1 & 2
7 JPB1-2 JPB1-1 JPF2-4
B+K4

LIFT MOTOR FAN

36V EE ONLY JPF2-2
JPF3-11 B+K2
B-FU6

Publication: 1031794/001E, Revised: 04 Dec 2019 8

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 8. Electrical Schematic Sheet 6

A B C D E F G
DETAIL C

2
VEHICLE MANAGER

FLOW SENSOR BASED INTELLISPEED JPS50 RAYMOND CARRIAGE MANAGER CARRIAGE CONTROL CARD
+ -1 JPT20-5

TRANSDUCER A
+12VP

PRESSURE
0 -2 JPT24-18 HEIGHT REF PROX JPFP
PRESS A P/T A JPRCM-21 JPC10-6
JPT24-10 + -1 JPRCM-24 CANO_H BUS+
-3 B+COIL
- DGND 0 JPRCM-23
-2
REF_SW_DIN
-3 JPRCM-10 JPRCM-15 JPC10-7
- DGND
CANO_L BUS-
JPY7
A P -1 VR
B -2 IN2
JPY1 JPS51 DETAIL B

FLOW MODULE

FREE LIFT ENCODER

-3 SHLD -1 -1 JPT22-13 FLOW A
JPT22-14 JPFLE

FLOW SENSOR
JPY6 -2 -2 FLOW B
P -1 VR -3 -3 JPT24-11 DGND
-3 JPRCM-17 ENC CH. A JPC5
A -2 JPRCM-11 ENC CH. B JPRCM-1 JPC5-3
B-F -1
-2 IN1 -4 -4 JPT24-19 FS TEMP B-
B+KEY CONTROL HANDLE HEATER

3 FLOW SENSOR -3 SHLD JPT20-2 -4 JPRCM-9 DGND

-5 -5 +12VP
B JPRCM-13 JPC5-4 -2
-1 JPRCM-14 5V OUT B-F

OPTION
POWER
JPY2 B+KEY B+KEY 1
-1 GND
SPL5
-3
-2 F/S TEMP B-F
-4
B+KEY S75 HTRH

1 2

VEHICLE MANAGER
JPC10-8
GND

JPS50
MAIN LIFT ENCODER (FOR HEIGHT + -1 JPT20-5 JPC10-9
+12VP 12VDC

TRANSDUCER A
SENSE AND INTELLISPEED) 0 -2 JPT24-18

PRESSURE
PRESS A P/T A
-3 JPT24-10
- DGND

JTC-1

JTC-2
MAIN LIFT ENCODER

4 JPMLE
-3
JPS51
-1 JPT22-13 CHANNEL A

MAIN LIFT ENCODER

-2 -2 JPT22-14 CHANNEL B
-4 -3 JPT24-11 DGND
-4
SEE SHEET 7
ZONE H3
-1 -5 JPT20-2 +12VP

Publication: 1031794/001E, Revised: 04 Dec 2019 9

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 9. Electrical Schematic Sheet 7

A B C D E F G H

NAVIGATION
2 SOLUTIONS

OPTIONAL
SEE SHEET 6
ZONE E4

JPDCI JPDCI CONVERTER PID

JPDCO JPDCO JPPID JPPID JPTC1 JPTC1
-1 -1 -1 -1 -35 -23 -2 -2
IN+ OUT+ 12VDC INP. AWAKE/SUSPEND
FROM 10A FUDC
OPTION -2 -2 -2 -2 -12 -4 -1 -1
DETAIL D IN- OUT- GND
CAN GND

3 JPTA4
-1
JPTA4
-1
JPS27 JPS27
-2 -2 -3
-2 -2 INP. CAN1 H

-3 -3 -1 -1 -5
INP. CAN1 L

-4 -4
TO TRACTION
TO TRACTION -5 -5 MOTOR/BRAKE
AMPLIFIER
-6 -6
-7 -7 JPTC2
-1
-8 -8
-2

-3
4 SEE SHEET 1
ZONE D3
-4
OVER-THE-MAST CABLE
JPDM JPDM SPLD1
-1 DIODE -2
RESISTOR
-3 JPTA1-25
MODULE
-6 SPLD2
-4

JPS31-1 -2

SEE SHEET 1
RFID READ/WRITE HEAD
JPRF1 JPRF2 JPZA ZPU JPZA ZONE E4

-1 -1 -17
RS232 CTS (DETECT) RS232 CTS (DETECT) -13
SPEED SENSOR
-18
5 RS232 RX
-2 -2
-19
RS232 RX
CH A
SPEED SENSOR
-6 APM PSC1-1 PSC1-2
-3 -3 CH B
RS232 RTS RS232 RTS
-4 -4 -20
RS232 TX RS232 TX
JPZSC1 JP56 JP55
-15 -1 -3 -2 JSC1-1
CAN1_L INT_CAN4_L INT_CAN0_L
JPZB
-9 -23 -2 -2
-5 -5 CAN1_H INT_CAN4_H -1 JSC1-2
12V 12V INT_CAN0_H
JP55
-6 -6 -16 -9
GND GND -1
B+ B+
1
FUZ
2A
JPANT1 2
ANT
1

6 ANT
1
JPANT2
TP1
-8
CAN1_L
-4 SPLZ
-10
CAN1_H GND
-2 -1

JPF3-11

FUSE/RELAY
CARD
7

Publication: 1031794/001E, Revised: 04 Dec 2019 10

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 10. Electrical Schematic Legend
LEGEND

IDENT. SHEET ZONE DESCRIPTION IDENT. SHEET ZONE DESCRIPTION IDENT. SHEET ZONE DESCRIPTION
2 STAGE SEL SOL 5 B6 TWO STAGE LIFT PUMP SOLENOID JPE4 1,2 F6 CONNECTOR FOR STEER MOTOR ENCODER MS 1,2 B5 STEER MOTOR
NOTES: JPF1 1,2,3 MULTI B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY CARD PID 7 F3 POSITIONING INFORMATION DISPLAY
1 36V TRUCK ONLY. AL- 5 D5 NEGATIVE SIDE OF ALARM JPF2 1,2,5 MULTI B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD PRESS SW1 5 B6 PRESSURE SWITCH FOR 24V HI PERF LIFT
2 350A FUSE REPLACES 500A FUSE ON SINGLE STAGE LIFT PUMP TRUCKS. AL+ 5 D5 POSITIVE SIDE OF ALARM JPF3 1,2,3,5 MULTI B- CONNECTOR ON FUSE/RELAY CARD RFID R/W HEAD 7 A5 RADIO FREQUENCY IDENTIFICATION READ/WRITE MODULE
3. SCHEMATIC SHOWS TRUCK SWITCHED OFF, DEADMAN SWITCHED OFF, APM 7 E5 AUXILLIARY PROCESSING MODULE JPF4 1,2,3 MULTI KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/RELAY CARD
AND CARRIAGE FULLY LOWERED. BRAKE 1,2 D6 ELECTRIC BRAKE JPFP 6 D2 CONNECTOR FOR HEIGHT REFERENCE SWITCH S1 3 F4 KEY SWITCH
4 AUSTRALIAN OPR ONLY.
JPFLE 6 D3 CONNECTOR FOR FREE-LIFT ENCODER S2 3 G5 DEADMAN SWITCH (BRAKE DEADMAN)
5 60 INCH LIMIT SWITCH NOT USED ON INTELLISPEED TRUCKS.
FSUP 5 F6 CONNECTOR ON FAN SUPPRESSOR JPLA1 1 D3 LIFT AMP CONNECTOR S3 3 F6 HORN SWITCH
6 OPR W/AUX LIFT OPTION. FU1 1,2 B3 POWER FUSE FOR STEER JPLA2 1 C3 LIFT MOTOR ENCODER CONNECTOR S4 3 F7 AUTO/MANUAL SWITCH
7 REFERENCE POWER DISTRIBUTION DIAGRAMS D20009008 FU2 1,2 B3 POWER FUSE FOR TRACTION JPLA3 1 C3 LIFT MOTOR TEMPERATURE SENSOR CONNECTOR S7 5 H4 LIFT/LOWER INHIBIT BYPASS SWITCH
AND D20009239.
FU3 1,2 B3 POWER FUSE FOR LIFT JPLA4 1 C3 CONNECTOR FOR LIFT MOTOR ENENCODER/TEMP SENSOR CONNECTOR S10 1,2 F4 150" LIMIT SWITCH OR 120" LIMIT SWITCH
8 CONNECTED TO JPF4-14 ON 24V TRUCKS WITH AC LIFT.
FU5 1,2 B6 CONTROL FUSE FOR VEHICLE MANAGER B+ 15A JPMLE 6 B4 CONNECTOR FOR MAIN-LIFT ENCODER S11 3 F5 24" LIMIT SWITCH
9 SEE FUSE RELAY CARD HARNESS ILLUSTRATION ON PAGE 4, FU6 1,2 B6 CONTROL FUSE FOR VEHICLE MANAGER B- 15A JPPID 7 F3,G3 CONNECTION ON PID S15 5 D3 RAIL SENSE SWITCH RIGHT
APPLIES TO TRUCKS WITH INCANDESCENT LIGHT AND FAN
FU7 1,2 B6 CONTROL FUSE FOR AUX. POWER B+ 15A/5A JPRCM 6 D2,D3 CONNECTOR FOR MAIN-LIFT ENCODER S16 3 E4 RAIL SENSE SWITCH LEFT
PACKAGE BETWEEN S/N 5XX-XX-X01011 AND 5XX-XX-X04700
FU8 1,2 B6 CONTROL FUSE FOR AUX. POWER B- 15A/5A JPRF1 7 B5 CONNECTOR FOR RFID READ/WRITE HEAD S21 3 F4 EPO SWITCH
10. THIS PART SHALL COMPLY WITH RESTRICTED SUBSTANCES
QAP D20014464. FU9 5 F4 CONTROL FUSE FOR RF TERMINAL B+ 2A JPRF2 7 B5 CONNECTOR FOR RFID READ/WRITE HEAD S22 4 D6 EMERGENCY POWER OFF
11 FU10 5 F4 CONTROL FUSE FOR RF TERMINAL B- 2A JPS1 1,2 MULTI CONTACTOR PANEL INTERFACE CONNECTOR S23 3 F5 DEADMAN SWITCH (CARRIAGE DEADMAN)
FOR MAIN HARNESS P/N 1040198/XXX USE DETAIL A1 AND B1;
FOR MAIN HARNESS P/N 1109225/XXX USE DETAIL A2 AND B2 FU11 4 B6 10A FUSE FOR 10A POWER HOOKUP OPTION JPS2 5 D5,D7 CONNECTOR ON TRUCK TRACKER FOR POWER S24 5 D3 LIFT INHIBIT SWITCH
ON PAGE 3.
FU12 4,4 F6,B6 CONTROL FUSE FOR EXTRA F/R HARNESS B+FU12 15A AND/OR FUSE FOR 10A POWER HOOKUP OPTION JPS4 5 D6 S25 5 H3 LOWER INHIBIT SWITCH
12 FUSES MAY NOT BE INSTALLED.
FU13 4 F6 CONTROL FUSE FOR EXTRA F/R HARNESS B-FU13 15A JPS8 1,2 F4 CONNECTOR FOR 120"/150" LIMIT SWITCH S27 5 D4 TRAVEL CUTOUT SWITCH
13 SEE DETAIL A ON SHEET 6. SOME TRUCKS HAVE FU21 4 F3 CONTROL FUSE FOR COLD STORAGE C.C.C. HEATER, 10A JPS10 5 D4 CONNECTOR FOR LIFT INHIBIT SWITCH S28 3 F6 60" LIMIT SWITCH
THIS SWITCH CONFIGURATION. 12 FU50 4 G3 CONTROL FUSE BLUE SPOT LIGHT JPS15 5 D5 CONNECTOR FOR TRAVEL ALARM S29 5 B4 SLACK CHAIN (MAIN #1)
12 FU51 4 G3 CONTROL FUSE BLUE SPOT LIGHT JPS16 5 D4 CONNECTOR FOR TRAVEL CUTOUT SWITCH S30 5 B4 SLACK CHAIN (MAIN #2)
FUDM 4 H2 CONTROL FUSE FOR COLD STORAGE DEADMAN HEATER, 5A JPS25 1,2,3 F2E3 CONNECTOR FOR OVER THE MAST CABLE #1 S31 5 E2 AUX LIFT LEFTHAND DEADMAN
FUZ 7 D6 FUSE FOR ZPU AND APM JPS26 1,2,3 D7,E7 CONNECTOR FOR OVER THE MAST CABLE #2 S32 5 E2 AUX LIFT
H1 5 E5 ELECTRONIC HORN JPS27 1,2 F3 CONNECTOR FOR SPARE OVER THE MAST WIRES S33 5 E2 AUX LOWER
H (HRN) 1,2 D6 HORN JPS28 5 D4 CONNECTOR FOR 180" LIMIT SWITCH S34 5 E3 AUX LIFT LIMIT SWITCH #1/REARGATE #1
HRES 5 D5 ELECTRONIC HORN RESISTOR JPS50 5 B3 CONNECTOR FOR PRESSURE TRANSDUCER A S36 5 E3 SLACK CHAIN CARRIAGE #1
HTR3 4 F3,G3 CONNECTOR FOR DEADMAN HEATER JPS51 5 B3 CONNECTOR FOR FLOW MODULE S37 5 E4 SLACK CHAIN CARRIAGE #2
HTRC 4 F2 C.C.C. HEATER JPS52 5 D5 CONNECTOR FOR LIFT/LOWER ALARM S40 4 C5 SWITCH FOR WORKING LIGHTS
+ +VS HTRDM 4 G2 DEADMAN HEATER JPS53 5 D3 CONNECTOR FOR RAIL SENSE SWITCH S41 4 C4 SWITCH FOR DOME LIGHTS
HTRH 5 H5 CONTROL HANDLE HEATER JPS53B 3 D4 CONNECTOR FOR RAIL SENSE SWITCH S43 4 C4 SWITCH FOR FAN
O OUT JP1L 5 E6 CONNECTOR FROM LOAD W.G. ANTENNA TO FILTER CARD JPS54 3,5 B6,D3 CONNECTOR FOR AISLE DECTECT SENSOR 1 S46A 3,5 C5,D2 AISLE DETECT SENSOR 1
JP1MPV 4 D6 EMERGENCY LIFT LOWER CONNECTION JPS55 3,5 B6,D3 CONNECTOR FOR AISLE DETECT SENSOR 2 S46B 3,5 C5,D2 AISLE DETECT SENSOR 1
- GND JP1T 5 E5 CONNECTOR FROM TRACTOR W.G. ANTENNA TO FILTER CARD JPS57 5 B4 CONNECTOR FOR LIFT CUTOUT S47A 3,5 C6,D3 AISLE DETECT SENSOR 2
JP1
JP10 1,2 D6 CONNECTOR FOR WARNING LIGHT JPS58 5 B5 CONNECTOR FOR SLACK CHAIN SWITCH S47B 3,5 C6,D3 AISLE DETECT SENSOR 2
JP10
JP1 4 G3 CONNECTOR FOR WARNING LIGHT & BLUE LIGHT CONNECTOR JPS59 5 B5 CONNECTOR FOR SLACK CHAIN SWITCH
DETAIL A
4 S56 5 F6 SWITCH FOR FAN
JP55 7 E6
G3 CONNECTION ON APM FOR INTERNAL CAN AND POWER JPSC1 1,2 D4,D3 SPLICE FOR CAN BUS S60 5 H2 SIDEGATE RIGHT SWITCH
JP56 7 E5,F5 CONNECTION ON APM FOR EXTERNAL CAN JPSC2 1 D4 SPLICE FOR CAN BUS S61 5 H3 SIDEGATE LEFT SWITCH
JPA7 1,2 F5 CONNECTOR FOR HOME SENSOR PROX JPT2 1,2 F6 USB CONNECTOR ON VM S75 5 H5 CONTROL HANDLE HEATER THERMOSTAT
JPANT1 7 B6 CONNECTOR FOR WIFI ANTENNA JPT4 5 C4,C5 CONNECTOR ON VM S80 4 H3 DEADMAN HEATER THERMOSTAT
JPANT2 7 B6 CONNECTOR FOR WIFI ANTENNA JPT6 1,2 E5 ELECTRIC STEER CONNECTOR ON VM S81 4 F2 C.C.C. HEATER THERMOSTAT
JPT9 1,2 F6 CONNECTOR ON VM FOR FLASHWARE S90 5 H4 SECURITY START SWITCH
JPB- 1,2 A4 BATTERY CONNECTOR - JPT10 1,2,3,5 E6,B6,C3 CAN, DIGITAL INPUTS AND OUTPUTS CONNECTOR ON VM S100 5 D4 180" LIMIT SWITCH
JPB+ 1,2 A3 BATTERY CONNECTOR + JPT12 5 C4 LIFT PENDANT CONNECTOR ON VM S111 4 E7 MPV/EMERGENCY LOWER SWITCH
JPBL10 4 H3 CONNECTOR FOR BLUE SPOT LIGHT(S) JPT14 1,2,3 MULTI B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM S112 4 E7 MPV/EMERGENCY LIFT SWITCH
JPBL11 4 H3 CONNECTOR FOR BLUE SPOT LIGHT(S) JPT18 1,2,5 MULTI COIL DRIVERS CONNECTOR ON VM S124 5 B4 LIFT DECEL SWITCH
JPBL12 4 H3 CONNECTOR FOR BLUE SPOT LIGHT(S) JPT20 1,2,5 MULTI PROPORTIONAL COIL DRIVERS CONNECTOR ON VM SA 1,2 B5 STEER POWER AMPLIFIER
JPBL13 4 H3 CONNECTOR FOR BLUE SPOT LIGHT(S) JPT22 1,2,3,5 MULTI DIGITAL INPUTS CONNECTOR ON VM SPL1 3 B2 BUTT SPLICE FOR LIFT AMP TO FUSE RELAY CARD
JPBL14 4 H3 CONNECTOR FOR BLUE SPOT LIGHT(S) JPT24 1,2,5 MULTI ANALOG INPUTS CONNECTOR ON VM SPL2 3 A2 BUTT SPLICE FOR TRACTION AMP TO FUSE RELAY CARD
JPBR 1,2 D6 CONNECTOR FOR BRAKE JPTA1 1,2 D2 TRACTION AMP CONNECTOR SPL22 4 G3 SPLICE FOR BLUE SPOT LIGHT(S)
JPC1 3 F2 CONNECTOR ON C.C.C. FOR STEERING ENCODER JPTA2 1,2 C2 TRACTION MOTOR ENCODER CONNECTOR SPLD1 7 C4 SPLICE FOR ENCODER SIGNAL SPLITTING
JPC2 3 E5 CONNECTOR ON C.C.C. FOR DISPLAY CARD JPTA3 1,2 C2 TRACTION MOTOR TEMPERATURE SENSOR CONNECTOR SPLD2 7 C4 SPLICE FOR ENCODER SIGNAL SPLITTING
JPC3 3 F6 CONNECTOR ON C.C.C. FOR 60" LIMIT SWITCH JPTA4 1,2 C2 CONNECTOR FOR TRACTION MOTOR ENCODER AND TEMPERATURE SPLZ 7 D6 SPLICE FOR GND CONNECTION ON ZPU
JPC4 5 G3 CONNECTOR ON C.C.C. FOR LOWER INHIBIT JPTC1 7 G3,H3 WAKE/SUSPEND AND CAN GND CONNECTION SUP6 4 G3 SUPPRESSOR FOR BLUE SPOT LIGHT(S)
JPC5 4,5 B4,G5 CONNECTOR ON C.C.C. FOR LIGHTS/FANS JPTC2 7 H4 CONNECTION FOR TRUCK COM
JPC6 3,5 F4,G3 CONNECTOR ON C.C.C. FOR LIFT/LOWER BYPASS SWITCH JPW1 .
5 .
D6 CONNECTOR ON FILTER CARD FOR LOAD SENSOR TA 1,2 D2 TRACTION POWER AMPLIFIER
JPC7 3 F5 CONNECTOR ON C.C.C. FOR DEADMAN SWITCHES JPW2 5 D6 CONNECTOR ON FILTER CARD FOR TRACTOR SENSOR TM 1,2 C3 AC TRACTION MOTOR
JPC8 3 F5 CONNECTOR ON C.C.C. FOR 24" LIMIT SWITCH JPXBR 3 B3 CONNECTOR FOR SEPERATE BRAKE HARNESS TME 1,2 C2 TRACTION MOTOR ENCODER
JPC9 3 F6 CONNECTOR ON C.C.C. FOR CONTROL HANDLE JPX1 4 A5 CONNECTOR FOR 10X AUX POWER TMT 1,2 C2 TRACTION MOTOR TEMPERATURE SENSOR
JPC10 6 E3,E5 CONNECTOR ON C.C.C. FOR CANBUS CONNECTION JPY1 5 B3 CONNECTOR ON FLOW MODULE TP1 1,2 B2 TIE POINT ON B+
JPC11 1,2,3 G2,E3 CONNECTOR ON C.C.C. FOR OVER THE MAST CABLE #1 JPY2 5 B3 CONNECTOR ON FLOW MODULE TO FLOW SENSOR TEMPERATURE SENSOR TP2 1,2 B3 TIE POINT ON STEER MOTOR FUSE
JPC12 4,5 F2,F4 CONNECTOR ON C.C.C. FOR SPARE POWER JPY6 5 B3 CONNECTOR ON FLOW MODULE TO FLOW SENSOR CHANNEL 1 TP3 1,2 B3 TIE POINT ON LIFT MOTOR FUSE
JPC13 5 G3 CONNECTOR ON C.C.C. FOR SIDEGATE SWITCHES JPY7 5 B3 CONNECTOR ON FLOW MODULE TO FLOW SENSOR CHANNEL 2 TP4 1,2 B4 TIE POINT ON B-
JPC14 5 G2 CONNECTOR ON C.C.C. FOR SIDEGATE SWITCHES JPZA 7 B5 CONNECTOR ON ZPU TP5 1,2 B3 TIE POINT ON TRACTION MOTOR FUSE
JPC15 3 E5 CONNECTOR ON C.C.C. FOR LIGHT DISPLAY CARD JPZB 7 B5 CONNECTOR ON ZPU FOR RFID R/W POWER TPC 1,2 B2 TRACTION POWER CONTACTOR
JPC16 1,2,3 G6,E6 CONNECTOR ON C.C.C. FOR OVER THE MAST CABLE #2 TS12 5,4 F5,F3 TERMINAL STRIP FOR SPARE POWER
JPC17 5 F2 CONNECTOR ON C.C.C. FOR AUX CARD K1 1,2 C6 KEYSWITCH RELAY-OPTIONS TS13 4 G6 TERMINAL STRIP FOR EXTRA F/R HARNESS
JPC18 5 F3 CONNECTOR ON C.C.C. FOR AUX CARD K2 1,2 C6 KEYSWITCH RELAY-SOLENOIDS, ATTACHMENTS, HORN VR1 3 F6 VARIABLE RESISTOR FOR THROTTLE
JPC19 5 F2 CONNECTOR ON AUX CARD FOR AUX LIFT & LOWER SWITCH K3 1,2 B6 KEYSWITCH RELAY-POWER AMPS VR2 3 F6 VARIABLE RESISTOR FOR LIFT/LOWER
JPC20 5 F3 CONNECTOR ON AUX CARD FOR AUX LIMIT SWITCH K4 1,2 C6 KEYSWITCH RELAY-AUX. VM POWER
JPC21 3,5 F3,F3 CONNECTOR ON C.C.C FOR SECONDARY STEER INPUT ENCODER K12 5 H4 HIDDEN KEY SWITCH RELAY ZPU 7 C5 ZONING AND POSITIONING UNIT
JPC22 5 F4 CONNECTOR ON AUX CARD FOR AUX SLACK CHAIN
JPC23 5 F4 CONNECTOR ON AUX CARD FOR AUX DEADMAN L/H 1,2 D6 LOAD/HOLD SOLENIOD
JPB1 5 B7 CONNECTOR FOR LIFT MOTOR FAN L/L 1,2 F5 LIFT/LOWER SOLENOID
JPDCI 7 D3,D4 CONNECTION FOR INPUT POWER TO DC CONVERTER LA 1 D4 LIFT POWER AMPLIFIER
JPDCO 7 E3 CONNECTION FOR OUTPUT POWER FROM DC CONVERTER LM 1,2 C4,B3 AC LIFT MOTOR OR DC LIFT MOTOR
JPDM 7 C4 CONNECTION FOR ENCODER SIGNAL DIODE MODULE LME 1 C3 LIFT MOTOR ENCODER
LMT 1 C4 LIFT MOTOR TEMPERATURE SENSOR
LPC 1,2 C4 LIFT POWER CONTACTOR

Publication: 1031794/001E, Revised: 04 Dec 2019 11

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 11. Hydraulic Schematic, Single Speed Lift

Publication: 1031794/001E, Revised: 04 Dec 2019 12

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 12. Hydraulic Schematic, Variable Speed Lift

Publication: 1031794/001E, Revised: 04 Dec 2019 13

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 13. Hydraulic Schematic, Variable Speed Lift with Auxiliary Lift

Publication: 1031794/001E, Revised: 04 Dec 2019 14