SENB8550-02

Parts Manual
Service Manual

Reach Trucks
NRR30 2NL00001-up
NRR35 2NL00001-up
NRR40 2NL00001-up
NRDR25 2NL00001-up
NRDR30 2NL00001-up
NSR30 2NL00001-up
NSR40 2NL00001-up
NRR30P 2GL00001-up
NRR35P 2GL00001-up
NRR40P 2GL00001-up
NRR45P 2GL00001-up
NRDR25P 2GL00001-up, 2PL00144-2PL00198
NRDR30P 2GL00001-up, 2PL00144-2PL00198
NSR30P 2GL00001-up
NSR40P 2GL00001-up
CATERPILLAR® Reach Service Manual Warning Pages

Warning Pages

0: Warning Pages

Warning Pages

The proper and safe lubrication and maintenance for this machine, recommended by
Caterpillar, are outlined in the SERVICE MANUAL for this machine.
Improper performance of lubrication or maintenance procedures is dangerous and could result
in injury or DEATH. Read and understand the SERVICE MANUAL before performing any
lubrication or maintenance.
The service person or mechanic may be unfamiliar with many systems on this machine. This
makes it important to use caution when performing service work. A knowledge of the system
and/or components is important before the removal or disassembly of any components.
Because of the size of some of the machine components, the service person or mechanic should
check the weights noted in this Manual. Use proper lifting procedures when removing any
components.
Following is a list of basic precautions that should always be observed:
1. Read and understand all Warning plates and decals on the machine before operating,
lubricating, or repairing the product.
2. Always wear protective glasses and protective shoes when working around machines. In
particular, wear protective glasses when pounding on any part of the machine or its
attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron, and other
protective clothing appropriate to the job being performed. Do not wear loose-fitting or torn
clothing. Remove all rings from fingers when working on machinery.
3. Do not work on any machine that is supported only by lift jacks or a hoist. Always use
blocks or jack stands to support the machine before performing any disassembly.
4. Lower the forks or other implements to the ground before performing any work on the
machine. If this cannot be done, make sure the forks or other implements are blocked
correctly to prevent them from dropping unexpectedly.
5. Use steps and grab handles (if applicable) when mounting or dismounting a machine. Clean
any mud or debris from steps, walkways, or work platforms before using. Always face the
machine when using steps, ladders, or walkways. When it is not possible to use the
designed access system, provide ladders, scaffolds, or work platforms to perform safe repair
operations.
6. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or
more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct
capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded
during a lifting operation.
7. To avoid burns, be alert for hot parts on machines which have just been stopped and hot
fluids in lines, tubes, or components.
8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located
at opposite ends of the covers or device and pry cover loose to relieve any spring or other
pressure, before removing the last two bolts or nuts completely.
9. Be careful when removing filler caps, breathers, and plugs on the machine. Hold a rag over
the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger
is even greater if the machine has just been stopped because fluids can be hot.

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Warning Pages

10. Always use tools that are in good condition and be sure you understand how to use them
before performing any service work.
11. Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if
replacements are necessary. Do not mix metric fasteners with standard nuts and bolts.
12. If possible, make all repairs with the machine parked on a hard, level surface. Block
machine so that it does not roll while working on or under the machine.
13. Disconnect battery and discharge capacitors (electric trucks) before starting to work on the
machine. Hang “Do Not Operate” tag in the Operator’s Compartment.
14. Repairs which require welding should be performed only with the benefit of the appropriate
reference information, and by personnel adequately trained and knowledgeable in welding
procedures. Determine type of metal being welded and select correct welding procedure and
electrodes, rods, or wire to provide a weld strength equivalent at least to that of the parent
metal.
15. Do not damage wiring during removal operations. Reinstall the wiring so that it is not
damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing
against some object or hot surface. Do not connect wiring to a line containing fluid.
16. Be sure all protective devices including guards and shields are properly installed and
functioning correctly before starting a repair. If a guard or shield must be removed to
perform the repair work, use extra caution.
17. Always support the mast and carriage to keep carriage or attachments raised when
maintenance or repair work is being performed which requires the mast in the raised
position.
18. Loose or damaged lubricant and hydraulic lines, tubes, and hoses can cause fires. Do not
bend or strike high pressure lines or install ones which have been bent or damaged. Inspect
lines, tubes, and hoses carefully. Do not check for leaks with your hands. Pin hole (very
small) leaks can result in a high velocity oil stream that will be invisible close to the hose.
This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate
pin hole leaks.
19. Tighten all connections to the correct torque. Make sure that all shields, clamps, and
guards are installed correctly to avoid excessive heat, vibration, or rubbing against other
parts during operation. Shields that protect against oil spray onto hot exhaust components
in the event of a line, tube, or seal failure must be installed correctly.
20. Relieve all pressure in air, oil, or water systems before any lines, fittings, or related items are
disconnected or removed. Always make sure all raised components are blocked correctly
and be alert for possible pressure when disconnecting any device from a system that utilizes
pressure.
21. Do not operate a machine if any rotating part is damaged or contacts any other part during
operation. Any high speed rotating component that has been damaged or altered should be
checked for balance before reusing.
22. On LP equipped lift trucks, be sure to close the valve on the LP tank before service work is
performed. Always close the valve on the LP tank when the lift truck is being stored. Do not
check for LP leaks with an open flame.

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CATERPILLAR® Reach Service Manual Warning Pages

Warning Pages

23. Caution should be used to avoid breathing dust that may be generated when handling
components containing asbestos fibers. If this dust is inhaled, it can be hazardous to your
health. Components in Caterpillar products that may contain asbestos fibers are brake
pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos
used in these components is usually found in a resin or sealed in some way. Normal
handling is not hazardous as long as airborne dust containing asbestos is not generated.
If dust which may contain asbestos is present, there are several common sense guidelines that
should be followed:
a. Never use compressed air for cleaning.
b. Avoid brushing or grinding of asbestos-containing materials.
c. For clean up, use wet methods or a vacuum equipped with a high efficiency particulate
air (HEPA) filter.
d. Use exhaust ventilation on permanent machining jobs.
e. Wear an approved respirator if there is no other way to control the dust.
f. Comply with applicable rules and regulations for the workplace (for example, in the
U.S.A., OSHA requirements as set forth in 29 CFR 1920.1001).
g. Follow environmental rules and regulations for disposal of asbestos.
h. Avoid areas where asbestos particles may be in the air.

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CATERPILLAR® Reach Service Manual

Manual Overview

0:

Manual Overview
This manual is comprised of operating and maintenance instructions for the specific equipment
listed on the cover. It is organized by major topics covering all areas of the truck, as follows:
• Warning Pages
• Manual Overview
• Description
• Installation
• Operating Instructions
• Theory of Operation
• Maintenance
• Troubleshooting
• Appendix
• Supplement - DCAT Program
The following symbols are used throughout this manual to represent a condition or hazard of
which the operator should be aware.

! WARNING
Denotes a serious hazard that could cause injury or death to the operator or other
personnel from a particular action or condition.

! CAUTION
Denotes a less serious hazard from an action or condition that could cause minor
injury to the operator or maintenance personnel, or cause damage to the
equipment.

NOTE: Denotes a particular statement pertaining to a particular procedure or explanation.

Using the Manual

This manual contains several elements necessary for effective use, which are:
1. Safety First and Last: Gives specific safety guidelines for truck operators, owners, and
maintenance personnel. This information is given at the beginning of the manual and at
various areas throughout the manual.
2. Table of Contents: Guides the reader to major topics by page number reference.
3. List of Illustrations: Guides the reader to specific illustrations by page number reference.
4. Troubleshooting Charts: For quick logical tracking of troubles and suggested remedies;
located in Chapter 6.
5. Schematics: For ease of troubleshooting the truck electrical and/or hydraulic systems;
located in Chapter 7.

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CATERPILLAR® Reach Service Manual

Table of Contents
0:

Table of Contents
Warning Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Truck Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Specification Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Mechnical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-6
Power Section Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-6
Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-6
Battery Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-6
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-6
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-6
Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-7
Mast Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-7
Telescopic Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-7
Mast Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-7
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-7
Operator’s Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-8
Compartment Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-9
Overhead Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-9
Operator’s Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 1-9
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 1-10
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 1-11
Pivot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 1-11
Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 1-11
Gear Reduction Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 1-11
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 1-11
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 1-11
Drive Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 1-11
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Lift/Lower System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Lift Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Return Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

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Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Lift/Lower Hydraulic Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
System Displays . . . . . . . . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-16
Operator’s Display (OD) . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-16
Maintenance Displays . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-17
Electronic Control System . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-17
Vehicle Manager . . . . . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-17
Power Panel Driver Assembly. . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-20
Hydraulic Driver Assembly (HDA) . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-21
Distribution Board . . . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-22
Travel System . . . . . . . . . . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-23
Drive Motor . . . . . . . . . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-23
Travel Contactors . . . . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-24
Steering System . . . . . . . . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-24
Auxiliary Motor . . . . . . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-24
X Contactor . . . . . . . . . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-24
Control Handle . . . . . . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-25
Deadman Pedal (Switch S2) . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-25
Emergency Disconnect . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-25
Key Switch (S1) . . . . . . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-25
Horn/Horn Button (S3) . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-25
Line Filter . . . . . . . . . . . . . . . . . . . . . ... ... ... .... . . . . . . . . . . . . . . . . . . . 1-25

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Inspecting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
How the Truck is Shipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Reasons for Doing a Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
What to Look For . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Repairing Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Repairing Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Uprighting a Cradled Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Warnings and Cautions. . .................. ... ..... . . . . . . . . . . . . . . . . . . . 2-4
Items Needed . . . . . . . . . .................. ... ..... . . . . . . . . . . . . . . . . . . . 2-4
Option 1: Uprighting with Two Chain Hoists . . . . ... ..... . . . . . . . . . . . . . . . . . . . 2-5
Option 2: Uprighting with One Chain Hoist and a Lift Truck . . . . . . . . . . . . . . . . . . . 2-6
Assembling the Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Removing the Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Greasing the Mast Uprights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Doing a Functional Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Who Does the Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
What Needs to be Done . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Starting the Caterpillar Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

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Reporting Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Using the Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Preparing the Truck for Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Classes of Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Types of Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Changing the Hydraulic System Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Preparing the Truck for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Storage Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
General Storage Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Mast Uprights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Micro CommandNA Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operator’s Display . . . . . . . . . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SelfTest . . . . . . . . . . . . . . . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Key On Hours (KH) . . . . . . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hours On Deadman (HD). . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hours Spent Lifting (HL) . . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Total Miles (TM). . . . . . . . . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Battery State-of-Charge . . . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Weight of Load on Forks . . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Truck Speed . . . . . . . . . . . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Status Messages . . . . . . . . . . . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Informational Messages . . . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Performance Limiting Codes ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Fault Codes. . . . . . . . . . . . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Audible Alarm . . . . . . . . . . . . . . ... .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Password Levels . . . . . . . . . . . . ... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Run Mode . . . . . . . . . . . . . . ... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Maintenance Mode (Maint) . ... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Configure Mode (Config) . . . ... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Learn Mode (Learn) . . . . . . . ... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Entering Program Mode . . . . ... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
During Initial Power Up . . . . ... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
After Initial Power Up . . . . . ... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Maintenance Mode . . . . . . . ... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Configure Mode . . . . . . . . . . ... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Learn Mode. . . . . . . . . . . . . . . . ... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Learn Mode Procedure. . . . . ... .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Operator’s Daily Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

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Operational Checks. . . . . . . . . . ... .... ... ... ... .... ... ... .... ... ... . . . 3-21
Start Up Procedure . . . . . . . ... .... ... ... ... .... ... ... .... ... ... . . . 3-21
Forward/Reverse Travel . . . ... .... ... ... ... .... ... ... .... ... ... . . . 3-22
Positive Speed Control . . . . . ... .... ... ... ... .... ... ... .... ... ... . . . 3-22
Braking . . . . . . . . . . . . . . . . ... .... ... ... ... .... ... ... .... ... ... . . . 3-22
Plugging . . . . . . . . . . . . . . . ... .... ... ... ... .... ... ... .... ... ... . . . 3-22
Parking . . . . . . . . . . . . . . . . ... .... ... ... ... .... ... ... .... ... ... . . . 3-23
Entering an Aisle. . . . . . . . . ... .... ... ... ... .... ... ... .... ... ... . . . 3-23
Ramp Operation . . . . . . . . . ... .... ... ... ... .... ... ... .... ... ... . . . 3-23
Travel Speed and Lift Limits ... .... ... ... ... .... ... ... .... ... ... . . . 3-24

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Wiring Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Operation of the Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Lowering: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Unique System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Lift/Lower Control Pin Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Auxiliary System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Operation of the Auxiliary System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Auxiliary Control Pin Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Sideshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Fork Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Traction System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-16
Chopper Control Module (CCM) . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-16
Power Transistor Control . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-16
Current Monitoring . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-16
Power Panel Temperature . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-17
Signal Verification . . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-17
Power Transistor (Q1) . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-17
H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-19
Contactor Coils . . . . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-20
Operation of the Traction System . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-21
Connecting Battery . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-21
Turning Key Switch (S1) ON - Before SelfTest ... .... ... ... .... ... ... . . . 4-22
Start-up Sequence. . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-23
SelfTest Checks . . . . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-24
Turning Key Switch (S1) ON - After SelfTest. . ... .... ... ... .... ... ... . . . 4-24
Closing Deadman Switch (S2) . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-25
Moving Directional/Speed Control . . . . . . . . . ... .... ... ... .... ... ... . . . 4-26
Closed-Loop Speed Control . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-28
Torque on Demand . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 4-29

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Thermal Cut-Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Operation of the Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Braking Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Troubleshooting Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance Practices . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . . 5-1
Jacking Truck . . . . . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . . 5-2
Welding Procedures . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . . 5-3
Electrostatic Discharge Damage . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . . 5-4
Proper Handling of Static Sensitive Devices . . ... .... ... ... .... ... ... . . . . 5-5
Special Tools Required . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . . 5-6
Integrated Circuit Removal/Replacement . . . . . . ... .... ... ... .... ... ... . . . . 5-8
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .... ... ... .... ... ... . . . 5-10
Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Planned Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Time Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Planned Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Battery Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Battery Electrical Leakage to Frame Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Battery State-of-Charge (BSOC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Hydrometer Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Battery History Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Vehicle Grounds General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Ground Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Adjustment and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Drive Transmission Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

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Drive Unit Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

ZF Drive Unit Repair Procedure -
24-Volt Vehicles (Serial Numbers 2NL01873 and below). . . .... ... ... . . . 5-49
Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-53
Braking Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-53
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-54
Brake Adjustment for Nut-Retained-Style Brakes . . . . . . . . . . .... ... ... . . . 5-57
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-74
Steering Adjustment (w/steerable caster). . . . . . . . . . . . . . . . . .... ... ... . . . 5-74
Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-77
Lift/Lower System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-80
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-80
Over The Mast Hose/Cable Adjustment . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-83
Over The Mast Hose Replacement . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-86
Flow Control Replacement (TT) . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-88
Equalization Chain Adjustment (TT) . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-90
Equalization Chain Removal/Installation (TT) . . . . . . . . . . . . . .... ... ... . . . 5-92
Equalization Chain Sheave Replacement . . . . . . . . . . . . . . . . . .... ... ... . . . 5-93
Equalization Chain Sheave Replacement (TT). . . . . . . . . . . . . . .... ... ... . . . 5-93
Reach Carriage Chain Anchors . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-94
Mechanical Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-94
Reach Carriage Lubrication Points. . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-95
Fork Carriage Pivot Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-95
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-97
Control Handle Linkage Adjustment . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 5-98

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TroubleshootingProcedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . . 6-1
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . . 6-3
Wiring-General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . . 6-3
Board and Component Swapping Precautions . . . . . . . . . . . . . .... ... ... . . . . 6-6
Likelihood of Component Failure . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . . 6-6
Handling Printed Circuit Cards . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . . 6-6
Major Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . . 6-7
Truck Completely Inoperative, S1 is ON, No 2-digit Display . . . .... ... ... . . . . 6-7
Power Panel Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-15
Power Panel Heat Sensor Replacement . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-16
Power Transistor (Q1) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-16
Chopper Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-17
TM1/TM2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-19
HCM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-21
Vehicle Manager Power Supply Test. . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-22
Coil Driver Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-23
Motor Open Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-24
Motor Short Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-25
Short Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-25
Motor Grounds Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-25
Motor Overheating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... ... . . . 6-26
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

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Hydraulic Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Hydraulic Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Hydraulic Maintenance Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Troubleshooting Micro CommandNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Learn Mode and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Maintenance Mode and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Using Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Informational Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Code 00 - All Systems Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Code 10 - Power Up Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Code 11 - Drive Motor Temperature HOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Code 12 - Lift Motor Temperature HOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Code 13 - Power Panel Temperature HOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Code 20 - Temperature Sensor Circuits Not Responding . . . . . . . . . ... ... . . . 6-41
Code 21 - Short Detected In Armature Circuit . . . . . . . . . . . . . . . . . ... ... . . . 6-42
Code 22 - Power Panel Overheated . . . . . . . . . . . . . . . . . . . . . . . . . ... ... . . . 6-43
Code 23 - Open Detected In Armature Circuit . . . . . . . . . . . . . . . . . ... ... . . . 6-44
Code 24 - Armature Current Sensor Circuit Not Responding . . . . . . ... ... . . . 6-45
Code 25 - Short Detected In Field Circuit. . . . . . . . . . . . . . . . . . . . . ... ... . . . 6-46
Code 26 - Open Detected In Field Circuit . . . . . . . . . . . . . . . . . . . . . ... ... . . . 6-47
Code 27 - Field Current Sensor Circuits Not Responding . . . . . . . . . ... ... . . . 6-48
Code 30 - Excessive Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . ... ... . . . 6-49
Code 32 - No Movement Detected When Travel Is Requested . . . . . . ... ... . . . 6-50
Code 34 - Drive Motor Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . ... ... . . . 6-51
Code 38 - Lift Motor Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . ... ... . . . 6-52
Code 40 - B Contactor Detected Closed When Commanded Open . . ... ... . . . 6-53
Code 41 - B Contactor Detected Open When Commanded Closed . . ... ... . . . 6-54
Code 42 - P Contactor Detected Closed When Commanded Open. . . ... ... . . . 6-55
Code 43 - P Contactor Detected Open When Commanded Closed. . . ... ... . . . 6-56
Code 44 - PC Contactor Detected Closed When Commanded Open . ... ... . . . 6-57
Code 45 - PC Contactor Detected Open When Commanded Closed . ... ... . . . 6-58
Code 49 - IS Contactor Detected Closed When Commanded Open . . ... ... . . . 6-59
Code 4A - IS Contactor Is Detected Open When Commanded Closed ... ... . . . 6-60
Code 6C - Main Lift Pressure Out Of Range . . . . . . . . . . . . . . . . . . . ... ... . . . 6-61
Code 73 - Armature Current Sensor Out Of Range . . . . . . . . . . . . . ... ... . . . 6-62
Code 74 - Power Panel Temperature Sensor Out Of Range . . . . . . . . ... ... . . . 6-63
Code 75 - Diag Sense Line Out Of Range . . . . . . . . . . . . . . . . . . . . . ... ... . . . 6-64
Code 77 - Battery Voltage Reading Out Of Range . . . . . . . . . . . . . . . ... ... . . . 6-65
Code 79 - +12-Volt Sense Reading Out Of Range . . . . . . . . . . . . . . . ... ... . . . 6-66
Code 7B - Traction Motor Temperature Sensor Out Of Range. . . . . . ... ... . . . 6-67
Code 7C - Lift Motor Temperature Out Of Range . . . . . . . . . . . . . . . ... ... . . . 6-68
Code 7E - Field Current Reading Out Of Range . . . . . . . . . . . . . . . . ... ... . . . 6-69
Code 80 - Throttle Controller Reading Out Of Range . . . . . . . . . . . . ... ... . . . 6-70
Code 84 - Brake Inoperable Or Not Properly Adjusted . . . . . . . . . . . ... ... . . . 6-71
Code 85 - Remote Lower Reading Out Of Range . . . . . . . . . . . . . . . . ... ... . . . 6-72
Code 86 - Remote Lift Reading Out Of Range . . . . . . . . . . . . . . . . . . ... ... . . . 6-73
Code 87 - Release Throttle To Resume Operation. . . . . . . . . . . . . . . ... ... . . . 6-74
Code A0 - Software Does Not Match Vehicle Setup. . . . . . . . . . . . . . ... ... . . . 6-75

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Code A1 - Uninitialized Operator's Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76

Code A2 - New VFC Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Code A3 - EPROM Failure Or Computer Not Enabled. . . . . . . . . . . . . . . . . . . . . 6-78
Code A4 - COP Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Code EC - Operating System Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Code EF - Bad ODI Checksum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Analog Test Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
Analog Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Test: A01 - 1S Contactor Sense Voltage . . . . . . . . . . . . ... ... .. . . . . . . . . . . . 6-85
Test: A02 - Lift Pump (P) Contactor Sense Voltage . . . . ... ... .. . . . . . . . . . . . 6-86
Test: A04 - Throttle Pot Voltage . . . . . . . . . . . . . . . . . . ... ... .. . . . . . . . . . . . 6-88
Test A06 - Display Remote Lift Sense Voltage . . . . . . . ... ... .. . . . . . . . . . . . 6-89
Test A07 - Display Remote Lower Sense Voltage . . . . . ... ... .. . . . . . . . . . . . 6-90
Test: A08 - Traction Motor Temperature Voltage . . . . . ... ... .. . . . . . . . . . . . 6-91
Test: A08 - Traction Motor Temperature (cont’d) . . . . . ... ... .. . . . . . . . . . . . 6-92
Test: A09 - Lift Pump Motor Temp/Voltage . . . . . . . . . ... ... .. . . . . . . . . . . . 6-93
Test: A09 - Lift Pump Motor Temp/Voltage (Cont’d) . . . ... ... .. . . . . . . . . . . . 6-94
Test: A10 - Panel Temperature Sensor Voltage . . . . . . . ... ... .. . . . . . . . . . . . 6-95
Test: A10 - Panel Temperature Sensor Voltage (Cont’d) ... ... .. . . . . . . . . . . . 6-96
Test: A11 - Armature Current Sensor Voltage . . . . . . . ... ... .. . . . . . . . . . . . 6-97
Test A12 - Field Current Sensor Voltage . . . . . . . . . . . ... ... .. . . . . . . . . . . . 6-98
Test A13 - Pressure Sensor Voltage . . . . . . . . . . . . . . . ... ... .. . . . . . . . . . . . 6-99
Test A14 - Power Supply +12 Voltage. . . . . . . . . . . . . . ... ... .. . . . . . . . . . . 6-101
Test A15 - Battery Voltage . . . . . . . . . . . . . . . . . . . . . . ... ... .. . . . . . . . . . . 6-102
Test A16 - Diag Sense Voltage . . . . . . . . . . . . . . . . . . . ... ... .. . . . . . . . . . . 6-103
Test A18 - Remote Lift/Lower . . . . . . . . . . . . . . . . . . . ... ... .. . . . . . . . . . . 6-104
Digital Input Test Summary . . . . . . . . . . . . . . . . . . . . ... ... .. . . . . . . . . . . 6-105
Digital Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107
Test I00 - Deadman Switch . . . . . . . . . . . . . . . . . .... ... ... .... ... ... . . 6-107
Test I01 - Remote EPO and/or Unnested Switch . .... ... ... .... ... ... . . 6-109
Test I02 - Mast Switch #1 . . . . . . . . . . . . . . . . . . .... ... ... .... ... ... . . 6-110
Test I03 - Mast Switch #2 . . . . . . . . . . . . . . . . . . .... ... ... .... ... ... . . 6-111
Test I04 - Lift Bypass Switch . . . . . . . . . . . . . . . . .... ... ... .... ... ... . . 6-112
Test I05 - Lift Inhibit Mast Switch . . . . . . . . . . . . .... ... ... .... ... ... . . 6-113
Test I06 - Reach Switch . . . . . . . . . . . . . . . . . . . . .... ... ... .... ... ... . . 6-114
Test I07 - Retract Switch . . . . . . . . . . . . . . . . . . . .... ... ... .... ... ... . . 6-115
Test I08 - Tilt-Up Switch . . . . . . . . . . . . . . . . . . . .... ... ... .... ... ... . . 6-116
Test I09 - Tilt-Down Switch . . . . . . . . . . . . . . . . . .... ... ... .... ... ... . . 6-117
Test I10 - Sideshift-Right Switch . . . . . . . . . . . . . .... ... ... .... ... ... . . 6-118
Test I11- Sideshift-Left Switch . . . . . . . . . . . . . . . .... ... ... .... ... ... . . 6-119
Test I12 - Power Panel Temperature Limit Signal . .... ... ... .... ... ... . . 6-120
Test I13 - Armature Current Limit Signal. . . . . . . .... ... ... .... ... ... . . 6-122
Test I14 - Field Current Limit Signal . . . . . . . . . . .... ... ... .... ... ... . . 6-124
Test I15 - Horn Button . . . . . . . . . . . . . . . . . . . . .... ... ... .... ... ... . . 6-126
Test I16 - Encoder Count . . . . . . . . . . . . . . . . . . .... ... ... .... ... ... . . 6-127
Test I17- Lift Switch & Lower Switch Status . . . . .... ... ... .... ... ... . . 6-129
Digital Output Test Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-130
Digital Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-132
Test O01 - Toggle the 1S Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134

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Test O02 - Toggle the P Contactor . . . . . . . . . . . . . . . . ... ... .... ... ... . . 6-136
Test O04 - Toggle Solenoid DIRA . . . . . . . . . . . . . . . . . ... ... .... ... ... . . 6-138
Test O05 - Toggle Solenoid DIRB . . . . . . . . . . . . . . . . . ... ... .... ... ... . . 6-140
Test O06 - Toggle Reach Solenoid . . . . . . . . . . . . . . . . ... ... .... ... ... . . 6-142
Test O07 - Toggle Tilt Solenoid . . . . . . . . . . . . . . . . . . ... ... .... ... ... . . 6-144
Test O08 - Toggle Sideshift Solenoid . . . . . . . . . . . . . . ... ... .... ... ... . . 6-146
Test O09 - Toggle Equalizing Solenoid (E/Q) . . . . . . . . ... ... .... ... ... . . 6-148
Test O10 - Toggle 2ND-Stage Solenoid . . . . . . . . . . . . . ... ... .... ... ... . . 6-150
Test O11 - Toggle Load-Holding Solenoid . . . . . . . . . . . ... ... .... ... ... . . 6-152
Test O13 - Chopper Control Module Enable Signal . . . ... ... .... ... ... . . 6-154
Test O14 - Chopper Control Module PWM Test . . . . . . ... ... .... ... ... . . 6-156
Test O15 - HCM Forward Enable Test . . . . . . . . . . . . . ... ... .... ... ... . . 6-158
Test O16 - HCM Reverse Enable Test. . . . . . . . . . . . . . ... ... .... ... ... . . 6-159
Test O17 - HCM PWM Ramp . . . . . . . . . . . . . . . . . . . . ... ... .... ... ... . . 6-160
Test O18 - Toggle Horn . . . . . . . . . . . . . . . . . . . . . . . . ... ... .... ... ... . . 6-161
Test O19 - Audible Alarm Test . . . . . . . . . . . . . . . . . . . ... ... .... ... ... . . 6-162
Test O20 - Forward Relay Test. . . . . . . . . . . . . . . . . . . ... ... .... ... ... . . 6-163
Test O21 - Reverse Relay Test . . . . . . . . . . . . . . . . . . . ... ... .... ... ... . . 6-164
Status Code Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-165
Status Code Summary Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-167

Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Supplement - Dealer/Technician
Configuration Program: User Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Overview . . . . . . . . . . . . . . . . . . . . .. ... ... ... .... ... ... .... ... ... . . . . 7-3
System Requirements . . . . . . . . . . .. ... ... ... .... ... ... .... ... ... . . . . 7-3
Connecting PC. . . . . . . . . . . . . . . . .. ... ... ... .... ... ... .... ... ... . . . . 7-4
Start-Up . . . . . . . . . . . . . . . . . . . . .. ... ... ... .... ... ... .... ... ... . . . . 7-5
Main Menu . . . . . . . . . . . . . . . . . . .. ... ... ... .... ... ... .... ... ... . . . . 7-6
MC2 Configuration Information . . . .. ... ... ... .... ... ... .... ... ... . . . . 7-9
Change Truck Options. . . . . . . . . . .. ... ... ... .... ... ... .... ... ... . . . . 7-9
Lost Communications . . . . . . . . . . .. ... ... ... .... ... ... .... ... ... . . . 7-14
Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Standard Torque Data For Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Electrical & Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

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0:

List of Figures
Figure 1-1: Caterpillar Reach Truck ................................................................................. 1-1
Figure 1-2: Specification Plate ......................................................................................... 1-3
Figure 1-3: Component Identification............................................................................... 1-5
Figure 1-4: Operator’s Console......................................................................................... 1-8
Figure 1-5: Hydraulic Steering Components................................................................... 1-10
Figure 1-6: Hydraulic System Components .................................................................... 1-12
Figure 1-7: Operator’s Display ....................................................................................... 1-17
Figure 1-8: Vehicle Manager - Installed View.................................................................. 1-18
Figure 1-9: Vehicle Manager - Internal View................................................................... 1-18
Figure 1-10: Vehicle Function Controller (VFC) ................................................................ 1-19
Figure 1-11: Power Panel Driver Assembly Location ......................................................... 1-20
Figure 1-12: Hydraulic Driver Assembly Board Location .................................................. 1-21
Figure 1-13: Drive Motor Encoder Location ...................................................................... 1-23
Figure 1-14: Platform Components (Hydraulic) ................................................................ 1-26
Figure 1-15: Platform Components (Electrical) ................................................................. 1-27
Figure 2-1: Recommended Oil by Temperature .............................................................. 2-12
Figure 3-1: Operator’s Display ........................................................................................ 3-2
Figure 3-2: Preparing Vehicle Manager for Program Mode (VFC display "00" appears
after truck has passed SelfTest) .................................................................... 3-8
Figure 3-3: Entering Program Mode ................................................................................. 3-9
Figure 3-4: Simultaneous Function Control Handle ....................................................... 3-10
Figure 3-5: Operator Display for Program Mode (Example Only) ..................................... 3-11
Figure 3-6: VFC Indicating SUPERWRD has been Entered ............................................. 3-12
Figure 3-7: Vehicle Manager in Configure Mode after Password is Entered ..................... 3-12
Figure 3-8: VFC Shown in Maintenance Mode................................................................ 3-14
Figure 3-9: Learn Mode.................................................................................................. 3-19
Figure 4-1: Lift/Lower Functional Block Diagram (36-Volt Vehicle with Two-Stage
Lift Shown). ................................................................................................... 4-4
Figure 4-2: Hydraulic Schematic-Variable Lift.................................................................. 4-5
Figure 4-3: Hydraulic Schematic-High Speed Lift ............................................................. 4-5
Figure 4-4: Auxiliary System Components ....................................................................... 4-6
Figure 4-5: Auxiliary System Functional Block Diagram................................................... 4-7
Figure 4-6: Hydraulic Schematic - Reach (Slow or First Speed)....................................... 4-10
Figure 4-7: Hydraulic Schematic - Sideshift ................................................................... 4-11
Figure 4-8: Hydraulic Schematic - Fork Tilt ................................................................... 4-12
Figure 4-9: Traction Circuit Functional Block Diagram .................................................. 4-15
Figure 4-10: Power Amplifier Schematic........................................................................... 4-16
Figure 4-11: Power Transistor Operation ......................................................................... 4-18
Figure 4-12: Power Transistor (Q1) Appearance ............................................................... 4-18
Figure 4-13: Power Transistor Electrical Symbol .............................................................. 4-19
Figure 4-14: Voltage Readings for 24-Volt Contactor Coil ................................................. 4-20
Figure 4-15: Torque on Demand ...................................................................................... 4-29
Figure 4-16: Speed Reduction as Drive Motor Temperature Increases .............................. 4-30
Figure 4-17: Thermal Cut-Back ....................................................................................... 4-31
Figure 4-18: Current Limiting .......................................................................................... 4-31
Figure 4-19: Duty Cycle Comparison for Current Limiting................................................ 4-32
Figure 4-20: Steering Components................................................................................... 4-35
Figure 4-21: Brake Hydraulic Schematic.......................................................................... 4-37
Figure 4-22: Electrical Schematic - Battery Connected (Sheet 1 of 2) ............................... 4-40
Figure 4-22: Electrical Schematic - Battery Connected (Sheet 2 of 2) ............................... 4-41

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Figure 4-23: Schematic - Turning Key Switch ON, Before SelfTest (Sheet 1 of 2) .............. 4-42
Figure 4-23: Schematic - Turning Key Switch ON, Before SelfTest (Sheet 2 of 2) .............. 4-43
Figure 4-24: Schematic - Turning Key Switch ON, After SelfTest (Sheet 1 of 2) ................ 4-44
Figure 4-24: Schematic - Turning Key Switch ON, After SelfTest (Sheet 2 of 2) ................ 4-45
Figure 4-25: Schematic - Closing Deadman Switch (Sheet 1 of 2) .................................... 4-46
Figure 4-25: Schematic - Closing Deadman Switch (Sheet 2 of 2) .................................... 4-47
Figure 4-26: Schematic - Moving Directional/Speed Control to Forward (Sheet 1 of 2) ..... 4-48
Figure 4-26: Schematic - Moving Directional/Speed Control to Forward (Sheet 2 of 2) ..... 4-49
Figure 4-27: Schematic - Plugging (Sheet 1 of 2) ............................................................. 4-50
Figure 4-27: Schematic - Plugging (Sheet 2 of 2) ............................................................. 4-51
Figure 4-28: Schematic - Power Transistor OFF (Sheet 1 of 2) ......................................... 4-52
Figure 4-28: Schematic - Power Transistor OFF (Sheet 2 of 2) ......................................... 4-53
Figure 4-29: Schematic - Reach (Sheet 1 of 2) ................................................................. 4-54
Figure 4-29: Schematic - Reach (Sheet 2 of 2) ................................................................. 4-55
Figure 4-30: Schematic - Sideshift (Sheet 1 of 2) ............................................................. 4-56
Figure 4-30: Schematic - Sideshift (Sheet 2 of 2) ............................................................. 4-57
Figure 4-31: Schematic - Fork Tilt (Sheet 1 of 2) ............................................................. 4-58
Figure 4-31: Schematic - Fork Tilt (Sheet 2 of 2) ............................................................. 4-59
Figure 5-1: Correct Jacking Locations.............................................................................. 5-3
Figure 5-2: Proper/Improper Method of Holding Circuit Card........................................... 5-4
Figure 5-3: Anti-Static Kit (P/N 1056022) with Wrist Strap and Mat ................................ 5-6
Figure 5-4: End View (Enlarged) of a Typical Molex Connector ......................................... 5-7
Figure 5-5: Pin Extraction Tool Inserted into Molex Connector ......................................... 5-7
Figure 5-6: Cable Connector Breakout Board ................................................................... 5-7
Figure 5-7: Removing Integrated Circuit........................................................................... 5-8
Figure 5-8: Preparing Integrated Circuit for Insertion ....................................................... 5-8
Figure 5-9: Integrated Chip/Socket Orientation ............................................................... 5-9
Figure 5-10: Installation of Integrated Circuit .................................................................... 5-9
Figure 5-11: Lubrication/Inspection Points...................................................................... 5-17
Figure 5-12: Example of Cleaning Motor .......................................................................... 5-28
Figure 5-13: Measuring Brush Spring Tension................................................................. 5-30
Figure 5-14: Drive Motor Armature Terminal - Proper Torque .......................................... 5-31
Figure 5-15: Motor Terminal Torque Specification for All Other Motors ............................ 5-32
Figure 5-16: Motor Terminals and Circuits ...................................................................... 5-33
Figure 5-17: Drive Unit Replacement Tool........................................................................ 5-41
Figure 5-18: Lower End of Drive Unit............................................................................... 5-44
Figure 5-19: Ring Gear Before Being Pressed Toward Flange............................................ 5-45
Figure 5-20: Ring Gear After Being Pressed Toward Flange .............................................. 5-45
Figure 5-21: Removing Bearing Spacer Using Bearing Puller ............................................ 5-46
Figure 5-22: Removing External Snap Ring...................................................................... 5-46
Figure 5-23: Removing Output Shaft ............................................................................... 5-47
Figure 5-24: Removal/Installation of Shaft Seal ............................................................... 5-47
Figure 5-25: Installing Ring Gear ..................................................................................... 5-48
Figure 5-26: Brake Assembly ........................................................................................... 5-54
Figure 5-27: Brake Schematic.......................................................................................... 5-54
Figure 5-28: Typical Snap-Ring-Style Brake Installation .................................................. 5-55
Figure 5-29: Brake Gap Tool............................................................................................ 5-57
Figure 5-30: Brake Adjusting Bolt Detail.......................................................................... 5-58
Figure 5-31: Deadman Brake Pedal Installation (Sheet 1 of 2) .......................................... 5-62
Figure 5-31: Deadman Brake Pedal Installation (Sheet 2 of 2) .......................................... 5-63
Figure 5-32: Nut-Retained Style Brake Assembly (Sheet 1 of 2) ........................................ 5-66
Figure 5-32: Nut-Retained Style Brake Assembly (Sheet 2 of 2) ........................................ 5-67

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List of Figures

Figure 5-33: Hydraulic Brake - 24 Volt ............................................................................ 5-71

Figure 5-34: Hydraulic Brake - 36 Volt ............................................................................ 5-72
Figure 5-35: High Side of Brake Hub Assembly ................................................................ 5-73
Figure 5-36: Steering Adjustments................................................................................... 5-74
Figure 5-37: Caster Adjustment....................................................................................... 5-76
Figure 5-38: Stops Adjustment ........................................................................................ 5-77
Figure 5-39: Steering Maintenance Notes (Sheet 1 of 2).................................................... 5-78
Figure 5-39: Steering Maintenance Notes (Sheet 2 of 2).................................................... 5-79
Figure 5-40: Lubrication of Lift Chain Spherical Nut ........................................................ 5-82
Figure 5-41: Blocking Mast.............................................................................................. 5-83
Figure 5-42: Hose Clamping on Inner Telescopic.............................................................. 5-84
Figure 5-43: Hose/Cable Tension Spring Adjustment....................................................... 5-84
Figure 5-44: Hose Routing Detail ..................................................................................... 5-87
Figure 5-45: Mast Flow Control ....................................................................................... 5-89
Figure 5-46: Rear Cylinder Piston/End Cap ..................................................................... 5-89
Figure 5-47: Adjusting Equalization Chain....................................................................... 5-91
Figure 5-48: Removing Equalization Chain Sheave .......................................................... 5-94
Figure 5-49: Mechanical Stop Adjustment ....................................................................... 5-95
Figure 5-50: Reach Assembly Lubrication (Deep Reach Shown)........................................ 5-95
Figure 5-51: Removing Tilt Pivot Pin ................................................................................ 5-96
Figure 5-52: Attaching Mast to Tractor ............................................................................ 5-97
Figure 5-53: Control Handle/Spool Valve Linkage............................................................ 5-98
Figure 5-54: Spool Valve Connecting Block ...................................................................... 5-98
Figure 5-55: Control Handle Assembly with Allen Wrench Inserted .................................. 5-99
Figure 6-1: Power Panel Assembly ................................................................................. 6-15
Figure 6-2: Voltage Test Points for Power Transistor Q1 ................................................. 6-17
Figure 6-3: Resistance Test Points for Power Transistor Q1............................................ 6-18
Figure 6-4: Power Transistor (Q1) Schematic ................................................................. 6-18
Figure 6-5: Transistor Module for Field Wiring Assembly ............................................... 6-19
Figure 6-7: HCM Test .................................................................................................... 6-22
Figure 6-8: Drive Motor Terminals and Circuits ............................................................. 6-24
Figure 6-9: Pinout for JPT2 ......................................................................................... 6-122
Figure 6-10: Pinout for JPH2 ......................................................................................... 6-124
Figure 6-11: Pinout for JPT2.......................................................................................... 6-154
Figure 6-12: Pinout for JPH2 - Reverse HCM Enable...................................................... 6-155
Figure 6-13: Pinout for JPH2 - Forward HCM Enable ..................................................... 6-158
Figure 6-14: Pinout for JPH2 - “Reverse HCM Enable” ................................................... 6-159
Figure 7-1: Communication Adapter Module (P/N NA012780).......................................... 7-3
Figure 7-2: Opening Display ............................................................................................ 7-5
Figure 7-3: Communication Error Screen......................................................................... 7-6
Figure 7-4: Main Menu .................................................................................................... 7-7
Figure 7-5: Checking Current Selected Options using F1 Key........................................... 7-7
Figure 7-6: Selecting Function in Main Menu................................................................... 7-8
Figure 7-7: Entering Vehicle Pass-Key ........................................................................... 7-10
Figure 7-8: Configuration Menu after Last Character is Entered But Before
Enter Key is Pressed. ................................................................................... 7-11
Figure 7-9: Configuration Menu after Enter Key is Pressed ............................................ 7-12
Figure 7-10: Reviewing Option List after Adding Option ................................................... 7-12
Figure 7-11: Display After an Incorrect Pass-Key is Entered............................................. 7-13
Figure 7-12: Selecting Initialize........................................................................................ 7-13
Figure 7-13: Vehicle Manager Initialized to Factory Default Values .................................. 7-14
Figure 7-14: Communication Error Screen....................................................................... 7-15

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List of Figures

Figure 7-15: Connector Wiring......................................................................................... 7-16

Figure 7-16: Problem Report ............................................................................................ 7-17
Figure 7-17: Electrical Schematic 24V, Single Filter (Sheet 1 of 8) ................................... 7-26
Figure 7-17: Electrical Schematic 24V, Single Filter (Sheet 2 of 8) ................................... 7-27
Figure 7-17: Electrical Schematic 24V, Single Filter (Sheet 3 of 8 .................................... 7-28
Figure 7-17: Electrical Schematic 24V, Single Filter (Sheet 4 of 8) ................................... 7-29
Figure 7-17: Electrical Schematic 24V, Single Filter (Sheet 5 of 8) ................................... 7-30
Figure 7-17: Electrical Schematic 24V, Single Filter (Sheet 6 of 8) ................................... 7-31
Figure 7-17: Electrical Schematic 24V, Single Filter (Sheet 7 of 8) ................................... 7-32
Figure 7-17: Electrical Schematic 24V, Single Filter (Sheet 8 of 8) ................................... 7-33
Figure 7-18: Electrical Schematic 36V, Single Filter (Sheet 1 of 8) ................................... 7-34
Figure 7-18: Electrical Schematic 36V, Single Filter (Sheet 2 of 8) ................................... 7-35
Figure 7-18: Electrical Schematic 36V, Single Filter (Sheet 3 of 8) ................................... 7-36
Figure 7-18: Electrical Schematic 36V, Single Filter (Sheet 4 of 8) ................................... 7-37
Figure 7-18: Electrical Schematic 36V, Single Filter (Sheet 5 of 8) ................................... 7-38
Figure 7-18: Electrical Schematic 36V, Single Filter (Sheet 6 of 8) ................................... 7-39
Figure 7-18: Electrical Schematic 36V, Single Filter (Sheet 7 of 8) ................................... 7-40
Figure 7-18: Electrical Schematic 36V, Single Filter (Sheet 8 of 8) ................................... 7-41
Figure 7-19: Hydraulic Schematic (Sheet 1 of 1) ............................................................. 7-42
Figure 7-20: Decal Replacement (Sheet 1 of 3) ................................................................. 7-43
Figure 7-21: Decal Replacement (Sheet 2 of 3) ................................................................. 7-44
Figure 7-22: Decal Replacement (Sheet 3 of 3) ................................................................. 7-45
Figure 7-23: Minimum Brush Lengths ............................................................................. 7-46

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