Service Manual - 7400-7420-7440 Reach Fork
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Maintenance Manual
Model 7400/7420/7440 Reach-Fork ® Truck
With The ACR System ™
Series Serial Numbers
AA 00001 and above
BA
CA
DA
EA
FA
1026304B Issued: 15 Jul 2007
Replaces 1026304A Issued: 15 Jun 2004
This 1026304B applies to the Model 7400/7420/7440 Reach-Fork ® Lift Truck, Series AA, BA, CA, DA, EA, FA,
S/N 00001 and above, and to all subsequent releases of this product until otherwise indicated in new editions
or bulletins. Changes occur periodically to the information in this publication.
For revision information, see “Page Revision Record” on page v.
If you need assistance with your lift truck, or to order additional copies of this manual, contact your local
authorized Raymond dealer.
To locate your local authorized Raymond dealer, go to www.raymondcorp.com.
©2004, 2005, 2006, 2007 The Raymond Corporation.
The following terms are trademarks of The Raymond Corporation: Raymond, Auto Power Off, Deep-Reach,
Maintenance Minder, Reach-Fork, and The ACR System. All other brand and product names are trademarks or
registered trademarks of their respective companies.
Model 7400/7420/7440 Reach-Fork ® Truck Table of Contents
Table of Contents
Page Revision Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Service Bulletins Included . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Product Improvement Notices Included . . . . . . . . . . . . . . . . . . . . . . . viii
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Design of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Abbreviations, Acronyms, and Symbols . . . . . . . . . . . . . . . . . . . . . . . 1-5
START Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Tie-Down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Minder ™ Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial 90 Day or 250 Deadman Hour Interval . . . . . . . . . . . . . . . . . . 4-5
Every 180 Days or 500 Deadman Hours . . . . . . . . . . . . . . . . . . . . . . 4-6
Every 360 Days or 2000 Deadman Hours (HD) . . . . . . . . . . . . . . . . 4-11
Scheduled Maintenance Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Chain Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Shorts to Frame Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
DC Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
AC Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Battery State-of-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-13
Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . 5-19
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . 5-31
Messages, Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Software Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Power Amplifier LED Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
1026304B, 15 July 2007 i
Table of Contents Model 7400/7420/7440 Reach-Fork ® Truck
Electrical Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-115
Circuit Card Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-116
Analog Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121
Digital Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-151
Digital Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-183
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Mast and Standard Reach Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Tractor, AC Lift, Fore-Aft Stance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Tractor, DC Lift, Side Stance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Mast with Standard Reach Carriage . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Underside Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Covers and Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Cover Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Covers Component Procedures Summary . . . . . . . . . . . . . . . . . . . . 7-24
Cover Drawings, All Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Cover Drawings, Series AA/BA/CA (Fore-Aft Stance) . . . . . . . . . . . . 7-28
Cover Drawings, Series DA/EA/FA (Side Stance) . . . . . . . . . . . . . . . 7-31
Decals and Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Steering and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Steering and Controls Component Procedures Summary . . . . . . . . . 7-40
Steering Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
Steer Limit Switch (S11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Steerable Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Steering Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Drive and Brake Component Procedures Summary . . . . . . . . . . . . . 7-76
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Brake, Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
Deadman Switch (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102
Inertial Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-103
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107
Electrical Component Procedures Summary . . . . . . . . . . . . . . . . . 7-108
Battery Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-113
Wiring and Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 7-116
Contactor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-121
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122
Temperature .Sensor, AC Motor, LMT/TMT (Danaher Motor) . . . . . 7-123
Speed Sensor, AC Motor (Danaher Motor) . . . . . . . . . . . . . . . . . . . 7-124
Steer Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-126
Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-129
Hydraulic Component Procedures Summary . . . . . . . . . . . . . . . . . 7-130
Hydraulic System Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-134
Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-135
Lift Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137
Manual Lowering of Fork Carriage . . . . . . . . . . . . . . . . . . . . . . . . . 7-138
Proportional Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-139
Auxiliary Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-140
Manifold, Main, AC Lift, Model 7400 . . . . . . . . . . . . . . . . . . . . . . . 7-141
ii 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Table of Contents
Manifold, Main, AC Lift, Model 7420/7440 . . . . . . . . . . . . . . . . . . 7-143
Manifold, Main, DC Lift, Model 7400 . . . . . . . . . . . . . . . . . . . . . . . 7-145
Manifold, Auxiliary (Single Reach) . . . . . . . . . . . . . . . . . . . . . . . . . 7-147
Manifold, Reach (Deep-Reach ®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-149
Manifold, Tilt/Sideshift (Deep-Reach ®) . . . . . . . . . . . . . . . . . . . . . . 7-151
Manifold Solenoids, Fittings, and Attachments . . . . . . . . . . . . . . . 7-152
Hydraulic Components, Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . 7-155
Hydraulic Component (Cylinder) Procedures Summary . . . . . . . . . 7-156
Lift Cylinder, Free Lift, Remove/Install . . . . . . . . . . . . . . . . . . . . . 7-157
Lift Cylinder, Free Lift, Exploded Parts Drawing . . . . . . . . . . . . . . . 7-161
Lift Cylinder, Free Lift, Seal Repacking . . . . . . . . . . . . . . . . . . . . . 7-164
Lift Cylinder, Main, Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . 7-167
Lift Cylinder, Main Lift, Exploded Parts Drawing . . . . . . . . . . . . . . 7-172
Lift Cylinder, Main, Seal Repacking . . . . . . . . . . . . . . . . . . . . . . . . 7-174
Lift Cylinder Lowering Cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-176
Reach Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-179
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-182
Flow Limiter, Main Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-184
Flow Limiter, Free Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-185
Mast, Chain, Hose, Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-187
Mast, Chain, Hose, Cable Component Procedures Summary . . . . . 7-188
Baseleg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-191
Bearings, Reach Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-193
Bearing Shimming, Mast Telescopics . . . . . . . . . . . . . . . . . . . . . . . 7-194
Bow Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-196
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-198
Chain Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-201
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-208
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-213
Height Encoder Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-214
Hose, Main Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-219
Hose and Cable, Over-the-Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-220
Cable, Over-the-Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-229
Hose/Tubing, Free Lift Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-234
Mast, Model 7400 (Complete Disassembly) . . . . . . . . . . . . . . . . . . 7-235
Mast, Model 7400 (Complete Assembly) . . . . . . . . . . . . . . . . . . . . . 7-239
Mast, Model 7420 (Complete Disassembly) . . . . . . . . . . . . . . . . . . 7-247
Mast, Model 7420 (Complete Assembly) . . . . . . . . . . . . . . . . . . . . . 7-252
Mast, Model 7440 (Complete Disassembly) . . . . . . . . . . . . . . . . . . 7-258
Mast, Model 7440 (Complete Assembly) . . . . . . . . . . . . . . . . . . . . . 7-262
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-271
Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-273
Options Component Procedures Summary . . . . . . . . . . . . . . . . . . . 7-274
Operator Compartment Sensor System . . . . . . . . . . . . . . . . . . . . . 7-275
Vantage Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-294
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Traction System Functional Operation . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Hydraulic System Functional Operation (AC Lift Motor) . . . . . . . . . . 8-25
Hydraulic System Functional Operation (DC Lift Motor) . . . . . . . . . . 8-68
Electric Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-110
Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-113
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
1026304B, 15 July 2007 iii
Table of Contents Model 7400/7420/7440 Reach-Fork ® Truck
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Straight Thread Face Seal O-Rings . . . . . . . . . . . . . . A-5
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Torque Chart - Metric (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Electrical Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17
Model 74xx Series CA/FA (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . A-18
Model 74xx Series CA/FA (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . A-19
Model 74xx Series AA/BA/DA/EA (DC lift) . . . . . . . . . . . . . . . . . . . A-20
Model 74xx Series AA/BA/DA/EA (DC lift) . . . . . . . . . . . . . . . . . . . A-21
Model 74xx Options (All Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-22
Model 74xx Options (All Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23
Model 74xx Options (All Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24
Model 74xx Options - Vantage Point . . . . . . . . . . . . . . . . . . . . . . . . A-25
Model 74xx Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26
Model 74xx Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27
Model 74xx Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28
Power Distribution Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-29
Model 74xx Series CA/FA (AC Lift) (Page 1 of 2) . . . . . . . . . . . . . . . . A-30
Model 74xx Series CA/FA (AC Lift) (Page 2 of 2) . . . . . . . . . . . . . . . . A-31
Model 74xx Series AA/BA/DA/EA (DC Lift) (1 of 2) . . . . . . . . . . . . . A-32
Model 74xx Series AA/BA/DA/EA (DC lift) (2 of 2) . . . . . . . . . . . . . . A-33
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-35
Model 74xx Series CA/FA (AC lift) (Page 1 of 2) . . . . . . . . . . . . . . . . A-36
Model 74xx Series CA/FA (AC lift) (Page 2 of 2) . . . . . . . . . . . . . . . . A-37
Model 74xx Series AA/DA (DC lift) (Page 1 of 2) . . . . . . . . . . . . . . . . A-38
Model 74xx Series AA/BA/DA/EA (Page 2 of 2, Single Reach) . . . . . A-39
Model 74xx Series BA/EA (DC Lift, Page 1 of 2) . . . . . . . . . . . . . . . . A-40
Model 74xx Series AA/BA/DA/EA (Page 2 of 2, Deep-Reach ®) . . . . . . A-41
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
iv 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck
Page Revision Record
Page Revision Record
• 1026304A . . . . . . . . . . . . . . . Original Issue, dated 15 Jun 2004
• 1026304B . . . . . . . . . . . . . . . Updated Issue, dated 15 Jul 2007
Publication 1026304B is a major update to Publication 1026304A. The book has been repaginated,
so page numbers in most cases will not correspond.
Publication 1026304B includes the following additions:
• Abbreviations, Acronyms, and Symbols • Control Handle Component Replacements
List • Model 7400 Over-the-Mast Cable
• Model 7420 Component Procedures Replacement using Bulk Cable
• Model 7440 Component Procedures • Electric Brake Theory of Operation
• Revised Scheduled Maintenance • Operator Compartment Sensor System
Schedules Option
• New Fault Codes 58, 8A • Vantage Point System Option
• New Tests I80, I81, I86
1026304B, 15 July 2007 v
Model 7400/7420/7440 Reach-Fork ® Truck
Page Revision Record
vi 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck
Service Bulletins Included
Service Bulletins
Included
Table 1-1. Service Bulletin content included in this manual
Document Number Subject Date
RCH-04-009 VM 2.2 and DM 2.1 software release 7 Dec 2004
RCH-04-010 Condensation in cold storage fore-aft primary control handle 8 Dec 2004
RCH-05-002 Condensation in cold storage fore-aft primary control handle 22 Feb 2005
RCH-05-004 SOL3 coil nut torque 16 Feb 2005
RCH-05-005 One-piece hydraulic filter 4 Apr 2005
RCH-05-006 HTI encoder/belt guard for freezer curtain application 8 Apr 2005
RCH-05-009 Main Lift Cylinder Hose/Cable Retainer Hardware 19 Apr 2005
RCH-05-010A Main Lift Cylinder retention 24 Feb 2006
RCH-05-013 Reach Scissor Roller shimming 20 May 2005
RCH-05-016 VM 2.5 and DM 2.3 software release 29 Jun 2005
RCH-05-019 Steer Manager cable routing 6 Oct 2005
RCH-06-007 Air gap adjuster nuts on electric brakes 7 Sep 2006
RCH-06-008 Over-the-Mast Pulley Hose Guard 6 Sep 2006
RCH-06-009 VM 2.7 and DM 2.4 software release 24 Oct 2006
RCH-06-011 VM 3.3 and DM 2.4 for false fault codes FE and FG 11 Oct 2006
RCH-06-013 Deep-Reach ® Carriage drift 21 Dec 2006
RCH-07-002 VM 3.7 and DM 2.6 software release 13 Mar 2007
RCH-07-004A Main Lift Chain Sheave Alignment Adjustment 1 May 2007
RCH-07-005 Error Code 2U 6 Jun 2007
RCH-07-006 Hydraulic Filter with Shield for Model 7400 Series BA/EA 17 May 2007
RCH-07-008 Reach Cylinder Jam Nut 11 Jun 2007
1026304B, 15 July 2007 vii
Model 7400/7420/7440 Reach-Fork ® Truck
Product Improvement Notices Included
Product Improvement
Notices Included
Table 1-2. Product Improvement Notice content included in this manual
Document Number Subject Date
RCH-04-R010 FlashWare version 2.0 7 Jun 2004
RCH-04-R011 2-piece hydraulic filter 27 Sep 2004
RCH-04-R012 Matching versions of VM and DM software 23 Sep 2004
RCH-04-R017 VM 2.1 and DM 2.0 software release 7 Dec 2004
RCH-05-R004 VM 2.3 and DM 2.2 software release 23 May 2005
RCH-05-R005 Loop back test corrections to Tests I33 through I36 1 Aug 2005
RCH-05-R007 7400 Lift Chain adjustment 1 Aug 2005
RCH-05-R010 Code FE performance limits 1 Aug 2005
RCH-05-R018 Power Amplifier cooling fan diagnosis 30 Oct 2005
RCH-06-R004 Field repair of Model 7400 control handles 28 Jul 2006
RCH-06-R005 Free Lift Cylinder Pressure Ring orientation 19 Sep 2006
RCH-06-R008 7400 Bow Pad inspection, adjustment, replacement 18 Oct 2006
RCH-06-R009 Service interval correction 8 Sep 2006
RCH-06-R010 Over-the-Mast electrical cable replacement 16 Oct 2006
RCH-06-R013 New style drive motor 5 Dec 2006
RCH-07-R001 Vehicle Manager Replacement 2 Jan 2007
RCH-07-R005 Hydraulic Fluids Used in Reach Trucks 5 Mar 2007
RCH-07-R008 Troubleshooting Control Handles 7 May 2007
RCH-07-R009 Orientation of Pinion Gear on Steer Gearmotor Assembly 6 Jun 2007
RCH-07-R012 Power Amplifier Cable Orientation 6 Jun 2007
RCH-07-R013 Battery connector disconnect block interference 25 Jun 2007
RCH-07-R014 VM 4.5 and DM 3.3 software released 9 Jul 2007
GEN-06-R003A Maintenance Schedules for Trucks with Electric Brakes 6 Jun 2007
viii 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 1. How to Use This Manual
Section 1. How to Use This Manual
1026304B, 15 July 2007 1-1
Section 1. How to Use This Manual Model 7400/7420/7440 Reach-Fork ® Truck
Map of the Manual
Map of the Manual
1MAP.WMF
Table of Trouble-
Contents shooting
Page Revision
Record Messages,
Codes, and
Tests
How to Use Component
This Manual Procedures
Map of the
Manual
Component
Locator Photos
Manual Design
Component
Procedures by Lift
Start Page Truck System
Theory of
Safety Operation
Systems Appendix
Overview
Scheduled Index
Maintenance
1-2 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 1. How to Use This Manual
Design of the Manual
Design of the Manual • Once you’re familiar with the symptoms
listed, you may instead simply find the
symptom in the Troubleshooting
The Model 7400/7420/7440 Reach-Fork ® Symptom Tables (beginning on
Truck is designed with the following objectives page 5-19).
in mind:
• When you complete a troubleshooting
• Provide technical coverage for expected procedure, be sure to follow the steps in
levels of user expertise. End of Troubleshooting Chart END-1
• Anticipate your needs and reduce your (page 5-17).
decisions regarding maintenance. • Messages, Codes, and Tests lists the
• Reduce page flipping through a “one-stop electrical fault codes, details for modes of
shopping” approach. operation, and procedures for running
firmware electrical tests.
The two-line running page header at the top of • Component Procedures gives information
each page tells you: for testing, removal, installation, and
• Name of the manual (Model adjustment of individual lift truck
7400/7420/7440 Reach-Fork ® Truck) components. Components are grouped by
lift truck system:
• Current chapter title (for example, this
page How to Use This Manual) • Covers and Finish
• Current topic (for example, this page • Steering and Controls
Design of the Manual) • Drive and Brake
• Electrical Components
We suggest you get in the habit of turning to the
START page first when you use this manual. • Hydraulics
• Mast, Chain, Hose and Cable
The START page asks a few simple questions to
To find a component procedure, you can
guide you to the proper chapter.
use one of three methods:
• How to Use This Manual explains the
• Look up the component name in the list
manual format and design and contains
of Component Procedures by lift truck
the Table of Contents and START page.
system (page 7-1).
• Safety explains warning and caution
• Find the component in the Component
notes, general safety rules and safety rules
Locator Photos (page 7-7).
for batteries, static, jacking, and welding.
• Look up the component name in the
• Systems Overview includes lift truck
Index (page I-1).
specifications.
• Theory of Operations explains flow
• Scheduled Maintenance outlines the
within hydraulic and electrical schematics
recommended schedule of preventive
for various conditions of lift truck
services to keep your lift truck working
operation. A pinout matrix chart lists
most efficiently.
functions and normal voltages of terminals
• Troubleshooting is a set of general and harness connector pins.
troubleshooting guidelines, a
• Appendix contains reference information
troubleshooting task flow, and a set of
such as torque values, lubrication
troubleshooting tables for symptoms not
specifications, and system schematics.
accompanied by a fault code.
• Index lists subjects alphabetically.
• The START TROUBLESHOOTING
chart (on page 5-15) is a general task
flow that will guide you to the
troubleshooting procedure you need.
1026304B, 15 July 2007 1-3
Section 1. How to Use This Manual Model 7400/7420/7440 Reach-Fork ® Truck
Design of the Manual
1-4 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck
Abbreviations, Acronyms, and Symbols
Abbreviations, Table 1-1. Abbreviations, Acronyms, and Symbols
Acronyms, and Symbols Term/Symbol Definition
CE compensating
These abbreviations, acronyms and symbols element (valve)
may be used in this manual.
cfg configuration
Table 1-1. Abbreviations, Acronyms, and Symbols CFS clogged filter switch
Term/Symbol Definition cm centimeter
A ampere COP computer operating
program
AC alternating current
CV check valve
ACR AC electronics in
combination with CW clockwise
functional
performance
enhancements
DC direct current
and/or ergonomic
enhancements DdManH hour meter hours on
deadman pedal
AGND analog ground
DGND digital ground
amp ampere or amplifier
diam. diameter
ANSI American National
Standards Institute DOT US Department of
Transportation
API American Petroleum
Institute DVM digital voltmeter or
multimeter
approx approximately
aux auxiliary
E UL Electric Truck
AWG American Wire
Type Certification
Gauge
Rating with
safeguards against
inherent fire and
B+, B– Battery Voltage electrical shock
hazards
BSOC Battery
State-of-Charge EE UL Electric Truck
Type Certification
Rating where
C Celsius or Centigrade electrical equipment
is completely
CAN controller area enclosed
network
EPO emergency power off
CB counterbalance valve
ESD electrostatic
CCW counterclockwise discharge (static)
1026304B, 15 July 2007 1-5
Model 7400/7420/7440 Reach-Fork ® Truck
Abbreviations, Acronyms, and Symbols
Table 1-1. Abbreviations, Acronyms, and Symbols Table 1-1. Abbreviations, Acronyms, and Symbols
Term/Symbol Definition Term/Symbol Definition
F Fahrenheit l liter(s)
ft. foot or feet lb. pound or pounds
ft. lb. foot pound(s) LA lift power amplifier
FR flow regulator LED light-emitting diode
FU fuse LiftH hour meter hours
spent lifting
L/H load holding
gal. gallon or gallons
L/L lift/lower
GGC heated glass guard
contactor LM lift motor
Gnd ground LME lift motor speed
encoder
gr gram(s)
LMT lift motor
temperature sensor
HOI height only indicator LPA lift power amplifier
HTI height-tilt indicator LPC lift power control
HTR heater contactor
LR LPA precharge
resistor
in. inch or inches
LS load shuttle
in. lb. inch-pound(s)
m meter(s)
JP jack and pin
connector mA milliampere
mm millimeter
K relay MM, MntMind Maintenance Minder ™
KeyH hour meter hours mph miles per hour
with key switch ON MS steer motor
kg kilogram(s)
km/cm2 kilograms per square N/A not applicable or not
centimeter available
km/hr kilometers per hour N/C normally closed
kPa kiloPascal(s)
1-6 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck
Abbreviations, Acronyms, and Symbols
Table 1-1. Abbreviations, Acronyms, and Symbols Table 1-1. Abbreviations, Acronyms, and Symbols
Term/Symbol Definition Term/Symbol Definition
NLGI National Lubricating RAM random access
Grease Institute memory
Nm newton meter REL relief
N/O normally open RCFP relay control fuse
panel
RF radio frequency
OACH overall collapsed
height ROM read only memory
OCSS Operator RPIN Raymond Product
Compartment Sensor Improvement Notice
System
rpm revolutions per
OD operator display minute
OR orifice R/R reach/retract
OSHA Occupational Safety RSB Raymond Service
and Health Bulletin
Association
oz. ounce(s)
S switch
SA steer power amplifier
P pump or lift
contactor SAE Society of Automotive
Engineers
PDD Power Distribution
Diagram S/N serial number
PODS priority-on-demand SOL solenoid
spool valve spec specification
pot potentiometer SPL wire splice
PR pressure reducing s/s sideshift
valve
SSL sideshift left
psi pounds per square
inch SSR sideshift right
PWM pulse width STR steer contactor
modulation
P/N part number
TA traction power
amplifier
qt. quart temp temperature
TH thermostat
1026304B, 15 July 2007 1-7
Model 7400/7420/7440 Reach-Fork ® Truck
Abbreviations, Acronyms, and Symbols
Table 1-1. Abbreviations, Acronyms, and Symbols Table 1-1. Abbreviations, Acronyms, and Symbols
Term/Symbol Definition Term/Symbol Definition
TM traction motor © copyright
TME traction motor speed + plus or positive
encoder
– minus or negative
TMT traction motor
temperature sensor ± plus or minus
TOTAL D hour meter total ° degrees
distance traveled °F degrees Fahrenheit
TP tie point °C degrees Celsius
TPA traction power < less than
amplifier
> greater than
TPC traction power
control contactor % percent
TR TPA precharge = equals
resistor
TS terminal strip
UL Underwriters
Laboratories, Inc.
UNC unified coarse thread
UNF unified fine thread
V volt or volts
VDC volts direct current
VM Vehicle Manager
VR variable resistor
(potentiometer)
WHLD Weight Height Limit
Display
wrt with respect to
@ at
™ trademark
1-8 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 1. How to Use This Manual
START Page
Section 1. How to Use This Manual
START Page
1STARTPG1.WMF
START: What do you want to do?
Go to Chapter 2
Review safety "Safety"
Yes
precautions?
No
Go to Chapter 3
Examine "Systems Overview"
Yes
specifications?
No
Go to Chapter 4
Do scheduled "Scheduled Maintenance"
Yes
maintenance?
No
Go to Chapter 5
Troubleshoot a "Troubleshooting"
Yes
problem?
No
Go to Chart
START-2
1026304B, 15 July 2007 1-9
Section 1. How to Use This Manual Model 7400/7420/7440 Reach-Fork ® Truck
START Page
1STARTPG2.WMF
START-2
Trouble- Go to Chapter 6
shoot a "Messages, Codes,
fault code or run Yes and Tests"
a diagnostic
test?
No
Test,
Go to Chapter 7
inspect, adjust,
"Component Procedures"
remove/install a Yes
component?
Component Locator
No
Photos
Find Go to Chapter 8
Component Procedures by
information on "Theory of Operation"
Yes Lift Truck System
theory of
operation?
No
Go to Chapter A
Find
"Appendix"
general reference Yes
information?
No
Locate
Go to the Index
an object or
Yes
procedure by
name?
1-10 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 2. Safety
Section 2. Safety
1026304B, 15 July 2007 2-1
Section 2. Safety Model 7400/7420/7440 Reach-Fork ® Truck
Definitions
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
Warning indicates a potentially
hazardous situation, which, if not
avoided, could result in death or serious
injury.
Caution indicates a potentially
hazardous situation, which, if not
avoided, may result in minor or
moderate injury or in damage to the lift
truck or nearby objects. It may also be
used to alert against unsafe practices.
2-2 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck 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.
26173_002.eps
Before working on this lift truck, always turn
the key switch OFF and disconnect the lift
28B15004D.EPS truck’s battery connector (unless this manual
tells you otherwise).
Know the lift truck’s controls and what they do.
26173_005.eps
26173_003.eps
Do not wear watches, rings, or jewelry when
working on this lift truck.
Do not operate this lift truck if it needs repair or
if it is in any way unsafe.
2jewelry.eps
26173_004.eps
1026304B, 15 July 2007 2-3
Section 2. Safety Model 7400/7420/7440 Reach-Fork ® Truck
General Safety
Follow the scheduled lubrication, maintenance Do not use gasoline or other flammable liquids
and inspection steps. for cleaning parts.
2schedmnt.eps 26173_007.eps
Follow exactly the safety and repair instructions Clean up any hydraulic fluid, oil or grease that
in this manual. Do not take “shortcuts.” has leaked or spilled on the floor.
28b15008d.eps 2spills.eps
Do not use an open flame near the lift truck. Always operate and park this lift truck indoors.
26173_006.eps 26173_008.eps
2-4 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 2. Safety
General Safety
Do not wash this lift truck with a hose.
26173_009.eps
Do not add to or modify this lift truck until you
contact your local Raymond dealer to receive
written manufacturer approval.
26173_010.eps
Do not park this lift truck in a cold storage area
overnight.
1026304B, 15 July 2007 2-5
Section 2. Safety Model 7400/7420/7440 Reach-Fork ® Truck
Battery Safety
Battery Safety 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
properly ventilated, this explosive gas
can remain in or around the battery for
several hours after charging. Be sure
there are no open flames or sparks in 225L6S016.eps
the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
Make sure a shower and eyewash station are
nearby in case of an accident.
Battery electrolyte is a solution of
sulfuric acid and water. Battery acid
causes burns. If any electrolyte comes in
contact with your clothing or skin, flush
the area immediately with cold water. If
the solution gets on your face or in your
eyes, flush the area with cold water and
get medical help immediately.
204G6S059.eps
Read, understand and follow procedures,
recommendations, and specifications in the
battery and battery charger manufacturer’s A battery gives off explosive gases. Never smoke,
manuals. use an open flame, or use anything that gives
off sparks near a battery.
225l6s014.eps
223L6S012.eps
Wear personal protective equipment to protect
eyes, face and skin when checking, handling or
filling batteries. This equipment includes
2-6 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 2. Safety
Battery Safety
Keep the charging area well-ventilated to avoid Keep batteries clean. Corrosion causes shorts
hydrogen gas concentration. to the frame and possibly sparks.
204g6s058.eps
Keep plugs, terminals, cables and receptacles in
good condition to avoid shorts and sparks.
Turn the key switch OFF before disconnecting
the battery from the lift truck at the battery
connector. Do not break live circuits at the
battery terminals. A spark often occurs at the
point where a live circuit is broken.
227Y7S013.tif
26173_005.eps
Keep filler plugs firmly in place at all times
except when the electrolyte level is checked,
when water is added to the cells, or when the
Do not lay tools or metal objects on top of the specific gravity is checked.
battery. A short circuit or explosion could
result.
204g6s057.eps
1026304B, 15 July 2007 2-7
Section 2. Safety Model 7400/7420/7440 Reach-Fork ® Truck
Battery Safety
Make sure the vent holes in the filler plugs are Never plug a battery charger into the lift truck’s
open to allow the gas to escape from the cells. battery connector. Plug the battery charger only
into the battery connector from the battery.
Vent
Hole
26173_012.eps
209g6s047.tif
Do not allow cleaning solution, dirt or any
foreign matter to enter the cells.
Make sure you install the correct size battery. A
smaller or lighter weight battery could seriously
affect lift truck stability. See the lift truck’s
specification plate for more information.
26173_011.eps
2-8 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 2. Safety
Static Precautions
Static Precautions 3. Handle circuit boards by edges only. Avoid
touching edge connectors.
4. If you will be removing or installing
The discharge of static electricity, called
static-sensitive components, place them
electrostatic discharge, can damage electronic
on a properly grounded static mat.
circuit boards and devices used on the
Raymond ® Model 7400/7420/7440 5. To transport static-sensitive components,
Reach-Fork ® truck. including failed components being
returned, place the components in an
Static charges accumulate from normal antistatic bag or box (available from your
operation of the lift truck as well as movement Raymond dealer).
or contact between non-conductive materials
(plastic bags, synthetic clothing, synthetic soles Test the wrist strap and related accessories
on shoes, styrofoam coffee cups, etc.) before each use to make sure they are working
properly.
Accumulated static can discharge through
human skin to a circuit board or component by Figure 2-2 on page 2-10 shows the components
touching the parts. Static discharge is also of the Raymond antistatic field service kit,
possible through the air when a charged object P/N 1-187-059. The kit includes a wrist strap,
is close to another surface at a different ground cord and static-dissipative work surface
electrical potential. Static discharge can occur (mat). Follow the instructions packaged with
without your seeing or feeling it. this kit.
Whenever working on or near static-sensitive Wrist straps are available in quantities of 25, as
electronics, always use static discharge P/N 1-187-058/001.
precautions.
A wrist strap tester is available as
1. Place a static discharge wrist strap around
P/N 1-187-060/100.
your wrist. Connect the ground lead to the
wrist strap connector. The wrist strap
Contact your local Raymond dealer for
must have a 1 megohm resistor to
information.
dissipate static charges slowly.
2. Connect the ground plug to the ESD
ground jack on the lift truck. The ESD
ground jack is located by the inertial
dampener cover under the traction power
amplifier.
Traction
Power
Amplifier
ESD Ground Jack
27074-004.TIF
Figure 2-1. ESD Ground Jack Location
1026304B, 15 July 2007 2-9
Section 2. Safety Model 7400/7420/7440 Reach-Fork ® Truck
Static Precautions
2mat2.tif
Figure 2-2. Anti-Static Kit with Wrist Strap and Mat
2-10 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 2. Safety
Jacking Safety
Jacking Safety
You need to jack the lift truck off the floor to Use extreme care when the lift truck is
perform some maintenance procedures. When jacked up. Never block the lift truck
doing so, follow approved safety precautions: between the telescopic and the floor.
1. Lower the forks completely. Remove any Use a suitable hoist to stabilize the mast.
load. Keep hands and feet clear while jacking
2. Place all controls in neutral. the lift truck. After the lift truck is
jacked, place solid blocks or jack stands
3. Block the wheels to prevent movement of beneath it to support it. Do not rely on the
the vehicle. jack alone to support the lift truck.
4. Turn the key switch OFF and disconnect
the battery connector.
5. If possible, stabilize the top of the mast Jack only in
with an overhead chain hoist. these areas
6. Before jacking the lift truck, examine the
A-frame down-travel adjustment bolt. See
Figure 2-3. If the bolt is missing, or the
hole that it passes through is excessively
worn, the A-frame will not be held in place
when the lift truck is jacked up; the No Jack Area
A-frame could pivot down and allow the
springs to fall out.
A-frame Springs
2toyrch_t.eps
Figure 2-4. Correct Jacking Locations
To elevate the rear of the lift truck:
1. Place the jack in the specified jacking
A-frame position. See Figure 2-4.
Down-Travel 2. Jack the rear of the lift truck so that the
Adjustment Bolt
drive tire is off the floor no more than
213Y7S001.TIF
2 inches (50 mm). If you must elevate the
Figure 2-3. Verify A-frame Down-Travel Adjustment Bolt drive tire more than 2 inches, attach the
(parts removed for clarity) lift truck at the overhead guard to a
suitable capacity hoist.
7. Place the jack under the designated
3. Block the lift truck in place.
jacking points. See Figure 2-4.
To elevate either side of the lift truck:
1. Place the jack in the specified jacking
position. See Figure 2-4.
2. Jack the side of the truck so that the load
wheel is off the floor no more than 1/2
inch (13 mm).
1026304B, 15 July 2007 2-11
Section 2. Safety Model 7400/7420/7440 Reach-Fork ® Truck
Jacking Safety
3. Block the lift truck in place.
NOTE: After working on a vehicle, test all
controls and functions to make sure
they operate correctly.
2-12 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 2. Safety
Tie-Down for Transport
Tie-Down for Transport
To transport your Raymond Model
7400/7420/7440 Reach-Fork truck in an
over-the-road vehicle or rail car, follow these
steps:
1. Lower the forks and locate the lift truck in
the center of the transport vehicle.
2. Using a suitable lifting device, remove the
battery. See “Battery Safety” on page 2-6.
3. Position the adjustable chain over and
through the battery compartment.
4. Position an additional adjustable chain
over and through the battery
compartment.
5. Position the chain ends of one chain
toward the front of the vehicle bed and the
chain ends of the other chain to the back
of the vehicle bed and draw taut.
NOTE: This will secure the lift truck to the
vehicle bed and prevent tip-over and
forward or backward movement.
6. Secure the battery according to the battery
manufacturer’s instructions.
1026304B, 15 July 2007 2-13
Section 2. Safety Model 7400/7420/7440 Reach-Fork ® Truck
Welding Safety
Welding Safety
Disconnect the battery before you
attempt to inspect, service, or repair the
lift truck.
Flame cutting or welding on painted
surfaces can produce potentially
harmful fumes, smoke and vapors.
Before doing flame cutting or welding,
remove the coating in the area where
the operation(s) will occur.
Coating removal can occur by
26173_005.eps
mechanical methods, chemical methods
or a combination of methods. Do flame
• Test for shorts to frame as described in
cutting and/or welding only in well
“Shorts to Frame Test” on page 5-5. If you
ventilated areas using local exhaust if
find any shorts, correct them before you
necessary.
weld.
• Clean the area to be welded.
• Protect all lift truck components from
heat, weld spatter and debris.
• Attach the ground cable as close to the
weld area as possible.
• Disconnect all electrical connectors from
circuit cards before doing any type of
electric resistance welding.
204G6S059.eps
• Do not weld near electrical components.
Before working on this lift truck, make sure • If you must weld near the battery
that: compartment, remove the battery from the
• Fire protection equipment is nearby. lift truck.
• You know where the nearest eyewash • When you are finished welding, re-install
station is. connectors on circuit cards and do all
ground tests and electrical inspections
before operating the lift truck.
2-14 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 3. Systems Overview
Section 3. Systems Overview
1026304B, 15 July 2007 3-1
Section 3. Systems Overview Model 7400/7420/7440 Reach-Fork ® Truck
Introduction
Introduction
This manual provides information for
maintenance and repair of the Model
7400/7420/7440 Reach-Fork ® truck by
Raymond.
This manual contains the most current and accurate
procedures, drawings, and photographs available at
the time of publication. Subsequent releases of this
product may differ slightly from that shown here.
Accordingly, some changes in parts, layout, or
procedures may not be reflected in this manual.
For the latest information on your Raymond lift
truck, contact your nearest authorized
Raymond dealer.
3-2 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 3. Systems Overview
Lift Truck Specifications
Lift Truck Specifications
This lift truck is rated for performance by load
center and load weight.
Review the specification plate located in the
operator compartment of the tractor for detailed
load capacity and load center information.
Due to continuous product enhancement,
specifications are subject to change without
notice or obligation.
Raymond model Serial number* Nominal battery voltage
THE RAYMOND CORP. GREENE NY
MODEL SERIAL NUMBER VOLTS BATTERY WIDTH
Approximate weight in. (mm)
Power rating of
of lift truck with TRUCK WEIGHT BATTERY WEIGHT BATTERY MAX. RATED CAPACITY
WITH MAXIMUM BATTERY MAXIMUM AMP HOURS
battery
heaviest battery lb. (kg) lb. (kg)
installed, minus load WITHOUT BATTERY MINIMUM HOUR RATE
and operator
lb. (kg) lb. (kg)
HORIZONTAL MOTION OF BATTERY NOT TO EXCEED 0.5" (13mm) ATTACH RESTRAINT AS REQUIRED
Maximum battery
WITH ATTACHMENT OR
weight for this lift
WITH FORKS
truck
ALTERNATE LOAD CENTER
Approximate weight HORIZONTAL LOAD CENTER A in. mm A in. mm
of lift truck minus VERTICAL LOAD CENTER B in. mm B in. mm
battery, load, and
LOAD CENTER SIDE TO SIDE C in. mm C in. mm
Minimum battery
operator
MAX.
CAPACITY
l b.
DIM. D
in.
MAX.
CAPACITY
l b.
DIM. D
in.
MAX.
CAPACITY
l b.
DIM. D
in.
MAX.
CAPACITY
l b.
DIM. D
in.
weight for this lift
C
truck
Load center B
Battery weight must
dimensions be between the
A D
FL
OO
R
minimum and
Maximum load ATTACHMENT TYPE MODEL SERIAL NUMBER
maximum weight
capacity for this lift MANUFACTURED TO COMPLY WITH THE MANDATORY REQUIREMENTS OF ASME B56.1 PART III EFFECTIVE ON THE DATE OF
truck MANUFACTURE FOR TYPE ___ INDUSTRIAL TRUCKS WHEN EQUIPPED WITH TYPE EO BATTERY
INCLUDE MODEL AND SERIAL NUMBER ON ALL CORRESPONDENCE
Attachment
MADE IN CANADA 412-843 information
3412-843_B.EPS
Figure 3-1. Lift Truck Specification Plate on Tractor
NOTE: * Lift truck serial number is also found: Load Capacity
• On the mast specification plate
on the lower right mast upright Always refer to the specification plate on your
lift truck for the correct ratings for your truck.
• Stamped on the top edge of the
rear bumper, to the left of center
1026304B, 15 July 2007 3-3
Section 3. Systems Overview Model 7400/7420/7440 Reach-Fork ® Truck
Lift Truck Specifications
Model 7000 Series Designation
Mast Series
The model number includes the model and the
mast series designation.
Table 3-1. Mast Series Designation
Max Load
Mast Series
Model(s) Forks Carriage Type
Designation
Lowered
7400 R35TT 3500 lbs. Standard Reach
1587 kg
7400 7420 7440 R45TT 4500 lbs. Standard
2041 kg Reach
7400 7420 7440 DR32TT 3200 lbs. Deep-Reach
1451 kg
Tractor Series
The lift truck serial number consists of a
three-digit model abbreviation, two-digit year of
manufacture, two-digit tractor series
designator, and five-digit serial number.
Table 3-2. Tractor Series Designation
Tractor Lift Lift
Model(s) Model Abbreviation Stance
Series Motor Pump
7400 740 AA, AB DC Single Fore-Aft
7400 740 BA, BB DC Dual Fore-Aft
7400 7420 7440 740 742 744 CA, CB AC Single Fore-Aft
7400 740 DA, DB DC Single Side Stance
7400 740 EA, EB DC Dual Side Stance
7400 7420 7440 740 742 744 FA, FB AC Single Side Stance
3-4 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 3. Systems Overview
Lift Truck Specifications
Battery Specifications
Table 3-3. Battery Specifications
Nominal
Weight (Pounds) Weight (Kilograms)
Volts Width Hours Amperes
(inches) Min Max Min Max
36 16.5 2000 2300 908 1044 6 930
18.5 2300 2600 1044 1180 6 1085
21.5 2600 2900 1180 1315 6 1240
UL note 583 specifies that a battery should
have no more than 0.5 inch (13 mm) movement
in any horizontal direction.
1026304B, 15 July 2007 3-5
Section 3. Systems Overview Model 7400/7420/7440 Reach-Fork ® Truck
Operator Display
Operator Display
8
Up Button
4
Right Button
Enter Button
5
Left Down
1 6 7 Button Button
1. Battery Charge
2. Lift Limit (optional)
3. Service Required
4. Drive/Lift Motor or Power Panel Over-Temperature
5. Lift Truck Speed
6. SelfTest, Hour Meters, BSOC, Weight of Load on Forks,
Clock/Calendar, and Status Messages
7. Display Dialog Buttons
8. Dashboard Selection and Optional Feature Buttons
3OPR DISP
Figure 3-2. Operator Display
Selecting Display Format • DdMan H: Total hours on deadman
• Lift H: Total hours spent lifting
The Operator Display shows date, time, BSOC,
• Total D: Total distance traveled (miles or
weight on forks, information/status messages,
kilometers, depending on Units specified
and (optionally) ambient temperature. Use the
in Config)
dashboard buttons 1 through 8 to select the
desired layout of these items on the display.
Graphic icons alert the operator to other
conditions:
Dashboard button 9 toggles display of up to 8
Active Service tests. See “Active Service Mode” • Battery State-of-Charge
on page 6-18. • Lift Limit
• Service Required
Use the display dialog buttons (up, down, left,
right, and enter) to navigate through display • Over-Temperature
menus and to select values for parameters. • Lift Truck Speed
Dashboard button 0 displays hour meters:
• KeyH: Total hours the key switch has been
turned ON
3-6 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 3. Systems Overview
Modes of Operation
Modes of Operation For detailed description, see “Using Configure
Mode” on page 6-6.
Overview of Modes Service Mode
This lift truck has two modes of operation: Run Use Service Mode to calibrate, test, cycle, and
Mode and Program Mode. Run Mode is the troubleshoot individual electrical circuits.
normal operating mode for the lift truck. Service Mode tests are divided into two
Program Mode permits configuration, categories: static and active.
calibration, and diagnostic testing (service).
Use the Learn Function to calibrate the lift
truck for correct operation. You can select the
Run Mode following categories for calibration:
When you power on the lift truck normally, the • Controls (travel, lift/lower)
on-board firmware does a number of internal • Weight
self-tests and enters the default mode of
operation, Run Mode. Run Mode is the normal To enter Learn Function, you must enter
operating mode. In Run Mode, the Operator Service Mode through the Superword.
Display shows date, time, BSOC, ambient
temperature, and weight on forks. For To enter Service Mode, you must enter the
information on the Operator Display, see Superword.
“Operator Display” on page 3-6.
For detailed description, see “Using Service
Run Mode is also entered when the lift truck Mode” on page 6-17.
exits Program Mode.
Passwords
Program Mode
For detailed description of how to enter
Use Program Mode for configuration, passwords, see “Entering an Electronic Key,
calibration, and diagnostic testing of the lift Password, or Superword” on page 6-6.
truck. You need a password in order to enter
Program Mode. See “Passwords” below. Electronic Operator Key
Program Mode is divided into several categories: Electronic Operator Key is a configurable
• Serial Number software feature that permits the customer to
set an operator electronic key or operator
• Version password. When the operator turns the key
• Hour Meters switch ON, the software prompts the operator to
• Configure Mode enter the electronic key. The lift truck will not
enter Run Mode unless the correct electronic
• Service Mode key is entered. Up to 20 different electronic
keys can be set.
Configure Mode
Password
Configure Mode is used to adjust various lift
truck performance parameters to specific Password permits access to Configure Mode
customer requirements. To enter Configure only. It is intended for customer use in setting
Mode, you must enter either the Password or performance parameters within those features
Superword for the lift truck. purchased with the lift truck.
Some items in Configure Mode will appear only
if the Superword is entered.
1026304B, 15 July 2007 3-7
Section 3. Systems Overview Model 7400/7420/7440 Reach-Fork ® Truck
Modes of Operation
Superword
Superword permits access to all Program
Modes. Superword is intended to limit service
access to qualified and trained service
technicians.
We strongly recommend that, during
installation, you change the Superword from
the factory default to a code known only to the
dealer and/or owner so that access to Service
Mode is limited to approved personnel. Make
sure to record the new Superword in a safe
place. If this code is lost or forgotten, a
technician will need to reset the lift truck to
factory default settings. This will make
necessary the reconfiguration of all variable
settings.
No two passwords (Electronic Key, Password,
Superword) may be set to the same value. If you
try to do so, the lift truck will treat the second
password as an invalid code and give an error
message. Each password must be set to a
unique value.
3-8 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Section 4. Scheduled Maintenance
1026304B, 15 July 2007 4-1
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Maintenance Guidelines
Maintenance Guidelines • Cleaning
• Inspection
Following a regularly scheduled maintenance • Service
program:
Perform all the scheduled inspections and
• Promotes maximum truck performance
maintenance at the suggested intervals. The
• Prolongs maximum truck life time intervals given in this guide are based on
• Reduces costly down time deadman hours under normal operating
conditions. When operating under severe or
• Prevents unnecessary repairs
extreme conditions, do these services more
often as specified in the chart below.
Scheduled maintenance includes:
• Lubrication
Table 4-1. Maintenance Frequency
Service
Type of Service Working Environment
Frequency
Light 180 days or
to An eight hour day of basic material handling 500 hours,
Moderate whichever is
less
Extended heavy duty operations
Severe Freezer operations 250 hours
Sudden temperature changes (for example, freezer to room
temperature)
All EE rated lift trucks
Dusty or sandy conditions: e.g. cement plant, lumber or flour mills,
Extreme coal dust or stone-crushing areas 100 hours
High temperature areas: e.g., steel mills, foundries, enclosed (EE)
applications
Corrosive atmosphere: e.g., chlorine, salt-sea air
See “Lubrication Specification Chart” on Hour Meters
page A-2 in the Appendix for lubrication
specifications. Refer to the manufacturer’s To display hour meters:
supplements for components not listed on the
following pages. With the lift truck in Run Mode, press the
dashboard button 0. The Operator Display lists:
• KeyH: Total hours the key switch has been
turned ON
• DdMan H: Total hours on deadman
• Lift H: Total hours spent lifting
• Total D: Total distance traveled (miles or
kilometers, depending on Units specified
in Config)
4-2 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Maintenance Minder ™ Tool
Maintenance Minder ™ Tool With Configuration Mode selected, use the
down button to display the “MNT MIND” item.
Press the right button. With “STATUS”
Maintenance Minder Tool is a feature that permits highlighted, press the right button. Use the
prompting of a customer when the lift truck is down button to select “ENABLE.” Press the enter
due for scheduled maintenance. button. Maintenance Minder is enabled with the
last stored time interval and action option.
Maintenance Minder, when configured and
enabled, monitors the Hours on Deadman (HD) Exit program mode as described under “Exiting
meter. When the time interval for scheduled Program Mode” on page 4-4.
maintenance has been exceeded, the operator is
informed in the following ways: Setting or Changing Time Interval and Action
• One of two messages appears on the Option
Operator Display following the “DAILY
CHECKLIST” message. With Configuration Mode selected, use the
down button to display the “MNT MIND” item.
• “Scheduled Maintenance Due”
Press the right button. Use the down button to
• “Lift Cutout, Scheduled Maintenance select “SETUP.” Press the right button.
Due”
• A wrench icon flashes Use the up/down buttons to scroll to
“INTERVAL.” Press the right button. The first
• The audible alarm sounds the high-low
time you enter the time interval menu, the
tone for approximately 5 seconds.
Operator Display shows the Factory Suggested
setting. Afterwards, when you enter the time
Lift Cutout, when active, will not disable the lift
interval menu, the Operator Display shows the
function until power to the control circuits is
last used setting. Values from 50 to 500
cycled (key switch OFF or battery
deadman pedal hours, in increments of 50, are
disconnected). When control circuit power is
available. Press the right button. Use the
cycled, lift will be disabled until Maintenance
up/down buttons to scroll to the desired time
Minder has been reset or disabled, or the lift
interval. With the selected value displayed,
cutout option is turned off.
press the enter button. Press the left button to
return to the SETUP menu.
Factory Configuration
Use the up/down buttons to select “ACTION.”
For field installations, this feature must be Then press the right button. The following
added to the configuration options via the options are available:
FlashWare program. The factory default is
• “MSG ONLY” causes the Operator Display
Disable.
to show “SCHEDULED MAINTENANCE DUE”
when the scheduled maintenance time
Maintenance Minder settings are not changed by
interval has been exceeded.
resetting Defaults in the Config menu.
• “L CUT OUT” causes the Operator Display to
Enabling show “LIFT CUT OUT, SCHEDULED
MAINTENANCE DUE” when the scheduled
Once installed, Maintenance Minder appears in maintenance time interval has been
the Configure Mode menu. The initial factory exceeded. Lift is disabled the next time the
setting is “DISABLE.” To enable the feature, enter power circuits are cycled.
Configure Mode.
Use the up/down buttons to select the option
NOTE: For instructions on selecting Modes of you want, then press the enter button.
Operation, see “Modes of Operation” on
page 6-4. Exit program mode as described under “Exiting
Program Mode”.
1026304B, 15 July 2007 4-3
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Maintenance Minder ™ Tool
Resetting Maintenance Minder VERSION
HR MTRS
If you want to reset the reminder prompt when
Maintenance Minder is active and you have done ▼CONFIG
scheduled maintenance, enter Configure Mode.
Press the left button to exit to Run Mode. The
With Configuration Mode selected, use the lift truck enters the Run Mode.
down button to display the “MNT MIND” item.
Press the right button. Use the down button to
select “SETUP.” Press the right button.
With “RESET” highlighted, press the right
button. Use the down buttons to scroll to “YES.”
Press the enter button.
Exit program mode as described under “Exiting
Program Mode”.
Disabling
When Maintenance Minder is active and you want
to disable it, enter Configure Mode.
With Configuration Mode selected, use the
down button to display the “MNT MIND” item.
Press the right button. With “STATUS”
highlighted, press the right button. Use the up
button to select “DISABLE.” Press the enter
button.
Exit program mode as described under “Exiting
Program Mode”.
Exiting Program Mode
1. Use the left button to back out of the
menus.
2. The Operator Display shows:
RESTORE
SAVE
3. Use the down button to select SAVE. Press
the enter button. Your new values are
saved.
NOTE: You will not be able to exit to the main
menu until you have selected either
RESTORE or SAVE and pressed the enter
button.
4. Press the left button to back out to the
main menu.
▲SERIAL # ➠
4-4 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Initial 90 Day or 250 Deadman Hour Interval
Initial 90 Day or 250
Deadman Hour Interval
Initial Days or 250 Deadman Hours (HD)
Item No.
See
“Scheduled
Component What to do Refer to
Maintenance
Points”
beginning on
page 4-12.
8 Drive Unit Break free, reapply thread-locking compound
(P/N 990-544), and retorque mounting bolts to
150 ft. lb. (204 Nm).
Change fluid
17 Hydraulic Change fluid and filter(s). Page 7-134
Reservoir and Page 7-135
Manifold Page A-2
21 Mast Retorque main frame mounting bolts (170 ft. lb. or
230 Nm), reapplying thread-locking compound
(P/N 990-544).
24 Power Amplifier Retorque power cable terminal nuts to 11 ft. lb.
(15 Nm).
1026304B, 15 July 2007 4-5
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Every 180 Days or 500 Deadman Hours
Every 180 Days or 500
Deadman Hours
Every 180 Days or 500 Deadman Hours (HD)
Item No.
See
“Scheduled
Component What to do Refer to
Maintenance
Points”
beginning on
page 4-12.
1 Battery Compare the weight stamped on the battery in the lift Page 3-5
truck against the minimum and maximum approved
weights on the spec tag for the lift truck. Report any lift
trucks that are operating with batteries under the
minimum, or over the maximum approved weight.
Make sure the 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.
Test for voltage leaks to frame. Page 5-5
2 Battery Inspect all battery connectors and leads for damage Page 7-113
Connectors and and cuts in protective coatings. Shorts to the truck
Leads frame cause electronic component failure or
intermittent electrical failures.
3 Brake and In a open area, measure stopping distance. Traveling at
Brake Pads 2 to 3 mph (3.2 to 4.8 km/hr) empty, push the EPO
switch; the empty lift truck 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 approximately one and one-half Page 7-98
truck lengths. Stopping distance depends on the load,
floor, and tire conditions.
Examine for signs of oil on the pads or rotor. If oil is Page 7-98
present, disassemble brake and clean the pads and
rotor. Use a file, if necessary, to clean the brake pad Page 7-96
surface.
Measure minimum thickness of pad and steel backing
plate: 0.80 in. (20 mm)
Measure for correct gap: 0.012 inch lower air gap;
0.030 total air gap.
Failure to keep brakes adjusted causes premature pad
and rotor wear and excessive motor heat.
4-6 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Every 180 Days or 500 Deadman Hours
Every 180 Days or 500 Deadman Hours (HD)
Item No.
See
“Scheduled
Component What to do Refer to
Maintenance
Points”
beginning on
page 4-12.
4 Contactors Inspect contactor tips for burnt or pitted surfaces.
Failure to replace the tips can cause surfaces to weld
together, causing unscheduled down time.
With the key switch OFF and the battery disconnected,
examine the plunger for smooth operation with no
binding. If binding occurs, the lift truck could
malfunction or display intermittent fault codes.
5 Control Handle Make sure travel function is smooth and responsive
Functions through full range of acceleration.
(primary and Make sure lift/lower function is smooth and
optional controllable.
secondary) Test for play in the center position of lift or travel
control; replace control handle if necessary.
Make sure nylon insert is in the lift knob set screw
hole.
Test the function of all switches.
6 Deadman Pedal Check for smooth operation with no binding through
full range of pedal stroke.
Run Test A28 – Deadman Inductive Sensor (VR4)
(Page 6-138)
Run Test I00 – Deadman Switch (S2) (Page 6-152)
Test correct activation of the deadman switch by the Page 7-102
pedal. Adjust pedal height and switch gap as required.
7 Drain Holes Make sure the drain holes under the deadman pedal
and in the battery compartment are free of any debris.
8 Drive Unit Examine fluid level. If low, check for leaks and refill. Page 7-79
Inspect for leaks. Make sure O-ring is present on the
dipstick.
Examine for drive unit radial ring wear.
9 Electrical Inspect all power cables for nicks or cuts. Give special Page 5-3
Cables attention to those cables that are not stationary, for
example, cables to the drive motor. Replace any cable Page 7-116
that is damaged or shows signs of excessive heat.
Failure to do so will cause intermittent system
shutdowns and/or electronic failures.
Measure the tension of the over-the-mast pulley cables. Page 7-229
Set tension so the cables just stay on the pulleys.
Higher tension will cause premature failure.
1026304B, 15 July 2007 4-7
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Every 180 Days or 500 Deadman Hours
Every 180 Days or 500 Deadman Hours (HD)
Item No.
See
“Scheduled
Component What to do Refer to
Maintenance
Points”
beginning on
page 4-12.
12 Forks Check fork mounting surfaces for wear. Make sure fork
positioning lock is working correctly.
Examine for excessive wear, bends, cracks, welding
arcs, excessive heat, or unauthorized modifications.
Replace if found.
Measure fork thickness (tool P/N 922-369). Page 7-213
13 Frame and Examine all structural parts of lift and tilt mechanism.
Baselegs Visually examine tractor, baselegs, and mast members
for cracks.
Hardware Check bolt torque of major components (motors, Page A-6
pumps, brake, drive unit, manifolds, mast-to-tractor Page A-8
mounting bolts, overhead guard). Page A-10
Tighten any loose hardware. Replace any broken or
missing hardware.
15 Horn Make sure horn sounds correctly when activated.
Examine mounting bracket insulators.
16 Hydraulic Inspect for leaks, nicks, cuts, chafing, and bulges. Page 5-13
Hoses Replace damaged or worn hoses immediately.
Inspect fittings for leaks; repair immediately.
Inspect over-the-mast hoses for correct tension. Page 7-229
Make sure over-the-mast pulleys spin freely and show
no signs of wear.
17 Hydraulic Examine fluid level. Page A-2
Reservoir
18 Lift Chains Examine for too much stretch or wear (tool Page 7-208
P/N 950-350/CG).
Check adjustment. Page 7-208
Lubricate. Page A-2
Lubrication Apply grease to all fittings on carriage and tractor. Page 4-18
Apply small amount of grease to steering gear on drive
unit.
4-8 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Every 180 Days or 500 Deadman Hours
Every 180 Days or 500 Deadman Hours (HD)
Item No.
See
“Scheduled
Component What to do Refer to
Maintenance
Points”
beginning on
page 4-12.
21 Mast Wipe old grease off mast uprights and apply new Page A-2
grease.
Check for smooth transition from free lift to tele lift.
Inspect anti-rattle pads and anti-bow pads (7400 only).
Anti-bow pad minimum thickness is 0.187 inch (4.75 Page 7-196
mm) and correct gap is 0.03 to 0.09 inch (0.8 to 2.3
mm).
Examine mast bearings.
Inspect mast and carriage stops for tightness and wear.
Inspect the outside of the main frame for wear,
especially if the lift truck is used in drive-in racks.
Inspect rails for abnormal wear, metal flakes or
shavings.
Repair any grooves worn in the mast deeper than
1/8 inch (3 mm).
22 Motors, DC Inspect brushes for excessive heat (discolored pigtails).
Check brush length and evenness of wear.
Check brush spring tension.
Inspect brush rigging for damage or loose brush
holders.
Retorque terminal stud nuts. Page 7-122
Replace power cables showing signs of excessive heat.
Use compressed air to clean the inside of the motor, Page 4-17
impeller, and cooling fins.
Check sensor wires for good connection and condition.
Motors, AC Retorque terminal stud nuts. Page 7-122
Replace power cables showing signs of excessive heat.
Check sensor wires for good connection and condition.
23 Overhead Inspect guard for physical damage. If structurally
Guard damaged, replace the guard.
24 Power Amplifier Make sure power amplifier heat sink fins are free of Page 7-110
debris and that air flows freely through them. Check
power cable torque.
26 Shorts to Frame Check for electrical shorts to frame. Page 5-5
27 Static Straps Make sure static straps are not worn or broken.
Clean debris from straps.
Measure resistance of resistor in standoff. Page 7-111
NOTE: EE lift trucks require phosphor-bronze, not
steel-braided straps.
1026304B, 15 July 2007 4-9
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Every 180 Days or 500 Deadman Hours
Every 180 Days or 500 Deadman Hours (HD)
Item No.
See
“Scheduled
Component What to do Refer to
Maintenance
Points”
beginning on
page 4-12.
28 Steering Inspect pivot points and bearings in the steering
linkage. Inspect teeth on the steering gear and drive
unit for wear.
Check adjustment of the steerable caster. Page 7-45
Lubricate the steer axle assembly.
Inspect the caster wheel axle and bearings for excessive
wear, play, or binding.
Inspect and adjust the steering encoder for correct Page 7-43
force to turn the wheel.
Make sure steering function is smooth and responsive,
without binding or excess play.
Check the gap on the steer limit switch (S11). Page 7-44
Switches Check all switches for correct operation and adjust as
needed.
29 Ventilation Make sure ventilation slots in the tractor frame are
Slots open, with no obstructions or debris.
30 Warning Decals Replace any unreadable or damaged decals. Page 7-33
31 Warning Lights Check for correct operation.
32 Wheels/Tires Examine for bond failure, chunking, and excessive or
uneven wear.
Inspect load wheel bearings for binding or excessive
play.
Inspect drive axle and idler axle for excessive play.
4-10 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Every 360 Days or 2000 Deadman Hours (HD)
Every 360 Days or 2000
Deadman Hours (HD)
Every 360 Days or 2000 Operating Hours
Perform all 180-day/500-hour checks plus the following:
Item No.
See
“Scheduled
Component What to do Refer to
Maintenance
Points”
beginning on
page 4-12.
8 Drive Unit Change fluid. Page 7-94
18 Lift Pump Separate pump and motor. Apply molybdenum anti-seize
Couplings compound (P/N 990-638) liberally to the splines.
17 Hydraulic Change hydraulic fluid and filter. Filter is located in Manifold
Reservoir & main manifold. drawing:
Manifold Series
CA/FA (AC
lift):
Page 7-141;
Series
AA/BA/DA/
EA (DC lift):
Page 7-145
Bleeding
procedure:
Page 7-134
1026304B, 15 July 2007 4-11
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Scheduled Maintenance Points
Scheduled Maintenance preceding scheduled maintenance
charts.
Points
NOTE: Numbered arrows in photos on the
following pages refer to Item No. in
23
18
21
30
30
13
7 (under battery)
12
32
46353_118.JPG
Figure 4-1. Scheduled Maintenance Points, Mast View, R45TT mast shown
4-12 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Scheduled Maintenance Points
31 (on OHG)
23
18
21
26
30
29
13
12
32
46353_117G.JPG
Figure 4-2. Scheduled Maintenance Points, Mast View, R45TT mast shown
1026304B, 15 July 2007 4-13
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Scheduled Maintenance Points
23
18
9, 16
30
22 18
24
17
24
15
22
11
8 (under frame)
3, 6, 7
28, 32
32
46353_012G.JPG
Figure 4-3. Scheduled Maintenance Points, Tractor View, Series CA/FA (AC lift)
4-14 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Scheduled Maintenance Points
28
47074_001.TIF
Figure 4-4. Scheduled Maintenance Points, Operator Compartment (Series AA/BA/CA shown)
1026304B, 15 July 2007 4-15
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Scheduled Maintenance Points
28 27
28 28
28
32
28 28
28, 32
4P5180009.TIF
Figure 4-5. Scheduled Maintenance Points, Underside
4-16 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Motor Maintenance
Motor Maintenance
DC Motor Cleaning
401A7S002.TIF
Figure 4-6. Motor cleaning with compressed air
Periodic cleaning is essential to prevent
overheating and electrical leakage (shorts). To
clean a motor correctly:
1. Wear safety glasses or goggles to protect
your eyes from dust and debris.
2. Work in a well ventilated area.
3. Using an OSHA approved air nozzle, use
clean, dry compressed air to blow carbon
dust and other foreign matter from:
• motor housing
• brush holders (DC motor)
• commutator (DC motor)
• field and armature windings (if
accessible)
Never use a chemical solvent to clean a
motor, as it can carry carbon dust to
inaccessible areas and cause shorts
within the motor.
Cleaning a motor with solvents requires
complete disassembly and drying and
must only be done by an authorized
motor repair shop.
1026304B, 15 July 2007 4-17
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Lubrication Points
Lubrication Points 6. Idler wheel axle
7. Drive unit radial rings and steer gear
NOTE: Locate items by numbers on the photos 8. Scissors mechanism
that follow this list: 9. Reach cylinder
1. Steering linkage arm, pivot point 10. Inner telescopic channels (left and right,
2. Steering linkage, steerable idler arm both sides)
3. Steering linkage, drive wheel arm 11. Lift chains (spray)
4. A-frame pivot bolts 12. Sideshift carriage
5. Idler wheel bearing
Lubrication Point Locator Photos
1 (access in battery
2 compartment)
4 (access on
top side) 3
4P5180009.TIF
Figure 4-7. Lubrication Points, Steering Linkage and A-frame (underside view)
4-18 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Lubrication Points
Deadman
4
Pedal
Battery
Compartment
4QAP289_B.JPG
4P5180011.TIF
Figure 4-8. Lubrication Points, Steering Linkage and A-frame (top views)
46353_005.JPG
4P5180019.TIF
Figure 4-9. Lubrication Points, Idler Wheel bearing and axle
1026304B, 15 July 2007 4-19
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Lubrication Points
46353_103G.JPG
Figure 4-10. Lubrication Points, Drive Unit
4-20 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Lubrication Points
8 (Both Sides)
8 (Both Sides)
8
8
8 (also
other side)
4R1020670_A1.CGM
4R1020670_A.CGM
Figure 4-11. Lubrication Points, Scissor Mechanism R45TT
1026304B, 15 July 2007 4-21
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Lubrication Points
8 (Inside Surface
8 (Both Sides)
Both Sides)
4R1021624_A1.CGM
4R1021575_A1.CGM
Figure 4-12. Lubrication Points, Scissor Mechanism DR32TT
4-22 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Lubrication Points
4DSC_0873A.JPG
Figure 4-13. Lubrication Points, Reach Cylinder
12
12
12
4R1020739_A.CGM
Figure 4-14. Lubrication Points, Sideshift Carriage
1026304B, 15 July 2007 4-23
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Lubrication Points
10
11
12
46353_117G.JPG
Figure 4-15. Lubrication Points, Mast and Carriage
4-24 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Chain Maintenance
Chain Maintenance
Condition-Cause Chart
Condition Cause Maintenance Procedure
Chain Elongation Wear Use a chain gauge or lay the chain on a flat
surface and push it together. Measure and
mark a 12 in. (305 mm) length that has
operated over the pulley sheave. Stretch the
chain; if more than 1/3 in. (8.5 mm) play is
detected, replace the chain.
Rust and corrosion Steam cleaning or Oil chain frequently.
degreasing new truck
chains
Cracked Plates Infrequent Oiling Replace the chain.
Rust
Corrosion
Chain Fatigue
Tight Joints Bent pins or plates Replace the chain.
Rusty joints or peened Replace the chain.
plate edges
Chain side wear Chain misalignment Replace the chain.
1026304B, 15 July 2007 4-25
Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Chain Maintenance
4-26 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Section 5. Troubleshooting
1026304B, 15 July 2007 5-1
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
How to Use This Chapter
How to Use This Chapter
This chapter contains a set of general
troubleshooting guidelines, a troubleshooting
task flow, and a set of troubleshooting tables for
symptoms not accompanied by a fault code.
Use the START TROUBLESHOOTING Chart
TS1 on Page 5-15 to guide you to the general
flow of troubleshooting.
Use the Symptom Tables beginning on
page 5-19 to identify possible causes of
problems that are not accompanied by a fault
code on the Operator Display.
Every time you complete a troubleshooting
procedure, be sure to follow the steps in End of
Troubleshooting Chart END1 on page 5-17.
Another troubleshooting resource is the
Pinout Matrix on page 8-113 in the Theory of
Operation chapter. The pinout matrix chart lists
functions and normal voltages of terminals and
harness connector pins.
If the troubleshooting symptom charts do not
isolate the problem, or if the symptoms are not
consistent or repeatable, go to the General
Troubleshooting Chart GEN1 on page 5-16.
This chart will help you approach the problem
in a systematic and logical manner.
5-2 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Electrical Troubleshooting Guidelines
Electrical During troubleshooting and repairs, you must
at times unplug a connector, move a harness,
Troubleshooting cut a cable tie, or remove the wire from a
bracket. Note carefully the location of the wire
Guidelines and all protective or mounting hardware before
moving the harness.
Many problems are caused by a faulty or dirty
After repair, return or replace all protective
battery. Make sure the battery is clean. See
and/or mounting hardware to its original
“Battery Exterior Cleaning” on page 7-114.
condition. Protective materials are necessary to
Measure the electrolyte level and state of
provide reliable performance of the interconnect
charge. See “Testing, Charging, and
system.
Maintenance” on page 7-115.
Examine and maintain any added materials
used to position or protect the wire. This
includes spiral wrap, brackets, cable ties,
Be sure to jack and block the lift truck fasteners, flexible conduit, etc.
whenever a troubleshooting procedure
requires turning key switch S1 ON. This Do not attach cable ties so tight that they pinch
will prevent accidents caused by or deform cable harnesses. Do not attach cable
unexpected travel. See “Jacking Safety” ties to hydraulic hoses, which expand with
on page 2-11. pressure, causing extra pinching of bundled
electrical cables.
Use a digital ohmmeter to test continuity in
Unless otherwise directed, disconnect wiring.
the battery connector when you
measure electrical circuits or For general instructions on repairing wiring
components with an ohmmeter. problems, see “Wiring and Harness Connectors”
Electrical current can damage the on page 7-116.
ohmmeter.
For information on electrical connector location
Save time and trouble by looking for simple and function, see “Electrical Connections” on
causes first. page 6-115.
Visually examine all wiring and electrical For diagrams showing electrical connector
components for: location on circuit cards, see “Circuit Card
Connectors” on page 6-116.
• Loose connections or connectors
• Loose or broken terminals Use a digital multi-meter such as a Fluke meter
• Damaged terminals, blocks, or strips for all measurements. Analog meters can give
inaccurate readings and load down sensitive
• Exposed wire at terminations, excessive electronic circuits enough to cause failure.
strip gap Make sure to connect meter cables to the
• Abrasions, scrapes, nicks in the wire, correct meter jacks and to select the correct
damage from overheating or burns, or function and scale.
other general insulation damage
• Broken wire strands and shorted When measuring voltage, connect the positive
conditions (especially those that are close meter lead to the connector or probe point
to metal edges or surfaces) marked (+) in the test. Connect the negative
meter lead to the connector or probe point
marked (–).
1026304B, 15 July 2007 5-3
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Electrical Troubleshooting Guidelines
Whenever measuring resistance, turn the key
switch OFF and disconnect the battery
connector. Battery current can damage an
ohmmeter.
For troubleshooting DC electric motors, see “DC
Motor Troubleshooting” on page 5-8.
For troubleshooting AC electric motors, see “AC
Motor Troubleshooting” on page 5-10.
5-4 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Shorts to Frame Test
Shorts to Frame Test To test for shorts to frame:
1. Turn the key switch OFF and disconnect
the battery connector.
“Shorts to frame” is an industry term for
unintentional current leakage paths between 2. To test the battery for shorts to case,
normally isolated electrical circuits and their connect a 12-volt test light to the battery
metal enclosures. case from battery B+, and then to the
battery case from battery B–. If the light
Shorts to frame can be metallic connections, comes on at all, even momentarily, there is
such as a wire conductor contacting metal a serious problem with the battery, either
through worn insulation. More often, shorts to external contamination or internal
frame are resistive “leakage” paths caused by damage. Do not continue until this condition is
contamination and/or moisture. corrected. Your meter can be damaged if
you proceed before correcting this
These leakage paths can result in unwanted condition.
electrical noise on the metallic lift truck Install another battery in the lift truck and
structure, and can result in incorrect operation. repeat this procedure from step 1.
If the test light does not come on, continue
Shorts to frame can be caused by:
to the next step.
• Accumulation of dirt
3. With the battery disconnected from the lift
• Battery electrolyte leakage truck, use a digital volt/ohm/ammeter on
• Motor brush dust the Ampere function to measure the
leakage current from the battery case to
• Motor brush leads touching the housing
battery B+ and from the battery case to
• Breakdown in insulation battery B–. Begin measuring at the highest
• Bare wires Ampere scale and work toward the lowest
scale. A reading of more than 0.001A
• Pinched wiring harness
(1 mA) shows a serious short. Do not continue
• Incorrect mounting of circuit cards until this condition is corrected. Your meter
can be damaged if you proceed before
Shorts to frame can occur at numerous correcting this condition.
locations on a lift truck, including:
Install another battery in the lift truck and
• Batteries repeat this procedure from step 1.
• Motors If the current is less than 0.0002 A
• Cables, wiring, harnesses (0.2 mA), go to step 4. If the current is
greater than 0.0002 A (0.2 mA) and less
• Heat sinks
than 0.001A (1 mA), remove the battery
• Bus bars from the lift truck, then continue with step
• Solenoids 4. Make sure the battery case does not
touch the lift truck frame during the
• Contactors
remaining tests.
• Terminal strips
4. With the battery disconnected (or removed
• Switches and disconnected) from the lift truck, use
• Power panel insulation a digital ohmmeter to measure the
resistance from lift truck frame to truck
• Circuit card mounts
B+, to truck B– (not battery B+ and B–),
and to all fuses and motors. A reading of
less than 1000 ohms shows a serious
short. Do not continue until this condition is
corrected. Your meter can be damaged if
1026304B, 15 July 2007 5-5
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Shorts to Frame Test
you proceed before correcting this a. To identify the cause of the short to
condition. frame, disconnect circuit components
a. To identify the cause of the short to until the leakage current reads less
frame, disconnect circuit components than 0.001A (1 mA). Do not reconnect
until the low resistance condition components one at a time, but leave
disappears. Do not reconnect them disconnected until the leakage
components one at a time, but leave current reads less than 0.001A (1mA).
them disconnected until the low Prevent disconnected terminals or
resistance reading disappears. Prevent connectors from touching lift truck
disconnected terminals or connectors frame or other conductive surfaces.
from touching lift truck frame or other b. The most likely areas to examine are:
conductive surfaces.
• Motors
b. The most likely areas to examine are: • Heat sinks
• Motors • Power cables and tie points
• Heat sinks • Power circuit components
• Power cables and tie points • Control circuit components and
• Power circuit components terminals strips
• Control circuit components and c. Repair or replace the component(s)
terminals strips causing the leakage current.
c. Repair or replace the component Repeat step 6.
causing the low resistance condition, d. Reconnect all other components
then repeat Step 4. previously disconnected, measuring
d. Reconnect all other components current between steps. If a reading is
previously disconnected, one at a time, more than 0.001A (1 mA) when
measuring resistance between steps. If reconnecting a component, that
a reading is less than 1000 ohms when component or its wiring is bad.
reconnecting a component, that Repair/replace as appropriate.
component or its wiring is bad; repair 7. When, after all components are
or replace as appropriate. reconnected, and you repeat Step 6, you
e. When, after all components are get a reading less than 0.001A (1 mA)
reconnected, and you repeat Step 4, there is no short to frame condition with
you get readings greater than 1000 the lift truck or the battery. If you
ohms, continue with the next step. previously removed the battery from the
lift truck, re-install the battery.
5. Reconnect the battery connector to the lift
truck and turn the key switch ON. If the
battery was previously removed, make
sure the battery case does not touch the
lift truck frame.
6. Use a volt/ohm/ammeter on the current
function to measure leakage current to the
lift truck frame from B+, B–, and all fuses
and motor terminals. Begin measuring at
the highest Ampere scale and work toward
the lowest scale. If the current is less than
0.001A (1mA), go to step 7. If the current
is more than 0.001A (1 mA), continue with
the following steps.
5-6 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Fuses
Fuses
Test/Inspection
Examine the fuse for signs of overheating,
discoloration, cracking, or other physical
damage. Replace the fuse if you find any of
these conditions.
To test a fuse, remove it from the lift truck.
The resistance should be less than 1 ohm.
Fuse Locator Chart
Table 5-1. Fuse Chart
Fuse Amps Location Function
FU1 150 Contactor/Fuse Panel Power fuse for steering
FU2 350 Contactor/Fuse Panel Power fuse for travel
FU3 500 Contactor/Fuse Panel Power fuse for lift
FU5 15 Relay/Control Fuse Panel Control fuse for Vehicle Manager B+
FU6 15 Relay/Control Fuse Panel Control fuse for Vehicle Manager B–
FU7 15/5 Relay/Control Fuse Panel Control fuse for aux power B+
FU8 15/5 Relay/Control Fuse Panel Control fuse for aux power B–
FU9 10 Travel alarm Control fuse for travel alarm
FU10 50 TP6 and Glass Guard Contactor Control fuse for heated glass mast guard
FU11 10 In-line harness Control fuse for warning light and strobe
FU12 10 In-line harness Control fuse for working lights and fan
FU13 n/a Control Handle Thermal fuse for control handle external heater
FU14 10 ThermaKit Control Module Control Fuse for ThermaKit handle and floor pad
heaters
1026304B, 15 July 2007 5-7
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
DC Motor Troubleshooting
DC Motor Refer to Figure 5-1.
• A series-wound motor has only two
Troubleshooting external connections because the
armature and field windings are connected
internally.
Motor Types
• A compound-wound motor has only two
external connections because the
Series-Wound Motor armature and field windings are connected
S/D internally.
• A permanent magnet motor has two
external connections. The field is produced
by an internal magnet.
NOTE: Field connections might be labeled A or
S. Series wound motor field connections
MP might be labeled D.
A Open Circuit Motor Test
An open circuit is one in which the electrical
circuit within the motor has been broken. This
can be caused by:
• Bad brushes or brush springs
Compound Motor
• A broken wire in the field or armature
A winding
• Loose or bad connections
MX
Refer to Figure 5-1 for the following procedure:
1. Isolate the motor from the lift truck circuit
by removing the power cables. Use two
wrenches to avoid twisting the terminal
S/D stud.
2. With the motor at room temperature,
connect the leads of a digital ohmmeter
between the individual circuits in the
Permanent Magnet motor.
Motor
3. Observe the measurements in Table 5-2:
A2
Table 5-2. DC Motor Troubleshooting
MS
Motor Probe Points Resistance
A1 Lift Motor A1 to Frame
Auxiliary A1 or A2 to
Greater than
Motor Frame
100,000 ohms
5MOTOR_SERIES.EPS
MOTOR_COMPOUND.EPS A1 or A2 to
Figure 5-1. Motor Circuits Steer Motor
Frame
5-8 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
DC Motor Troubleshooting
4. If the meter indicates high resistance in
the armature, check the condition of the
brushes before replacing the motor.
5. If you find an open circuit in a
series-wound motor, the motor must be
disassembled by a motor rebuilding facility
to isolate the problem to the field or
armature circuit.
Grounded Motor Test
In a grounded motor, an electrical circuit exists
between the current-carrying conductors and
the motor housing. This can be caused either by
direct contact or through conductive foreign
material.
The ground may be caused by:
• Insulation breakdown
• Brush leads touching the motor
housing
• Build-up of carbon dust or other
materials
Isolate the motor from the lift truck circuit by
removing the power cables. Use two wrenches
to avoid twisting the terminal studs.
Attach one lead of a megohm meter or a digital
ohmmeter to a motor terminal and the other
lead to an unpainted surface of the motor
housing. Set the ohmmeter to the highest scale.
If the ohmmeter reads resistance of less than
100,000 ohms, the motor is grounded. Clean,
repair, or replace the motor as necessary.
1026304B, 15 July 2007 5-9
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
AC Motor Troubleshooting
AC Motor Shorted Winding
Troubleshooting If the AC motor fails with a shorted winding, the
motor speed will fluctuate up and down, as if
hunting.
U Using a clamp-on ammeter, measure current in
each of the motor power cables. The shorted
phase will read significantly higher than the
other two phases.
AC
3φ
V W
U
AC
V
3φ
W
5MOTOR_AC3PHASEA.EPS
MOTOR_AC3PHASEB.EPS
Figure 5-2. Drive Motor circuits
Motor Type
The drive motor is a brushless, 3-phase,
variable speed AC motor.
The AC motor has a rotor (in place of the DC
armature) and a stator (in place of the DC field).
There is no electrical connection to the rotor;
current is induced in the rotor. The stator has
three windings and three external connections
labeled U, V and W. See Figure 5-2.
Open Winding
If the AC motor fails with an open winding, the
motor will move erratically, as if hunting.
Rotation will be much slower than normal.
Using a clamp-on ammeter, measure current in
each of the motor power cables. The open phase
will read significantly lower than the other two
phases.
5-10 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Battery State-of-Charge
Battery State-of-Charge resets the Operator Display to show the
replacement battery’s charge.
b. Example 2: A battery in the lift truck is
Theory at 20% charge and lift cutout has not
occurred. The replacement battery has
Battery State-of-Charge (BSOC) is a feature that a state-of-charge equal to 50%.
monitors and remembers the charge level of the Because the difference is only 30%, the
battery connected to the lift truck and helps to display will remain at 20% until the
prevent excessive discharging of that battery. replacement battery has discharged to
Operating a lift truck using a discharged 20%. Then the display will begin
battery can damage both the battery and the counting down.
electrical components of the lift truck.
c. Example 3: A battery in the lift truck is
at 20% charge and lift cutout has
At power-up, BSOC tests the battery voltage to
occurred. The replacement battery has
determine if it is the same as it was at
a state-of-charge equal to 50%.
power-down. If the voltage is the same, BSOC
Because the difference is only 30%, the
assumes it is the same battery and continues to
display will remain at 20% and lift
monitor the battery for discharge and updates
cutout will remain in effect until a
the Operator Display as required.
battery with a charge of at least 70%
and a state-of-charge exceeding the
If a different battery voltage is detected, BSOC
configured BSOC setting is installed in
assumes a different battery has been installed
the lift truck.
and tests to determine the state-of-charge of the
replacement battery. The replacement battery 2. BSOC looks at the configured reset point.
must meet one of the following criteria before BSOC reset is programmable from 55% to
the display will be reset and lift restored. 100% of total battery charge and can be
changed by entering the Configure Mode
1. The replacement battery must have a
using the Superword. The replacement
charge level at least 50% different from the
battery must be greater than the
previously installed battery,
configured percent of charge before the
2. The charge value of the replacement BSOC will change. Example - BSOC
battery must be greater than the configured at 95%. Plugging in a battery at
configured BSOC setting. anything below 95% charge will not
change the Operator Display. Older
The criteria are determined in this way: batteries or applications providing
1. BSOC compares the charge of the battery inadequate charging time could require a
that was connected to the lift truck with lower configured value for BSOC since
the replacement battery’s charge. A charge older batteries might be unable to reach a
difference of at least 50% between the two higher percent charge. Therefore, some
batteries resets BSOC to show the batteries could require BSOC configured
state-of-charge of the replacement battery, as low as 55% before lift cutout will reset
that is, the measured state-of-charge of and the Operator Display shows the
the replacement battery minus the charge of the replacement battery.
remembered state-of-charge of the old
battery must equal or exceed 50%. This The following example describes installing a
reset can be higher or lower than the old replacement battery when the Operator Display
battery. does not reset. Assume the following:
a. Example 1: A battery in the lift truck is • BSOC configured at 95%, the battery
at 10% charge; the replacement battery connected is at 45% charge, and the
is at 95%. With more than a 50% replacement battery is at 92% charge.
difference in the charge levels, BSOC
1026304B, 15 July 2007 5-11
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Battery State-of-Charge
Since the replacement battery charge has not
changed by at least 50% and the state-of-charge
of the replacement battery is not greater than
the BSOC reset configured value, the Operator
Display continues to show the old battery's
charge of 45% (even though the replacement
battery is at 92%). What occurs is that the
Operator Display remains at 45% until the
charge of the replacement battery declines to
45%. Then the display resumes its normal
descent.
One final example. Assume the following:
• BSOC configured at 95%, the battery
connected is at 65% charge, and the
replacement battery is at 20% charge.
Again, the change in charge is not at least 50%
and the replacement battery is not above the
configured BSOC level. The Operator Display
continues to show 65%, but then descends
rapidly as the lift truck operates until the
Operator Display shows the original charge of
20%. Once the display shows 20%, it resumes a
normal descent.
Setting Battery State-of-Charge
Cutout
1. Fill, charge, and install a battery that is
typical of the batteries normally used in
this application.
2. Have a customer operator use the lift
truck in normal application until cutout
occurs.
3. Permit the battery to cool and stabilize for
at least two hours.
4. Before filling the battery, either take
specific gravity readings or measure open
circuit voltage of the battery cells.
5. Compare the measurements with the
battery manufacturer’s recommendations
for maximum discharge.
6. Adjust the cutout value as needed and
repeat the previous steps until battery
cutout occurs at the desired discharge
level.
5-12 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Hydraulic Troubleshooting Guidelines
Hydraulic
Troubleshooting
Guidelines
After elevating or reaching the carriage
for troubleshooting, be sure to use
blocks to secure the carriage.
Use extreme care when blocking the
mast for any reason. Never remove a
block when it is supporting the mast.
Lower the carriage fully and retract the reach
mechanism fully.
Stabilize the top of the mast with an overhead
chain hoist.
When you measure voltage at solenoids, make
sure hydraulic lines and components are fully
installed.
Whenever possible, keep the key switch OFF
and the battery connector disconnected.
Cap open hydraulic lines to prevent
contamination.
1026304B, 15 July 2007 5-13
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic Troubleshooting Guidelines
5-14 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Troubleshooting Procedure
Troubleshooting Procedure
Section 5. Troubleshooting
TS1: START TROUBLESHOOTING
TS1: START TROUBLESHOOTING
Is a
Message or
Yes
Fault Code
displayed?
Find
Message or Code
No in Chapter 6
Is
symptom
listed in symptom Yes
tables in
Chap. 5?
Follow symptom
table directions
in Chapter 5
No
Go to
Chart GEN-1
5TS1A.WMF
1026304B, 15 July 2007 5-15
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Troubleshooting Procedure
GEN1: General Troubleshooting
GEN1: General Troubleshooting
Gather as much
information as you Eliminate unlikely
What is the problem?
can about the causes.
problem.
Where did it happen?
When did it happen?
What functions are affected?
Select and prioritize
What conditions trigger the problem? the most likely
causes.
Examine each
Talk directly with the likely cause, using
Process
operator or foreman. the tests in this
manual.
Test all other
Operate the lift truck truck functions
yourself. before returning the
lift truck to service.
Using schematics
if necessary,
identify all
components that
could cause the
problem.
5GEN_1.WMF
5-16 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Troubleshooting Procedure
END1: End of Troubleshooting Procedure
END1: End of Troubleshooting Procedure
Operate the lift truck as it
Make sure ALL wires,
was being operated when
hoses, and cables that
the problem occurred.
you removed have been
Make sure the problem
reattached correctly.
does not recur.
Have the driver operate
Make sure all panels are the lift truck. Make sure
correctly reinstalled. the problem does not
recur.
Make sure any
component that was
Fill out any
drained has been refilled
required forms.
with the correct level of
fluid.
If you are a Raymond
Create the same dealer technician This is especially
conditions that occurred and contacted important if the
when the problem first Raymond Field Service solution you
happened. to discuss the problem, found is not in the
call them again to let troubleshooting
them know what fixed the chart.
problem.
End of Troubleshooting
5END1.WMF
1026304B, 15 July 2007 5-17
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Troubleshooting Procedure
5-18 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Symptom Tables: Hydraulic Functions
Symptom Tables: Hydraulic Functions
Section 5. Troubleshooting
NOTE: If you determine that a component failed as a
result of hydraulic fluid contamination,
replace the failed component and flush, fill,
and bleed the hydraulic system. Reference
“Hydraulic System Bleeding” on
page 7-134.
NOTE: Reference electrical schematics
beginning on page A-17 and hydraulic
schematics beginning on page A-35
Auxiliary Functions
Multiple Functions Affected
No Auxiliary Functions Work (Reach/Retract, Tilt, Sideshift)
Series CA/FA (AC lift):
Possible Cause Action
Bad K2 relay circuit Troubleshoot K2 relay circuit.
Bad LS1 shuttle Replace LS1.
Bad aux directional solenoid 5B or 5T (valve or Run Tests O04 and O05. Follow test
wiring) recommendations.
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Bad K2 relay circuit Troubleshoot K2 relay circuit.
Bad SOL8 (valve or wiring) Run Test O09. Follow test recommendations.
Bad CE1 valve Repair/replace CE1 valve.
Bad LS1 shuttle Repair/replace LS1.
Bad aux directional solenoid 5B or 5T (valve or Run Tests O04 and O05. Follow test
wiring) recommendations.
Open in motor circuit Check continuity from TP2 to TP4.
1026304B, 15 July 2007 5-19
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Symptom Tables: Hydraulic Functions
All Auxiliary Functions are Slow
Series CA/FA (AC lift):
Possible Cause Action
Incorrect hydraulic fluid for application Replace hydraulic fluid with correct fluid. See
“Lubrication Specification Chart” on page A-2.
Bad POD-1 valve Replace POD-1 valve.
Aux system relief pressure too low Adjust aux pressure. See “Auxiliary Pressure
Adjustment” on page 7-140.
Bad LS1 shuttle Replace LS1.
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Incorrect hydraulic fluid for application Replace hydraulic fluid with correct fluid. See
“Lubrication Specification Chart” on page A-2.
Aux system relief pressure too low Measure pressure; normal operation should
be below bypass pressure. See “Auxiliary
Pressure Adjustment” on page 7-140. If
pressure is still too low, replace steering
orbitrol.
Bad CE1 valve Repair/replace CE1 valve.
Bad SOL8 Check for contamination. Repair/replace
valve.
Bad aux pump Measure pressures.
Bad aux motor Measure current draw.
5-20 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Symptom Tables: Hydraulic Functions
Tilt
No Tilt or Tilt one direction only; other Aux Functions OK
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Bad tilt switch (S6 and/or S7) Run Test I08 and/or I09. Follow
recommendations in test.
Bad tilt solenoid valve or coil, or wiring. Check Run Test O07. Follow recommendations in
for contamination. test. If contamination is found, flush, refill,
and bleed hydraulic system. Swap hoses with
sideshift to check valve and cylinder.
Broken tilt cylinder pin Replace tilt cylinder pin.
Mechanical binding in tilt cylinder or carriage Measure pressure; normal operation should
be below bypass pressure. See “Auxiliary
Pressure Adjustment” on page 7-140. Binding
will produce higher pressures. Repair/replace
cylinder or other binding components.
Slow Tilt; other Aux Functions OK
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Mechanical binding in tilt cylinder or carriage Measure pressure; normal operation should
be below bypass pressure. See “Auxiliary
Pressure Adjustment” on page 7-140. Binding
will produce higher pressures. Repair/replace
cylinder or other binding components.
Bad Tilt Solenoid Examine for binding or contamination. Swap
hoses with sideshift to check valve and
cylinder.
1026304B, 15 July 2007 5-21
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Symptom Tables: Hydraulic Functions
Sideshift
No Sideshift or One Direction Only; Other Aux Functions OK
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Bad sideshift switch (S8 and/or S9) Run Test I10 and/or I11. Follow
recommendations in test.
Bad sideshift solenoid, or wiring Run Test O08. Follow recommendations in
test. Swap hoses with tilt to check valve and
cylinder.
Mechanical binding in sideshift cylinder or Measure pressure; normal operation should
carriage be below bypass pressure. See “Auxiliary
Pressure Adjustment” on page 7-140. Binding
will produce higher pressures. Repair/replace
cylinder or other binding components.
Sideshift - Slow Operation; Other Aux Functions OK
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Mechanical binding in sideshift cylinder or Measure pressure; normal operation should
carriage be below bypass pressure. See “Auxiliary
Pressure Adjustment” on page 7-140. Binding
will produce higher pressures. Repair/replace
cylinder or other binding components.
Bad sideshift solenoid valve Repair/replace sideshift solenoid valve.
5-22 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Symptom Tables: Hydraulic Functions
Reach
Reach and Retract Do Not Work or are Slow; Other Functions OK
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Bad reach solenoid (valve or wiring) Run Test I06. Check wiring. Check valve for
binding.
Damaged or worn reach cylinders Inspect cylinder. Measure pressure; normal
operation should be below bypass pressure.
See “Auxiliary Pressure Adjustment” on
page 7-140. Binding will produce higher
pressures. Repair/replace cylinder or other
binding components.
Damaged or worn scissors assembly Inspect for damage. Measure pressure;
normal operation should be below bypass
pressure. See “Auxiliary Pressure Adjustment”
on page 7-140. Binding will produce higher
pressures. Repair/replace cylinder or other
binding components.
Switches S4 and S5 both bad (or wiring) Run tests I06 and I07. Follow
recommendations in tests.
Reach - Does Not Work; Other Functions OK
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Bad reach switch (S4) Run Test I06. Follow recommendations in test.
1026304B, 15 July 2007 5-23
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Symptom Tables: Hydraulic Functions
Retract
Retract - Does Not Work; Other Functions OK
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Bad retract switch (S5) Run Test I07. Follow recommendations in test.
Steering
Steering Does Not Work; Other Functions OK
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Mechanical binding of linkage Repair/replace bad components as necessary.
Bad steering orbitrol Repair/replace orbitrol.
Bad hydraulic steer motor Repair/replace hydraulic steer motor.
No Steering, Reach/Retract, Tilt, or Sideshift
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Aux system relief pressure too low:
Bad aux pump Repair/replace aux pump.
Bad aux motor Repair/replace aux motor.
Bad/contaminated pressure relief in steering Replace orbitrol.
orbitrol
5-24 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Symptom Tables: Hydraulic Functions
Lift/Lower System
Lift Function
No Lift - Motor Runs
Series CA/FA (AC lift):
Possible Cause Action
Bad POD-1 valve Replace POD-1 valve.
SOL3 main relief dump valve pressure too low Run Test O09. Replace SOL3.
SOL2 lift/lower valve open Run Test O12. Follow recommendations in
test.
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Check main lift pressure at main manifold If pressure is greater than bypass pressure,
port G1 check for binding of mast or cylinders.
If pressure is less than or equal to bypass
pressure, disconnect coil wires to SOL2.
• If lift works, run Test O12 and troubleshoot
per the test.
• If lift still does not work:
1. Replace REL1 main relief valve.
2. Replace SOL2 lift/lower valve.
3. Replace lift pump.
No Lift - Motor Does Not Run
Series CA/FA (AC lift):
Possible Cause Action
Battery below BSOC cutout setting Check battery voltage and BSOC settings.
Maintenance Minder ™ interval exceeded with Display config settings for Maintenance
LCutout specified Minder.
1026304B, 15 July 2007 5-25
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Symptom Tables: Hydraulic Functions
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Battery below BSOC cutout setting Check battery voltage and BSOC settings.
Maintenance Minder ™ interval exceeded with Display config settings for Maintenance
LCutout specified Minder.
Open in lift motor circuit Run Test O28. Follow recommendations in
test.
Slow Lift - Empty
Series CA/FA (AC lift):
Possible Cause Action
Plugged or malfunctioning flow limiter in lift Replace flow limiter. If contamination is
cylinder present, flush, fill and bleed the hydraulic
system.
Binding in the mast Check for binding.
Bad SOL3 Run Test O09. Follow recommendations in
test.
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Relief valve REL1 stuck open Replace REL1. If contamination is present,
flush, fill and bleed the hydraulic system and
clean the relief valve.
Bad lift pump Measure pressures.
Bad lift motor Test lift motor.
5-26 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Symptom Tables: Hydraulic Functions
Unable to Pick Up a Load
Series CA/FA (AC lift):
Possible Cause Action
Bad SOL3 Run Test O09. Follow recommendations in
test.
Bad lift pump Check pressures. Replace pump.
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Contaminated or bad relief valve REL1 Replace relief valve. If contamination is
present, flush, fill and bleed the hydraulic
system.
Bad lift pump Measure pressures.
Bad lift motor Test lift motor.
Lower Function
Slow Lower
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Clogged hydraulic filter Replace hydraulic filter.
Mechanical binding in bearings or tele Adjust or replace bearings. Check shimming.
Bad lift/lower proportional solenoid valve Run Test O12. Follow recommendations in
SOL2 test.
Maximum Lower Speed not matching SOL2 In Configure Mode, adjust Lift M LwrSpd.
Contamination in load holding solenoid valve Inspect load holding solenoid SOL1 for
SOL1 contamination.
Plugged or malfunctioning flow limiter Replace flow limiters.
1026304B, 15 July 2007 5-27
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Symptom Tables: Hydraulic Functions
Intermittent Lower
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Bad SOL2 solenoid (valve or wiring) Run Test O12. Check wiring. Replace SOL2.
Bad SOL1 load holding solenoid (valve or Run Test O11. Check wiring. Replace SOL1.
wiring)
Plugged or malfunctioning flow limiter valves Replace flow limiters.
Load Drifting/Settling
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Load too large for lift truck capacity Check load weight.
DC Only: Incorrect lift pressure adjustment Check and adjust lift pressure setting.
DC Only: Contaminated or bad relief valve Replace relief valve REL1. If contamination is
REL1 present, flush, fill and bleed the hydraulic
system.
AC Only: Leaking or contaminated Replace SOL3.
proportional relief solenoid SOL3
Leaking or contaminated load holding Replace SOL1.
solenoid SOL1
5-28 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Symptom Tables: Travel Functions
Symptom Tables: Travel Functions
Slow or Sluggish Acceleration
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Configuration:
Accel set to “soft” Set accel to “medium” or “hard.” See “Using
Configure Mode” on page 6-6.
Mechanical: Measure current draw.
Worn load wheel or idler assembly Replace load wheel/idler assembly as
required.
Debris in load wheel axle or idler Remove debris.
Dragging brake Adjust brake. See “Brake Adjustment” on
page 7-96.
Binding drive unit Inspect for wear.
Electrical:
Current is limited due to high temperature Check temperature and temperature sensors
for drive motor and power amplifier. Run tests
A08, A10, A24.
1026304B, 15 July 2007 5-29
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Symptom Tables: Travel Functions
Slow Travel
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Mechanical:
Binding drive unit Check for excessive current draw in drive
motor.
Dragging brake Adjust brake. “Brake Adjustment” on
page 7-96.
Electrical:
Incorrect configuration of speed Reconfigure the lift truck. See “Using
Configure Mode” on page 6-6.
If equipped with nested switch option, bad Run Test I01.
S14 switch
Speed limited due to high temperature Run Tests A08, A10, A24. Follow
recommendations in tests.
Bad height encoder (causing false speed Run Test I26. Follow recommendations in test.
limiting)
5-30 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Symptom Tables: Electrical Symptoms
Symptom Tables: Electrical Symptoms
NOTE: Reference electrical schematics
beginning on page A-17 and hydraulic
schematics beginning on page A-35.
Electrical Motors
Motor Overheating
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Especially Series AA/BA/DA/EA (DC lift): Contact Dealer Service Manager to make sure
Application exceeds designed workload -- of application.
short runs with plugging/acceleration or
heavy-duty lifting cycles
Incorrect BSOC Cutout value Measure battery specific gravity at cutout,
after battery has stabilized. Compare to
battery manufacturer specifications for
discharged battery. Adjust BSOC Cutout as
needed.
Clogged motor vents Examine and clear motor vent openings.
DC Motors: worn, damaged, or bad brushes or Check motor brushes.
springs (lift and aux motor only) Check brush spring tension.
Cable, terminal, or wiring problems. Look for Replace wiring or cables as needed. Make sure
loose or discolored terminals, loose or motor cables are torqued correctly.
damaged crimps.
High motor current due to binding gearbox, Inspect gearbox or pump for binding. Check
pump, or dragging brake brake adjustment. See “Brake Adjustment” on
page 7-96.
See also “DC Motor Troubleshooting” on
page 5-8 and “AC Motor Troubleshooting” on
page 5-10.
1026304B, 15 July 2007 5-31
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Symptom Tables: Electrical Symptoms
Operator Display Problems
Scrambled or Intermittent Display
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Electrostatic discharge resulting from dirty, Clean or replace static straps as needed.
worn, or wrong type static straps
Loose display harness or card connectors; Reseat cards and harness connections. Test
intermittent wires or connectors in harness for continuity while flexing harness. If no
continuity is found, replace wiring harness.
See “Wiring and Harness Connectors” on
page 7-116.
Short to frame See “Shorts to Frame Test” on page 5-5.
Unmatched Vehicle Manager and Display Install matching Vehicle Manager and Display
Manager software Manager software. Matching VM and DM
versions may or may not have the same
version number. See “Matching Software
Versions” on page 7-272.
Incorrect installation of options or Verify correct installation of options.
unauthorized parts
Bad Operator Display card Replace Operator Display card.
5-32 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Symptom Tables: Electrical Symptoms
Dead Lift Truck
Display is Dark; Lift Truck is not Operational
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift):
Possible Cause Action
Fuse FU5 or FU6 could be blown Remove fuses and test fuse continuity. If
continuity is missing, replace fuse.
Problem in key switch circuit or with B+ to Troubleshoot B+ to B+KEY circuits from
Vehicle Manager or bad Vehicle Manager battery to VM.
Problem with +12V power supply Troubleshoot +12V supply at VM.
Run Test A14.
Bad Operator Display Replace Operator Display.
Bad battery cables or connector Repair or replace as necessary.
1026304B, 15 July 2007 5-33
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Symptom Tables: Electrical Symptoms
Vantage Point
NOTE: Reference “Adjusting the Monitor” on
page 7-308.
Vantage Point Monitor is Blank
Indication and Possible Cause Action
Button 3 LED lit - monitor in standby mode, Normal condition: To activate display, elevate
Monitor Standby disabled, Carriage below free above free lift transition.
lift transition
Button 3 LED it - monitor in standby mode, Normal condition: To activate display, elevate
Monitor Standby enabled, Carriage below free above free lift transition.
lift transition
Or, unlock keypad. Press Button 3. Lock
keypad.
Button 8 LED off - monitor turned off. Unlock keypad. Press Button 8.
Powersave Mode is enabled
Or, unlock keypad. Press and hold Buttons 4
& 5 for 60 seconds to disable Powersave Mode.
Lock keypad.
Button 1 LED and camera LED both blinking - Return lift truck to operating temperature
Ambient temperature out of operating range range of unit.
(–13°F/–25°C to +167°F/+75°C)
Button 8 LED off - one or both power fuses Replace fuse(s) in Aux Power circuit.
blown
Vantage Point Keypad Keys Inoperative
Indication and Possible Cause Action
Monitor is OK- keypad locked Press and hold Buttons 1 and 5 for 15
seconds to unlock the keypad.
Do not leave keypad unlocked.
Vantage Point Video Picture Problems
Indication and Possible Cause Action
Black horizontal bar in picture: Wrong Unlock keypad. Press and hold Button 4 for
monitor frequency 15 seconds. Lock keypad.
Picture is reversed (mirror-image): Image Unlock keypad. Press and hold Buttons 1 and
reversed 3 for 5 seconds. Lock keypad.
Picture is inverted (upside-down): Image Unlock keypad. Press and hold Buttons 1 and
inverted 2 for 35 seconds. Lock keypad.
5-34 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Symptom Tables: Electrical Symptoms
Indication and Possible Cause Action
Picture too light or too dark, Button 2 LED is Unlock keypad. Press Button 2 to turn
OFF. automatic brightness ON. Button 2 LED turns
ON. Lock keypad.
If picture is still too light or too dark, go to
next action.
Picture too light or too dark, Button 2 LED is Unlock keypad, press Button 2 to turn
ON, automatic brightness OFF.
To adjust brightness, press Button 5, then
Button 6 to decrease, Button 7 to increase.
To adjust contract, press Button 4, then
Button 6 to decrease, Button 7 to increase.
Press Button 2 to turn automatic brightness
ON. Lock keypad.
See also “Testing and System Setup” on
page 7-306, step 4.
Vantage Point Electrical Schematic
In Appendix A, Electrical Schematics, see
“Model 74xx Options - Vantage Point” on
page A-25.
1026304B, 15 July 2007 5-35
Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
Symptom Tables: Electrical Symptoms
5-36 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Section 6. Messages, Codes, and Tests
1026304B, 15 July 2007 6-1
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Software Changes
Software Changes
When changing Vehicle Manager or Operator
The following tables summarize version changes Display Manager software, make sure a
in the Model 7400/7420/7440 Reach-Fork ® matched VM/DM set of software is installed.
truck Vehicle Manager, Operator Display See “Matching Software Versions” on
Manager, and Power Amplifier software. The page 7-272.
tables do not discuss details of engineering
changes contained in these versions.
Table 6-1. Vehicle Manager Software
Version Date Series Changes
01.8 05-15-04 All 7400 Initial version
01.9 8-24-04 All 7400 Add Tests A41 EPO Sense and I62 Bump Detect
02.1 12-7-04 All 7400 Add M Lwr Spd parameter, high speed travel speed limit
switch support and Test I63
02.2 12-7-04 All 7400 Add Embedded Statistics to Config Menu
02.3 5-22-05 All 7400 Add OACH support to 450 in., some parameters no
longer reset by Config Defaults
02.5 6-29-05 All 7400 Add FlashWare option Ext Access Enable, correct loop
back tests I33 through I36
02.7 12-7-05 All 7400 Changes to fault codes 2H, 43, CD, FG, FT; Enable Test
O02 for Series AA/BA/DA/EA; add Vantage Point and
OCSS support
03.3 10-4-06 All 7400 Changes to fault codes FE and FG
03.7 3-13-07 All 7400, 7420, 7440 Add 7420 and 7440 support, new FlashWare options
WHLD and Sauer Danfoss Traction Motor, SOL3
pressure change, renumber Test I42 to Test I86,
improve fault code detection, enhanced brake software
under low voltage operation,
04.3 5-14-07 All 7400, 7420, 7440 Add Vertical Hold support
04.5 7-9-07 All 7400, 7420, 7440 Add alternate lift limit bypass options
6-2 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Software Changes
Table 6-2. Operator Display Manager Software
Version Date Series Changes
01.6 05-15-04 All Initial version
01.7 8-24-04 All Add Tests A41 EPO Sense and I62 Bump Detect
02.0 12-7-04 All Add M Lwr Spd parameter, high speed travel speed limit
switch support and Test I63
02.1 12-7-04 All Add Embedded Statistics to Config Menu
02.2 5-22-05 All Add OAH support to 450 in., some parameters no
longer reset by Config Defaults
02.3 6-29-05 All Add FlashWare option Ext Access Enable, correct loop
back tests I33 through I36
02.4 12-7-05 All 7400 Changes to fault codes 2H, 43, CD, FG, FT; Enable Test
O02 for Series AA/BA/DA/EA
02.6 10-4-06 All 7400 Changes to fault codes FE and FG
02.6 3-13-07 All 7400, 7420, 7440 Add 7420 and 7440 support, new FlashWare options
WHLD and Sauer Danfoss Traction Motor, SOL3
pressure change, renumber Test I42 to Test I86,
improve fault code detection,
03.0 5-14-07 All 7400, 7420, 7440 Add Vertical Hold support
03.3 7-9-07 All 7400, 7420, 7440 Add alternate lift limit bypass options
Table 6-3. Power Amplifier Software
Version Date Series Changes
03.0 04-01-04 All Initial version
03.1 04-16-07 All Changes to fault code 2U detection
1026304B, 15 July 2007 6-3
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Modes of Operation
Modes of Operation Hour Meters and Distance Indicator
The Operator Display shows the following
Overview of Modes accumulated totals:
• KeyH: Total hours the key switch has been
This lift truck has two modes of operation: Run turned ON
Mode and Program Mode. Run Mode is the • DdMan H: Total hours on deadman
normal operating mode for the lift truck.
Program Mode permits configuration, • Lift H: Total hours spent lifting
calibration, and diagnostic testing (service). • Total D: Total distance traveled (miles or
kilometers, depending on Units specified
Run Mode in Config)
When you power on the lift truck normally, the These accumulated totals cannot be changed
on-board firmware does a number of internal from Program Mode.
selftests and enters the default mode of
operation, Run Mode. Run Mode is the normal You can also display hour meters and distance
operating mode. In Run Mode, the Operator indicator in Run Mode by pressing dashboard
Display can show date, time, BSOC, weight on button 0 on the Operator Display panel.
forks, and (optionally) ambient temperature.
For information on the Operator Display, see Configure Mode
“Operator Display” on page 3-6.
Use Configure Mode to adjust various lift truck
Run Mode is also entered when the lift truck performance parameters to specific customer
exits Program Mode. requirements. To enter Configure Mode, you
must enter either the Password or Superword
for the lift truck.
Program Mode
Some items in Configure Mode will appear only
Use Program Mode for configuration, if the Superword is entered.
calibration, and diagnostic testing of the lift
truck. You need a password in order to enter For detailed description, see “Using Configure
Program Mode. See “Passwords” below. Mode” on page 6-6.
Program Mode is divided into several categories: Service Mode
• Serial Number
• Version Use Service Mode to calibrate, test, cycle, and
troubleshoot individual electrical circuits.
• WHLD (Weight-Height Limit Display) Service Mode tests are divided into two
• Hour Meters categories: static and active.
• Configure Mode
Use the Learn Function to calibrate the lift
• Service Mode truck for correct operation. You can select the
following categories for calibration:
Serial Number
• Controls (travel, lift/lower)
The serial number recorded in the lift truck • Weight
firmware must match the serial number on the
lift truck tractor and mast specification plates. To enter Learn Function, you must enter
This field cannot be changed from Program Service Mode through the Superword.
Mode.
6-4 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Modes of Operation
To enter Service Mode, you must enter the Run Mode Tones
Superword.
The lift truck signals various situations by
For detailed description, see “Using Service using different tone patterns.
Mode” on page 6-17.
1. A single tone (chirp) occurs when:
Passwords • The enter button is used to enter a
value in a Program Mode.
For detailed description of how to enter 2. A double tone (high/low) means the
passwords, see “Entering an Electronic Key, system has detected a fault condition.
Password, or Superword” on page 6-6. • One of the PC contactors may be
de-energized (open). Travel, lift/lower,
Electronic Operator Key and auxiliary functions are disabled.
3. A triple tone (high/medium/low) means
Electronic Operator Key is a configurable
one of the following:
software feature that permits the customer to
set an operator electronic key or operator • Travel performance limitation: The lift
password. When the operator turns the key truck is limited to a maximum travel
switch ON, the software prompts the operator to speed of 1 MPH (1.6 km/h). Lift, lower,
enter the electronic key. The lift truck will not auxiliary functions, steering, and horn
enter Run Mode unless the correct electronic all operate normally.
key is entered. Up to 20 different electronic • Traction system shutdown: The lift
keys can be set. truck is disabled for travel. Lift, lower,
auxiliary functions, steering, and horn
Password all operate normally.
• Lift system shutdown: The lift truck is
Password permits access to Configure Mode
not permitted to lift. Lower, travel,
only. It is intended for customer use in setting
steering, and aux all operate normally.
performance parameters within those features
purchased with the lift truck. 4. A descending “arcade” tone means:
• An incorrect password or electronic key
Superword was entered.
Superword permits access to all Program
Modes. Superword is intended to limit service Entering Program Mode
access to qualified and trained service
technicians. To enter Program Mode on Model
7400/7420/7440 Reach-Fork ®:
We strongly recommend that, during
installation, you change the Superword from From Run Mode, press the enter button on the
the factory default to a code known only to the Operator Display.
dealer and/or owner so that access to Service
Mode is limited to approved personnel. Make You will see an eight character password
sure to record the new Superword in a safe prompt field, displaying underscores:
place. If this code is lost or forgotten, a
________
technician will need to reset the lift truck to
factory default settings. This will make Enter the Password or Superword for the
necessary the reconfiguration of all variable lift truck. See “Entering a Password or
settings. Superword” below.
1026304B, 15 July 2007 6-5
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Modes of Operation
Entering an Electronic Key, INVALID, TRY AGAIN
Password, or Superword 7. If you make a mistake while entering a
character, repeat steps 2 through 5.
An Electronic Key, Password, or Superword
may be from one to eight characters in length, When you have entered the correct Password or
having any combination of letters, numbers, Superword, you will see the following display:
and/or spaces (indicated by an underscore). A VSERIAL # °
password of all spaces is not permitted. VERSION
NOTE: No two passwords (Electronic Key, HR MTRS
Password, Superword) may be set to the WCONFIG
same value. If you try to do so, the lift
truck will treat the second password as To change Password or Superword
an invalid code and give an error
message. Each password must be set to 1. Enter the Configure Mode using the
a unique value. current Password or Superword. See
“Using Configure Mode” on page 6-6. If
1. When the password prompt displays, an Password is entered, Password is available
eight character field of underscores for change, but Superword is not.
appears. Initially, the left-most character
2. Use the up/down buttons to scroll to
position is flashing, showing it is the
Password. Press the right button.
currently selected position.
3. Use the up/down buttons to scroll to the
2. Use the left/right buttons to select a
Password or Superword item.
different character position. The selected
position will flash. 4. With Password or Superword selected,
press the right button. (If Password was
NOTE: After about 2.7 seconds, the display entered in step 1 above, Password is
prompt automatically increments to the available for change, but Superword is
next position to the right. not.)
3. Once you select the character position, 5. Enter the new password as specified under
use the up/down buttons to select the “Entering an Electronic Key, Password, or
number, letter, or space you want. The Superword” above.
character set wraps between “0” and “-”
6. With the new password displayed, press
(space). In other words, to go quickly from
the enter button.
the number “0” to the letter “z,” press the
up button twice. 7. Save the new password as specified under
“To Save New Values” on page 6-7.
0123456789
ABCDEFGHIJKLMNOPQRSTUVWYZ-
NOTE: To enter numerical values, you can also
Using Configure Mode
use the dashboard keys 1 through 0 on
Use Configure Mode to adjust various lift truck
the Operator Display panel.
performance parameters to specific customer
4. Repeat steps 2 and 3 for the remaining requirements. To enter Configure Mode, you
characters in the Password or Superword. must enter either the Password or Superword
5. When you have completed entering all the for the lift truck.
characters in the Password or Superword,
press the enter button once. Some items in Configure Mode appear only if
the Superword is entered.
6. If you enter an invalid Password or
Superword, a descending “arcade” tone “Program Mode Menus” on page 6-9 lists all
sounds and the following message appears possible lift truck configurations and options. If
on the Operator Display: your lift truck does not have one or more of the
6-6 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Modes of Operation
listed options, those options do not appear in To Configure Additional Items
the Operator Display. • After configuring the first item, press the
left button. Navigate to the next item as
To Place the Lift Truck in Configure Mode specified under “To configure an item.”
1. Enter Program Mode as described on
page 6-5. If You Make a Mistake
2. Enter Password or Superword as • If you make a mistake in configuring an
described on page 6-6. item, simply navigate back to that item
3. The Operator Display shows: and configure it again.
VSERIAL # ° To Save New Values
VERSION
HR MTRS Changes to configuration values are not saved
until you exit Configuration Mode. If you have
WCONFIG made changes to configured values:
4. Press the down button until Config is 1. Use the left button to back out of the
displayed. Press the right button. The menus.
Operator Display shows:
2. The Operator Display shows:
VDEFAULT °
RESTORE
TRAVEL
SAVE
LIFT
3. Use the down button to select SAVE. Press
WBSOC the enter button. Your new values are
saved.
To Configure an Item
NOTE: You will not be able to exit to the main
1. Use the up/down buttons to move to the
menu until you have selected either
item you want. If you see an up (V) or
RESTORE or SAVE and pressed the enter
down (W) arrow in front of an item, it
button.
means there are more items above or
below that item. 4. Press the left button to back out to the
2. Use the up/down buttons to move to the main menu.
item you want. VSERIAL # °
3. To configure the selected item, press the VERSION
right button. Follow the directions on the HR MTRS
Operator Display. Use up/down buttons
to select among specified values or to enter WCONFIG
a numerical value. Use right/left buttons 5. Press the left button to exit to Run Mode.
to move to lower/higher menu levels. The lift truck enters the Run Mode.
SelfTest is not re-run.
NOTE: To enter numerical values, you can also
use the dashboard keys 1 through 0 on
If You Change Your Mind About Making
the Operator Display panel.
Changes
When you have entered the values you
want via the up/down buttons, press the Changes to configuration values are not saved
enter button. The values are accepted and until you exit Configuration Mode. If you made
the Operator Display shows the name of configuration changes, but do not wish to keep
the item you last selected. the changes:
NOTE: Changes are not saved until you exit 1. Use the left button to back out of the
Configure Mode and reply SAVE to the menus.
Restore/Save prompt.
1026304B, 15 July 2007 6-7
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Modes of Operation
2. The Operator Display shows: • BSOC
RESTORE • Lift Cutout
SAVE • Travel Alarm
3. With RESTORE selected, press the enter The following functions are disabled:
button. Your new values are discarded. • Mnt Mind l
NOTE: You will not be able to exit to the main • Auto Off
menu until you have selected either 3. Press the left button twice to select the
RESTORE or SAVE and pressed the enter main menu.
button.
4. Press the left button to exit Program Mode
4. Press the left button to back out to the and enter Run Mode.
main menu.
VSERIAL # °
VERSION
HR MTRS
WCONFIG
5. Press the left button to exit to Run Mode.
The lift truck enters the Run Mode.
SelfTest is not re-run.
To Reinstate Factory Default Settings
1. Enter Configure Mode and use the down
button to select DEFAULT. Press the right
button. The Operator Display shows:
DEF NO
DEF YES
2. Use the up/down buttons to select DEF
YES. Press the enter button.
Factory default values are restored for all
items except:
• Password
• SuperWord
• Electronic Key
• Error Log
• Emb Stats (VM Ver. 2.3+)
• BumpResp (VM Ver. 2.3+)
• Switch 2H (VM Ver. 2.3+)
• Lft Lmt (VM Ver. 2.3+)
• M Lwr Spd (VM Ver. 2.3+)
• Maximum Reach and Retract Speeds
(VM Ver. 2.3+)
The following factory default values are
restored only if menu was entered from
SuperWord:
6-8 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Modes of Operation
Program Mode Menus
Program Mode Menus
NOTE: CAPITALIZED value is the Factory Default.
Among values displayed on Operator Display, the item with an asterisk (*) is the
currently selected value.
Shaded items are available only from the Superword menu structure.
Group Item Values Description
Lift Truck Identification
Serial # SN _ _ _ _ _ Lift truck serial number. Cannot be changed.
Version Lift truck firmware versions. Cannot be
changed.
VM xx.y Vehicle Manager
DM xx.y Display Manager
PAT xx.y Traction Power Amplifier
PAP xx.y Lift Power Amplifier (series CA/FA only)
WHLD Cfg Weight 1 xxxx lb Weight-Height Limit Display configuration table.
Height 1 xxx in Values for weights and heights are
Weight 2 xxxx lb factory-configured and not editable.
Height 2 xxx in (Available with VM Ver 3.7+)
...
Weight 6 xxxx lb
Height 6 xxx in
Hr Mtrs Display hour meters. Cannot be changed.
Key H Key Switch Hours
DdMan H Deadman Hours
Lift H Lift Hours
Total D Traction Distance (mi./km)
NOTE: You can also display hour meters by
pressing the number 0 dashboard
button on the Operator Display.
1026304B, 15 July 2007 6-9
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Modes of Operation
Program Mode Menus
NOTE: CAPITALIZED value is the Factory Default.
Among values displayed on Operator Display, the item with an asterisk (*) is the
currently selected value.
Shaded items are available only from the Superword menu structure.
Group Item Values Description
Config Mode Menu
6-10 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Modes of Operation
Program Mode Menus
NOTE: CAPITALIZED value is the Factory Default.
Among values displayed on Operator Display, the item with an asterisk (*) is the
currently selected value.
Shaded items are available only from the Superword menu structure.
Group Item Values Description
Default Def No Do not restore factory default settings.
Def Yes Restore factory values to all settings except:
Password and SuperWord
Electronic Key
Error Log, Emb Stats
Lft Lmt Height, M Lwr Spd
Max Reach & Retract Speeds
Switch 2H
Bump Response
Disable:
Mnt Mind and Auto Power Off
Restore factory values only if menu was entered
from SuperWord:
BSOC, Lift Cutout
Travel Alarm
Travel
Speed 7.5 Maximum Travel Speed
(depends on model/series)
0.0 to 8.0 mph (0.0 to 12.8 km/h)
(8.0 mph with 7400 High Performance Option)
T Accel Soft Travel Acceleration
MEDIUM
Hard
Coast LONG Coast Distance after releasing directional/speed
Medium control
Short
Switch 1 3.5 [default] Travel Speed Limit at Height 1
0 to 3.5 mph (0 to 5.6 km/h)
Switch 2 (option) 1.8 [default] Travel Speed Limit at Height 2
0 to 1.8 mph (0 to 2.9 km/h)
Switch 2H OACH [default] Height at which speed is reduced to Switch 2
configured value.
Range - overall collapsed height to maximum
elevated height
Default = overall collapsed height
UnNested (option) 3.5 [default] Travel Speed Limit with Reach Extended
0 to 3.5 mph (0 to 5.6 km/h)
AlarmT (option) None Travel Alarm enabled for forks leading, forks
Fork Ld trailing, both directions, or not enabled.
Fork Trl
BOTH
1026304B, 15 July 2007 6-11
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Modes of Operation
Program Mode Menus
NOTE: CAPITALIZED value is the Factory Default.
Among values displayed on Operator Display, the item with an asterisk (*) is the
currently selected value.
Shaded items are available only from the Superword menu structure.
Group Item Values Description
Lift
L Accel Soft Lift Acceleration
Medium
HARD
L Decel Soft Lift Deceleration at end of lift
Medium
HARD
Lwr Accel Soft Lower Acceleration
Medium
HARD
Lwr Decel Soft Lower Deceleration at end of lower
Medium
HARD
M LwrSpd 70% to 80% Maximum Lower Speed. Factory-set to the
[VM ver. 02.1+/ DM [typical] original proportional valve installed. 50%
02.0+] (slowest) to 100% (fastest)
Lft Lmt STD BYP To bypass limit or continue past limit, press and
[VM ver. 04.5+] hold Up arrow on Operator Display.
(option) Alt Byp To bypass or continue past limit press and
release Up arrow on Operator Display.
No Byp No bypass even if Up arrow is pressed.
Lim Hgt Height at which limit cuts out. See next item
below.
Lft Lmt OACH [default] Height at which lift cuts out. To bypass limit or
[VM ver. < 04.5] continue past limit, press and hold Up arrow on
(option) Operator Display.
Range = overall collapsed height to maximum
elevated height
Default = overall collapsed height
BSOC Reset by Config Default only when invoked from
Superword. Cannot be reset by FlashWare.
BSOC 75% [default] The percentage of charge which a new battery
must exceed in order for the BSOC display to be
reset to the new battery. For an explanation of
how BSOC is calculated, see “Battery
State-of-Charge” on page 5-11. 55% to 100%
Lift c/o 20% [default] Battery State-of-Charge value at which Lift
Cutout occurs (to permit lift truck to travel to
charging station). 0 to 50%
6-12 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Modes of Operation
Program Mode Menus
NOTE: CAPITALIZED value is the Factory Default.
Among values displayed on Operator Display, the item with an asterisk (*) is the
currently selected value.
Shaded items are available only from the Superword menu structure.
Group Item Values Description
Units ENGLISH Measurement units used in display
Metric
Carriage
Reach 1-Spd Reach Speed
2-SPD
MaxHiRch 100% [default] Maximum High Reach Speed Value
0% to 100%
MaxHiRtr 75% [default] Maximum High Retract Speed Value
0% to 100%
MaxLoRch 40% [default] Maximum Low Reach Speed Value
0% to 100%
MaxLoRtr 40% [default] Maximum Low Retract Speed Value
0% to 100%
Rch Spd S High Reach Speed
. . . . . . . .High *
**
***
****
*****
F
Rch Spd S Low Reach Speed
. . . . . . . .Low *
**
***
****
*****
F
Rtr Spd S High Retract Speed
. . . . . . . .High *
**
***
****
*****
F
Rtr Spd S Low Retract Speed
. . . . . . . .Low *
**
***
****
*****
F
1026304B, 15 July 2007 6-13
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Modes of Operation
Program Mode Menus
NOTE: CAPITALIZED value is the Factory Default.
Among values displayed on Operator Display, the item with an asterisk (*) is the
currently selected value.
Shaded items are available only from the Superword menu structure.
Group Item Values Description
Password
Elec Key (option) ________ Electronic Key prompt. Up to 20 different keys
permitted. Note: No two passwords (Electronic
Key, Password, Superword) may be set to the
same value. If you try to do so, the lift truck will
treat the second password as an invalid code
and give an error message. Each password must
be set to a unique value.
Password ________ Change Password. See note under Electronic
Key.
Superwrd ________ Change Superword. See note under Electronic
Key.
Embedded View ES Display embedded statistics.
Statistics
(option) Interval Daily Set interval
Weekly
Monthly
Clear ES NO Do not clear statistics.
Yes Clear statistics log.
BumpResp None Specifies action to be taken if the optional bump
(option) detect feature is triggered. If “none” is not
selected, more than one action can be specified.
X.X mph 3.5 to 8.0 (default = 8.0)
Lift Int Lift Interrupt (default)
Snd Horn Sound Horn
Mnt Mind Status Maintenance Minder ™ tool
DISABLE Disables the feature (when enabled)
Enable Enables the feature, using last stored setup
Reset Resets internal timer to current deadman pedal
hours (restarts the countdown)
Action Action to be taken at specified interval
. . . . MSG ONLY . . .Display message but do not disable lift
. . . . L CutOut . . .Disable lift
Interval Set reminder interval from 50-500 hours on
. . . . 250 [default] deadman pedal, by 50 hour increments. Default
is initially 500, then 250.
NOTE: Action and Interval cannot be reset by
Config Default or by FlashWare.
See “Maintenance Minder ™ Tool” on page 4-3.
6-14 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Modes of Operation
Program Mode Menus
NOTE: CAPITALIZED value is the Factory Default.
Among values displayed on Operator Display, the item with an asterisk (*) is the
currently selected value.
Shaded items are available only from the Superword menu structure.
Group Item Values Description
Auto Off 0 Auto Power Off ™ device
1 0 (Disabled), 1, 2, 3, 4, 5, 10 minutes
..
NOTE: Auto Power Off will shut down a lift
10
truck only when the lift truck is in Run
Mode.
Clock Set Time and Date
Time hh:mm a/p
NOTE: Holding Up or Down button changes
Date mm/dd/yy
value faster.
24 hr DISABLED 12-hour format (1 PM = 01:00)
Enabled 24-hour format (1 PM = 13:00)
ES Mode DISABLE Energy Saving Mode is disabled.
Series CA/FA Minimum Minimum Energy Saving Mode is achieved by
(AC lift) Maximum slightly reducing maximum lift speed.
Maximum Energy Saving Mode is achieved by
reducing maximum lift speed.
WHLD Weight-Height Limit Display format
(VM Ver 3.7+)
Two Ln H Show height, use left and right buttons to
change to 2-line height and weight.
Two Ln W Show height and weight, use left and right
buttons to change to 1-line height.
Toggle Display toggles automatically between 1-line
height and 1-line weight
Fixed Use left and right buttons to toggle between
1-line height and 1-line weight.
VH Cfg Vertical Hold Configuration
xxx nnn 1- to 3-character alphanumeric label, followed
by 3-character numeric height (minimum is
OACH plus 12 in. or 30 cm)
Quit Cfg Restore Quit Configuration Mode without saving
changes.
Save Quit Configuration Mode after saving changes.
1026304B, 15 July 2007 6-15
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Modes of Operation
Program Mode Menus
NOTE: CAPITALIZED value is the Factory Default.
Among values displayed on Operator Display, the item with an asterisk (*) is the
currently selected value.
Shaded items are available only from the Superword menu structure.
Group Item Values Description
Service Mode
Learn
Controls Operator Display message scrolls:
“Learning”
“Return Handle Controls to Neutral, Press Horn
Button.”
“Lower Carriage to Floor, Press Horn Button
When Done.”
“Done”
Weight Operator Display message scrolls:
“Learning”
“Lower Carriage to Floor, Then Lift 4 Inches,
Press Horn Button When Done.”
“Raise Carriage Out of Free Lift, Press Horn
Button When Done”
Analog A04 Tra Pot 1.13 V Use Up and Down buttons to scroll list of Analog
... ... Tests. Test shows real time value.
A41 EPO Sns
Input I00 Dman Sw Down/Up Use Up and Down buttons to scroll list of Input
... ... Tests. Test shows real time value.
I60 Start Sw Open
Output O00 TPC Tgl Off/On Operator Display message scrolls:
... ... “WARNING...Jack Up the Drive Wheel, Press
O34 Htr En Off/On Enter When Ready.”
Use Up and Down buttons to scroll list of
Output Tests. Test shows real time value.
Use Enter button to toggle test.
Clr Act This item appears only if tests have been
selected for active service.
Clr No Do not clear active service tests.
Clr Yes Clear active service tests.
Log “No errors in log”
“Date Time Code Log holds up to 20 errors in order of occurrence.
BSOC” BSOC is normalized to Lift Cutout = 0%.
Clr Log Clr No Retain error log entries.
Clr Yes Clear error log entries.
6-16 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Modes of Operation
Using Service Mode CLR LOG
Use the up/down buttons to select the
Service Mode is divided into two categories: test category desired, then press the right
static and active. button.
5. If you select Output tests, the Operator
Static Service Mode Display scrolls this warning:
WARNING: JACK UP THE DRIVE WHEEL,
Static Service Mode permits testing of PRESS ENTER WHEN READY...
individual circuits while the lift truck is
standing still. You can use Static Service Mode After you jack up and block the lift truck,
for most analog and digital input and digital respond to the Ready prompt by pressing
output tests. the enter button.
6. Within a test category, tests numbers are
displayed, in numerical sequence. Use the
up/down buttons to move to the test you
want.
By entering Static Service Mode, you are
disabling the safety circuits. Therefore, 7. Analog and Input test results are
you must take extra precautions while displayed as soon as you select the test, to
in Static Service Mode. Follow all the right of the test number. For example,
instructions in this manual for each test. Test A04 might show:
If you are unsure how to conduct a test A04 TRA POT 1.10 V
while in Service Mode, Stop: Do Not
8. You must explicitly start output tests.
Proceed with the test. Contact an
Select the test number you want by
authorized Raymond dealer.
scrolling and highlighting the test.
O01 STR TGL OFF
Press the enter button. The Operator
Display shows the test results to the right
While in Static Service Mode: of the test number.
Elevate the drive tire off the floor. See O01 STR TGL ON
“Jacking Safety” on page 2-11.
Use the enter button to toggle the test.
To Place the Lift Truck in Static Service Mode O01 STR TGL OFF
1. Press the enter button to enter Program To exit output test, press the left button.
Mode. 9. The Error Log stores the last twenty error
2. Enter the Superword and press enter. codes recorded on the lift truck. Entries
3. Use the up/down buttons to select are stored in order of occurrence, with the
SERVICE, then press the right button. most recent error first.
4. You can select the following from Service a. To access the Error Log, use the
Mode: up/down buttons to select LOG, then
press the right button.
LEARN
b. If no errors are stored, the message
ANALOG
“NO ERRORS IN LOG” appears in the
INPUT display.
OUTPUT c. If errors have been logged, use the
CLR ACT (ONLY IF TESTS ARE SELECTED FOR up/down buttons to scroll through the
ACTIVE SERVICE) list.
LOG d. To clear the log, use the up/down
buttons to scroll to CLR LOG. Press the
1026304B, 15 July 2007 6-17
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Modes of Operation
right button. Scroll to CLR YES and 3. Use the up/down buttons to select
press the enter button. CLR ACT. This item only appears if you have
selected one or more tests for active
service.
Active Service Mode
4. Press the enter button. Active service tests
Active Service Mode permits testing circuits are cleared. Exit Service Mode and
while the lift truck is enabled for normal Program Mode.
operation. You can use Active Service Mode for
all analog and digital input tests.
You can select up to eight tests at a time to run
in Active Service Mode. Tests can be displayed
whether you are on or off the deadman pedal.
Tests selected for Active Service are stored in
memory even if the key switch is turned OFF.
To Enable a Test For Active Service Mode
1. Enter Static Service Mode.
2. Scroll to the test you want. Press one of
the dashboard buttons 1 through 8 on the
Operator Display. The button number
appears to the left of the test number in
the test list to show that this test is
selected for Active Service Mode.
3. Assigning a test to a particular dashboard
button resets any previous assignment for
that button.
4. Use the up/down buttons to select more
tests from the same category. To select
more tests from a different category, exit
the current category and select the other
category from the SERVICE menu. Use the
up/down buttons and remaining
dashboard buttons to select more tests
from that category.
5. Quit Service Mode and Program Mode. Let
the lift truck enter Run Mode.
6. To display Active Service tests while in
Run Mode, press dashboard button 9.
Four tests will display at a time. Use the
up/down buttons to scroll through the list
of selected tests.
To Clear All Active Maintenance Tests At
Once
1. Go to Program Mode.
2. Use the up/down buttons to select
SERVICE, then press the right button.
6-18 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Messages and Codes Summary List
Section 6. Messages, Codes, and Tests
Code 12 – Bump Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 1H – Traction Power Amplifier Overheated . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 1T – Battery Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code 1V – Lift Power Amplifier Overheated, Series CA/FA (AC lift) . . . . . . . . . . . 6-25
Code 2A – Traction Motor Approaching Overtemperature . . . . . . . . . . . . . . . . . . 6-26
Code 2C – Traction Power Amplifier Temperature Sensor Out-of-Range . . . . . . . 6-27
Code 2E – Traction Motor Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . 6-28
Code 2H – Failure Detected in Traction Motor Feedback Encoder . . . . . . . . . . . . 6-29
Code 2M – Traction Power Amplifier Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code 2P – Traction Power Amplifier Reverted to Default Parameters. . . . . . . . . . 6-31
Code 2T – Traction Power Amplifier Current Calibration Error . . . . . . . . . . . . . . 6-32
Code 2U – Traction Power Amplifier Fault - Overcurrent. . . . . . . . . . . . . . . . . . . 6-33
Code 2V – Traction Power Amplifier Fault - High DC Voltage . . . . . . . . . . . . . . . 6-34
Code 42 – Lift Contactor Detected Closed When Commanded Open . . . . . . . . . . 6-35
Code 43 – Lift Contactor Detected Open, Low DC Voltage After Power-Up . . . . . 6-36
Code 44 – TPC Contactor Detected Closed When Commanded Open . . . . . . . . . 6-37
Code 45 – TPC Contactor Detected Open, Low DC Voltage After Power-Up . . . . . 6-38
Code 4B – Steer Contactor Detected Closed When Commanded Open . . . . . . . . 6-39
Code 4C – Steer Contactor Detected Open When Commanded Closed . . . . . . . . 6-40
Code 4D – No Pre-Charge Traction DC Input Voltage During Start-Up . . . . . . . . 6-41
Code 4E – No Pre-Charge Lift DC Input Voltage During Start-Up,
Series CA/FA (AC lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Code 57 – VM Not Responding to Operator Display . . . . . . . . . . . . . . . . . . . . . . 6-43
Code 58 – Operator Compartment Sensor System CAN Communication Failure. 6-44
Code 59 – CAN Transmission Buffer Error for BUS_I . . . . . . . . . . . . . . . . . . . . . 6-45
Code 5A – CAN Bus Error/Vehicle Manager for BUS_I . . . . . . . . . . . . . . . . . . . . 6-46
Code 5B – CAN Receive Bus Error/Vehicle Manager. . . . . . . . . . . . . . . . . . . . . . 6-47
Code 5G – No Communications Received from Traction Power Amplifier . . . . . . . 6-48
Code 5J – No Communication from Lift Power Amplifier Series CA/FA (AC lift). . 6-49
Code 5M – Traction Power Amplifier CAN Watchdog Timeout . . . . . . . . . . . . . . . 6-50
Code 5P – Lift Power Amplifier CAN Watchdog Timeout Series CA/FA (AC lift) . . 6-51
Code 5Q – Display Manager Not Responding . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Code 5R – Secondary CAN Bus Error for BUS_E . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Code 5T – No CAN Message from any Node . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Code 61 – Mast Switch #1 Not Crossed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Code 62 – Lift Power Amplifier Reverted to Default Parameters . . . . . . . . . . . . . 6-56
Code 63 – HS Travel and First Speed Limiting Switches Do Not Agree . . . . . . . . 6-57
Code 64 – No Pulses Seen from Height Indicator Encoder . . . . . . . . . . . . . . . . . 6-58
Code 66 – Calculated Height Greater Than Configured Height . . . . . . . . . . . . . . 6-60
Code 67 – Calculated Height Does Not Match First Speed Limiting Switch (S12) 6-61
Code 6D – Pressure Sensor Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Code 6F – Lift Motor Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Code 6G – Lift Motor Temperature Sensor Out-of-Range. . . . . . . . . . . . . . . . . . . 6-64
Code 6S – Lift Power Amplifier Temperature Sensor Out-of-Range,
Series CA/FA (AC lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Code 6T – Lift Power Amplifier Current Calibration Error, Series CA/FA (AC lift) 6-66
Code 6U – Excessive Lift Motor Brush Wear, Series AA/BA/DA/EA (DC lift). . . . 6-67
Code 6V – Lift Power Amplifier Failure, Series CA/FA (AC lift) . . . . . . . . . . . . . . 6-68
1026304B, 15 July 2007 6-19
Messages and Codes Summary List Model 7400/7420/7440 Reach-Fork ® Truck
Code 6W – Failure Detected in Lift Motor Feedback Encoder,
Series CA/FA (AC lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
Code 6X – Lift Power Amplifier Fault - Overcurrent, Series CA/FA (AC lift) . . . . . . 6-70
Code 6Y – Lift Power Amplifier Fault - High DC Voltage, Series CA/FA (AC lift) . . 6-71
Code 6Z – FlashWare parameters do not match stored values . . . . . . . . . . . . . . . 6-72
Code 80 – Primary Throttle Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . . . 6-73
Code 81 – Lift Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Code 83 – Primary Throttle Potentiometer Out-of-Neutral-Zone . . . . . . . . . . . . . . 6-75
Code 84 – Brake Inoperable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
Code 88 – +5VDC Power Supply Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Code 8A – Operator Compartment Sensor System Failure . . . . . . . . . . . . . . . . . . 6-78
Code 8C – Deadman Pedal Signals Do Not Agree . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Code 8F – Lift Throttle Out-of-Neutral-Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Code 8G – Secondary Throttle Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . 6-81
Code 8H – Secondary Throttle Potentiometer Out-of-Neutral-Zone . . . . . . . . . . . . 6-82
Code 8J – Ambient Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . 6-83
Code 8K – Deadman Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Code 8L – Brake Feedback Current Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . 6-85
Code 8M – Internal Handle Heater Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
Code 8N – Optional Start Switch Closed at Start-Up . . . . . . . . . . . . . . . . . . . . . . 6-87
Code A0 – Incorrect Software For Proper Lift Truck Operation . . . . . . . . . . . . . . . 6-88
Code AH – Bad Operator Display Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Code AJ – Bad VM Flash Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Code AK – Bad VM RAM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
Code AL – Bad Battery Backed-Up VM RAM Memory . . . . . . . . . . . . . . . . . . . . . . 6-92
Code AM – Bad Operator Display Flash Memory . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Code AN – Malfunctioning Operator Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94
Code EH – Invalid Interrupt - Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95
Code F4 – Vehicle Manager COP Time-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Code F5 – Bad Op Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
Code F8 – Vehicle Manager COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
Code FE – Vehicle Manager Not Calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99
Code FG – 5 and/or 12 Volt Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . 6-100
Code FH – Battery Voltage Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
Code FN – VM Did Not Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102
Code FP – VM Hardware Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
Code FR – VM Config Item Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104
Code FT – VM Internal Software Related Failure . . . . . . . . . . . . . . . . . . . . . . . . 6-105
Code FV – Display Internal Software Related Failure . . . . . . . . . . . . . . . . . . . . . 6-106
Code G0 – Steer Tiller 1 Channel A/B Fault, Series CA/FA (AC lift) . . . . . . . . . . 6-107
Code G3 – Steer Feedback Proximity Sensor Fault, Series CA/FA (AC lift) . . . . . 6-108
Code G4 – Open Detected in Steer Control Circuit, Series CA/FA (AC lift) . . . . . 6-109
Code G5 – Short Detected in Steer Motor Encoder Circuit, Series CA/FA (AC lift) 6-110
Code G7 – Steer Tiller 2 Channel A/B Fault, Series CA/FA (AC lift) . . . . . . . . . . 6-111
Code GD – Open Detected in Steer Motor Encoder Circuit, Series CA/FA (AC lift) 6-112
Code GE – Steer Encoder failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
6-20 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Power Amplifier LED Diagnostics
Power Amplifier LED Diagnostics
Section 6. Messages, Codes, and Tests
Error conditions involving the power amplifier
usually display as fault codes on the Operator
Display.
The power amplifier also contains a light
emitting diode (LED) status indicator, which
supplies very limited diagnostic information.
When the LED is illuminated (steady or
blinking), the amplifier is receiving power.
A steady LED means the amplifier is operating
normally.
A blinking LED means a malfunction.
Electrical Codes
NOTE: In this section, the table shows, for each
message or code, the expected operating
status of the lift truck, based on software,
after the message or code has been
displayed.
Other factors, such as mechanical failures,
could prevent the lift truck from operating as
specified in the table.
1026304B, 15 July 2007 6-21
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 12 Electrical Codes
Code 12
Code Title Code 12 – Bump Detect
Reason The optional bump detector has detected an impact.
System Response
Alarm Sounds Yes
Operator Display Bump Detector Activated.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Speed derated
Hydraulic System Lift disabled, lower and aux enabled
Steering System No limits
How to Clear Must be cleared by Warehouse Manager
Tests to Run None
NOTE: Code 8N will be logged.
6-22 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 1H
Code 1H
Code Title Code 1H – Traction Power Amplifier Overheated
The traction power amplifier has measured an amplifier
heatsink temperature greater than 239°F (115°C). This code
Reason
was sent via BUS+/BUS– to the Vehicle Manager to be
displayed.
System Response
Alarm Sounds Yes
Code 1H. Overheated. Allow time to cool.
Operator Display
[Temperature icon is lit.]
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Disabled
Hydraulic System No limits
Steering System No limits
Allow time for the power amplifier to cool. Turn key switch
How to Clear
OFF, then ON.
Test A10 – Traction Power Amplifier Heatsink Temperature
Tests to Run (Page 6-128)
Test O23 – Toggle Fans (Page 6-198)
NOTE: This code cannot be caused by a bad
Vehicle Manager.
Check:
1. Make sure power cables are torqued
properly at both traction power amplifier
and traction motor.
2. Check BSOC setting. If BSOC cutout is set
too low, a weak battery can result in
overheating.
3. If problem still exists, evaluate the duty
cycle and application.
1026304B, 15 July 2007 6-23
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 1T Electrical Codes
Code 1T
Code Title Code 1T – Battery Low
Reason Lift cutout point configured for BSOC has been reached.
System Response
Alarm Sounds Yes
Operator Display Lift Cut-Out Pending...Low Battery. Code 1T.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Lift disabled 5 minutes after message displayed;
Hydraulic System
lower and aux functions have no limits
Steering System No limits
How to Clear Change battery. Self resetting.
Tests to Run None
The BSOC setting of the Config Mode Menu is
listed on page 6-12.
The theory and procedure for setting BSOC is
described under “Battery State-of-Charge” on
page 5-11.
BSOC is also discussed under Battery
Procedures on page 7-115.
6-24 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 1V
Code 1V
NOTE: Series CA/FA (AC lift)
Code 1V – Lift Power Amplifier Overheated, Series
Code Title
CA/FA (AC lift)
The lift power amplifier has measured an amplifier heatsink
Reason temperature greater than 239°F (115°C). This information was
sent via BUS+/BUS– to the Vehicle Manager to be displayed.
System Response
Alarm Sounds Yes
Code 1V. Overheated, Allow Time to Cool.
Operator Display
[Temperature icon is lit.]
Travel PC Contactor Energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System Lift disabled; lower enabled; aux disabled
Steering System No limits
Allow time for power amplifier to cool.
How to Clear
Turn key switch OFF, then ON.
Test A19 – Lift Power Amplifier Heatsink Temperature
Tests to Run (Page 6-133)
Test O23 – Toggle Fans (Page 6-198)
NOTE: This code cannot be caused by a bad
Vehicle Manager.
Check:
1. Make sure power cables are torqued
properly at both lift power amplifier and
lift motor.
2. Check BSOC setting. If BSOC cutout is set
too low, a weak battery can result in
overheating.
3. If problem still exists, evaluate the duty
cycle and application.
1026304B, 15 July 2007 6-25
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 2A Electrical Codes
Code 2A
Code 2A – Traction Motor Approaching
Code Title
Overtemperature
The traction power amplifier has detected a traction motor
Reason temperature greater than 300°F (149°C). This information was
sent via BUS+/BUS– to the Vehicle Manager to be displayed.
System Response
Alarm Sounds Yes
Code 2A. Overheated, Allow Time to Cool.
Operator Display
[Temperature icon is lit.]
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Top speed is reduced beginning at:
266°F (130°C) [Danaher] or 278°F (137°C) [Sauer Danfoss].
Travel System
Top speed limited to 1 mph at:
At 300°F (149°C) [Danaher] or 311°F (155°C) [Sauer Danfoss]
Hydraulic System No limits
Steering System No limits
How to Clear Allow time for the motor to cool. Self resetting.
Tests to Run Test A08 – Traction Motor Temperature (Page 6-124)
NOTE: This code cannot be caused by a bad
Vehicle Manager.
Check:
See “Motor Overheating” under “Symptom
Tables: Electrical Symptoms” on page 5-31.
6-26 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 2C
Code 2C
Code 2C – Traction Power Amplifier Temperature
Code Title
Sensor Out-of-Range
The traction power amplifier has informed the Vehicle Manager
Reason that the value provided by the TPA temperature sensor is
out-of-range.
System Response
Alarm Sounds Yes
Code 2C. Inform Service.
Operator Display
[Temperature icon is lit.]
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Reduced acceleration
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Test A10 – Traction Power Amplifier Heatsink Temperature
Tests to Run
(Page 6-128)
NOTE: This code cannot be caused by a bad
Vehicle Manager.
Corrective Action:
Replace the traction power amplifier. See “Power
Amplifier, Traction” on page 7-110.
1026304B, 15 July 2007 6-27
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 2E Electrical Codes
Code 2E
Code 2E – Traction Motor Temperature Sensor
Code Title
Out-of-Range
The traction power amplifier has informed the Vehicle Manager
Reason that the value provided by the drive motor temperature sensor
is out-of-range.
System Response
Alarm Sounds Yes
Code 2E. Inform Service.
Operator Display
[Temperature icon is lit.]
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System 6.5 mph speed limit
Hydraulic System No limits
Steering System No limits
How to Clear Self resetting
Tests to Run Test A08 – Traction Motor Temperature (Page 6-124)
NOTE: This code cannot be caused by a bad
Vehicle Manager.
6-28 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 2H
Code 2H
Code 2H – Failure Detected in Traction Motor Feedback
Code Title
Encoder
The traction power amplifier has informed the Vehicle Manager
Reason
that the speed feedback circuit is inoperative.
System Response
Alarm Sounds Yes
Operator Display Code 2H. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System 1 mph speed limit
Hydraulic System No limits
Steering System No limits
How to Clear Self resetting
Tests to Run Test I19 – Drive Motor Speed Sensor (Page 6-164)
NOTE: This code cannot be caused by a bad
Vehicle Manager.
Prior to Vehicle Manager version 3.7, this failure
sometimes appears as a Fault Code 2U.
1026304B, 15 July 2007 6-29
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 2M Electrical Codes
Code 2M
Code Title Code 2M – Traction Power Amplifier Failed
The traction power amplifier has informed the Vehicle Manager
Reason
that there is an internal fault in the TPA.
System Response
Alarm Sounds Yes
Operator Display Code 2M. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Traction system shutdown
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
NOTE: This code cannot be caused by a bad
Vehicle Manager.
Corrective Action:
Replace the traction power amplifier. See “Power
Amplifier, Traction” on page 7-110.
6-30 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 2P
Code 2P
Code 2P – Traction Power Amplifier Reverted to Default
Code Title
Parameters
The traction power amplifier has detected an internal
Reason
malfunction with the amplifier software.
System Response
Alarm Sounds Yes
Operator Display Code 2P. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System No limits
Steering System No limits
Should clear automatically after 30 seconds; if not, turn key
How to Clear
switch OFF, then ON.
Tests to Run None
NOTE: This code may appear when first turning
key switch ON after installing a new
Vehicle Manager or traction power
amplifier or after updating software.
Corrective Action:
• If code continues to appear infrequently,
keep running.
• If code continues to appear often, reload
FlashWare; if problem continues, replace
traction power amplifier. See “Power
Amplifier, Traction” on page 7-110.
1026304B, 15 July 2007 6-31
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 2T Electrical Codes
Code 2T
Code 2T – Traction Power Amplifier Current Calibration
Code Title
Error
The traction power amplifier has informed the Vehicle Manager
Reason
that there is an internal fault.
System Response
Alarm Sounds Yes
Operator Display Code 2T. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System 2.5 mph speed limit
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
NOTE: This code cannot be caused by a bad
Vehicle Manager.
Corrective Action:
Replace the traction power amplifier. See “Power
Amplifier, Traction” on page 7-110.
6-32 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 2U
Code 2U
Code Title Code 2U – Traction Power Amplifier Fault - Overcurrent
The traction power amplifier has informed the VM that it
detected current exceeding 540A or that there is a shorted
Reason
output. The traction power contactor suppressor diode could
be shorted.
System Response
Alarm Sounds Yes
Operator Display Code 2U. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Traction system shutdown
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test A11 – Traction Motor Current (Page 6-129)
NOTE: This code cannot be caused by a bad
Vehicle Manager.
NOTE: This code could be caused by a shorted
traction power contactor suppressor
diode.
NOTE: Prior to Vehicle Manager version 3.7,
Operator Display Manager version 2.6,
and Traction Power Amplifier version
3.1, Fault Code 2U sometimes reflects a
failure of the traction motor encoder.
See Fault Code 2H.
1026304B, 15 July 2007 6-33
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 2V Electrical Codes
Code 2V
Code 2V – Traction Power Amplifier Fault - High DC
Code Title
Voltage
The traction power amplifier has detected input voltage
Reason
exceeding 50 volts at TPA (+).
System Response
Alarm Sounds Yes
Operator Display Code 2V. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Traction system shutdown
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
• If this code occurs during plugging,
replace all battery cables and connections
that show signs of heat or corrosion.
• Install a battery that is in good condition.
• If code persists, replace the traction power
amplifier.
NOTE: This code cannot be caused by a bad
Vehicle Manager.
6-34 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 42
Code 42
Code 42 – Lift Contactor Detected Closed When
Code Title
Commanded Open
Series CA/FA (AC lift): The Lift Power Amplifier detected an
incorrect voltage at LPA (+) during SelfTest.
Reason Series AA/BA/DA/EA (DC lift): The Vehicle Manager detected
greater than 10VDC at JPC22-20 (FU3 Sense) after the lift
contactor was commanded open.
System Response
Alarm Sounds Yes
Operator Display Code 42. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Series CA/FA (AC lift): Lift disabled; lower enabled; aux
disabled
Hydraulic System
Series AA/BA/DA/EA (DC lift): Lift disabled; lower and aux
enabled only when on deadman pedal
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test O02 – Toggle the LPC Contactor (Page 6-186)
NOTE: If contactor tips are welded or burnt,
check the BSOC setting. Low battery
voltage can contribute to burnt tips.
The BSOC setting of the Config Mode Menu is
listed on page 6-12.
The theory and procedure for setting BSOC is
described under “Battery State-of-Charge” on
page 5-11.
NOTE: On Series CA/FA, this code can be
caused by an open circuit in the
U-phase lift motor power cable.
1026304B, 15 July 2007 6-35
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 43 Electrical Codes
Code 43
Code 43 – Lift Contactor Detected Open, Low DC
Code Title
Voltage After Power-Up
Series CA/FA (AC lift): The lift power amplifier detected less
than +12VDC at LPA (+) after the LPC coil was energized.
Reason Series AA/BA/DA/EA (DC lift): The Vehicle Manager detected
less than +18VDC at JPC22-20 after the LPC coil was
energized.
System Response
Alarm Sounds Yes
Operator Display Code 43. Inform Service.
Travel PC Contactor Energized
Series CA/FA (AC lift): De-energized
Lift PC Contactor
Series AA/BA/DA/EA (DC lift): Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Series CA/FA (AC lift): Lift disabled; lower enabled; aux
Hydraulic System disabled
Series AA/BA/DA/EA (DC lift): Lift disabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test O02 – Toggle the LPC Contactor (Page 6-186)
NOTE: This fault code cannot be caused by the
Vehicle Manager on trucks with AC lift.
Check:
Check cables for signs of damage from heat or
corrosion; replace as required.
6-36 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 44
Code 44
Code 44 – TPC Contactor Detected Closed When
Code Title
Commanded Open
The Traction Power Amplifier detected an incorrect voltage at
Reason
TPA (+) during SelfTest.
System Response
Alarm Sounds Yes
Operator Display Code 44. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Disabled
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test O00 – Toggle the TPC Contactor (Page 6-184)
NOTE: This fault code cannot be caused by the
Vehicle Manager.
NOTE: If contactor tips are welded or burnt,
check the BSOC setting. Low battery
voltage can contribute to burnt tips.
The BSOC setting of the Config Mode Menu is
listed on page 6-12.
The theory and procedure for setting BSOC is
described under “Battery State-of-Charge” on
page 5-11.
NOTE: This code can be caused by an open
circuit in the U-phase traction motor
power cable.
1026304B, 15 July 2007 6-37
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 45 Electrical Codes
Code 45
Code 45 – TPC Contactor Detected Open, Low DC
Code Title
Voltage After Power-Up
The traction power amplifier detected less than +12VDC at
Reason
TPA (+) after the TPC coil was energized.
System Response
Alarm Sounds Yes
Operator Display Code 45. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Disabled
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Test O00 – Toggle the TPC Contactor (Page 6-184)
Tests to Run
In Active Service, verify battery voltage only with
Test A15 – Battery Voltage (Page 6-132)
NOTE: This fault code cannot be caused by the
Vehicle Manager.
Check:
Check cables for signs of damage from heat or
corrosion; replace as required.
6-38 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 4B
Code 4B
Code 4B – Steer Contactor Detected Closed When
Code Title
Commanded Open
The Vehicle Manager measured greater than +10VDC at
Reason
JPC22-19 when the STR coil was de-energized.
System Response
Alarm Sounds Yes
Operator Display Code 4B. Inform Service.
Travel PC Contactor Energized
Electric steering: Energized
Lift PC Contactor
Hydraulic steering: De-energized.
Steer Contactor Energized
Performance Limits
Electric steering: 6.5 mph speed limit
Travel System
Hydraulic steering: No limits
Electric steering: No limits
Hydraulic System
Hydraulic steering: Disabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
If closed: Test O01 – Toggle the STR Contactor (Page 6-185)
Tests to Run
If open: Test I14 – Steering Fuse (FU1) (Page 6-162)
1026304B, 15 July 2007 6-39
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 4C Electrical Codes
Code 4C
Code 4C – Steer Contactor Detected Open When
Code Title
Commanded Closed
The Vehicle Manager measured less than +10VDC at JPC22-19
Reason
when the STR coil was energized.
System Response
Alarm Sounds Yes
Operator Display Code 4C. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Electric steering: No limits
Travel System
Hydraulic steering: 1.0 mph speed limit
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
If contactor closes: Test I14 – Steering Fuse (FU1) (Page 6-162)
Tests to Run If contactor does not close: Test O01 – Toggle the STR
Contactor (Page 6-185)
6-40 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 4D
Code 4D
Code 4D – No Pre-Charge Traction DC Input Voltage
Code Title
During Start-Up
The traction power amplifier detected an incorrect pre-charge
Reason
voltage, less than +25VDC, at TPA (+).
System Response
Alarm Sounds Yes
Operator Display Code 4D. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Disabled
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Diagnosis:
• Check components, connections, and
wiring between JPF1-5 and TPA (+) for
correct resistance and continuity.
• TR = 12 ohms
• Thermistor on Relay/Control Fuse
Panel = 6 to 12 ohms at room
temperature (70°F, 21°C).
1026304B, 15 July 2007 6-41
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 4E Electrical Codes
Code 4E
NOTE: Series CA/FA (AC lift)
Code 4E – No Pre-Charge Lift DC Input Voltage During
Code Title
Start-Up, Series CA/FA (AC lift)
The lift power amplifier detected an incorrect pre-charge
Reason
voltage, less than 25VDC, at LPA (+).
System Response
Alarm Sounds Yes
Operator Display Code 4E. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System Lift disabled; lower enabled; aux disabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Diagnosis:
• Check components, connections, and
wiring between JPF1-3 and LPA (+) for
correct resistance and continuity.
• LR = 12 ohms
• Thermistor on Relay/Control Fuse
Panel = 6 to 12 ohms at room
temperature (70°F, 21°C).
6-42 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 57
Code 57
Code Title Code 57 – VM Not Responding to Operator Display
The Operator Display has lost communication with the Vehicle
Reason Manager over the CAN bus. This code is initiated by the
Operator Display.
System Response
Alarm Sounds Yes
Operator Display Code 57. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System No limits
Steering System No limits
How to Clear Self resetting
Tests to Run Test I23 – CAN Bus Test (Page 6-166)
NOTE: This code will not normally be recorded
in the error log since the log resides in
the Vehicle Manager and this fault code
means communication with the VM has
been disrupted.
A code 5Q will often be in the error log
when a code 57 is on the Operator
Display.
1026304B, 15 July 2007 6-43
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 58 Electrical Codes
Code 58
Code 58 – Operator Compartment Sensor System CAN
Code Title
Communication Failure
No communication has been received from the OCSS
Reason
controller.
System Response
Alarm Sounds Yes
Operator Display Code 58. Inform Service.
Travel PC Contactor Energized
PC Contactor Energized
Lift (P) Contactor Energized
Performance Limits
Travel System 1 mph speed limit
Auxiliary System No limits
Lift/Lower System No limits
How to Clear Cycle the key switch.
Tests to Run
Diagnosis:
• Check for +12V at JPX1-1 and 0V at
JPX1-4 on the OCSS CAN I/O Expander
Module.
6-44 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 59
Code 59
Code Title Code 59 – CAN Transmission Buffer Error for BUS_I
Reason There is an error on the CAN bus transmission buffer.
System Response
Alarm Sounds Yes
Operator Display Code 59. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System Shutdown
Series CA/FA (AC lift): Lift disabled; lower enabled; aux
Hydraulic System disabled
Series AA/BA/DA/EA (DC lift): No restrictions
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I23 – CAN Bus Test (Page 6-166)
Diagnosis:
• Check for shorts to frame, static, electrical
leakage from battery.
1026304B, 15 July 2007 6-45
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 5A Electrical Codes
Code 5A
Code Title Code 5A – CAN Bus Error/Vehicle Manager for BUS_I
Reason The Vehicle Manager detected an error in the CAN bus.
System Response
Alarm Sounds Yes
Operator Display Code 5A. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System Shutdown
Series CA/FA (AC lift): Lift disabled; lower enabled; aux
Hydraulic System disabled
Series AA/BA/DA/EA (DC lift): No restrictions
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I23 – CAN Bus Test (Page 6-166)
Diagnosis:
• This code cannot be caused by an error on
the secondary bus BUS_E.
• Check for shorts to frame, static, electrical
leakage from battery.
6-46 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 5B
Code 5B
Code Title Code 5B – CAN Receive Bus Error/Vehicle Manager
There is a CAN Receive Bus error in the Vehicle Manager. for
Reason
BUS_I.
System Response
Alarm Sounds Yes
Operator Display Code 5B. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System Shutdown
Series CA/FA (AC lift): Lift disabled; lower enabled; aux
Hydraulic System disabled
Series AA/BA/DA/EA (DC lift): No restrictions
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I23 – CAN Bus Test (Page 6-166)
Diagnosis:
• This code cannot be caused by an error on
the secondary bus BUS_E.
• Check for shorts to frame, static, electrical
leakage from battery.
1026304B, 15 July 2007 6-47
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 5G Electrical Codes
Code 5G
Code 5G – No Communications Received from Traction
Code Title
Power Amplifier
The Vehicle Manager has received no communication from the
Reason
traction power amplifier.
System Response
Alarm Sounds Yes
Operator Display Code 5G. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Disabled
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I23 – CAN Bus Test (Page 6-166)
Diagnosis:
• Check for shorts to frame, static, electrical
leakage from battery.
• Code 5G can be caused by bad K3 relay
tips. Check for LEDs illuminated on both
power amplifiers. If both are not lit, check
the K3 relay.
6-48 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 5J
Code 5J
NOTE: Series CA/FA (AC lift)
Code 5J – No Communication from Lift Power Amplifier
Code Title
Series CA/FA (AC lift)
The Vehicle Manager has received no communication from the
Reason
lift power amplifier.
System Response
Alarm Sounds Yes
Operator Display Code 5J. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System Lift disabled; lower enabled; aux disabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I23 – CAN Bus Test (Page 6-166)
Diagnosis:
• Check for shorts to frame, static, electrical
leakage from battery.
1026304B, 15 July 2007 6-49
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 5M Electrical Codes
Code 5M
Code 5M – Traction Power Amplifier CAN Watchdog
Code Title
Timeout
Reason CAN watchdog circuit timeout detected by TPA.
System Response
Alarm Sounds Yes
Operator Display Code 5M. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Disabled
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I23 – CAN Bus Test (Page 6-166)
Diagnosis:
• Check for shorts to frame, static, electrical
leakage from battery.
• This code can only be caused by a problem
in the Traction Power Amplifier. Code 5M
occurs when an internal circuit detects a
fault internal to the amplifier. This fault,
however, could be caused by a source
external to the amplifier, such as static
discharge, shorts to frame, bad power
amplifier cables or wiring, and CAN Bus.
6-50 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 5P
Code 5P
NOTE: Series CA/FA (AC lift)
Code 5P – Lift Power Amplifier CAN Watchdog Timeout
Code Title
Series CA/FA (AC lift)
The CAN watchdog circuit has not received communication
Reason
from other amplifier circuits.
System Response
Alarm Sounds Yes
Operator Display Code 5P. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System Lift disabled; lower enabled; aux disabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I23 – CAN Bus Test (Page 6-166)
Diagnosis:
• Check for shorts to frame, static, electrical
leakage from battery.
• This code can only be caused by a problem
in the Lift Power Amplifier. Code 5P occurs
when an internal circuit detects a fault
internal to the amplifier. This fault,
however, could be caused by a source
external to the amplifier, such as static
discharge, shorts to frame, bad power
amplifier cables or wiring, and CAN Bus.
1026304B, 15 July 2007 6-51
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 5Q Electrical Codes
Code 5Q
Code Title Code 5Q – Display Manager Not Responding
The Vehicle Manager is not receiving communication from the
Reason Display Manager. This code appears in the error log but not
usually on the Operator Display.
System Response
Alarm Sounds Yes
Operator Display Code 5Q. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
The height sensor plugs into the Operator Display. If the
Performance Limits Display is not communicating, the Vehicle Manager cannot
know the actual height. Performance is limited as follows:
• Below first speed limiting switch: no limits
• Above first speed limiting switch: speed limited to configured
speed for first speed limiting switch
• Above first speed limiting switch, and equipped with virtual
second speed limiting switch: speed limited to configured
speed for virtual second speed limiting switch
Travel System
• Above first speed limiting switch, and equipped with lift limit
switch: speed limited to configured speed for first speed
limiting switch
• Above first speed limiting switch, and equipped with lift
cutoff switch: speed limited to configured speed for first
speed limiting switch
• Lower and aux: no limits
• Lift, below first speed limiting switch: no limits
• Lift, above first speed limiting switch:
Series AA/BA/DA/EA (DC lift): no limits
Series CA/FA (AC lift): ES mode minimum speed
Hydraulic System • Lift, above first speed limiting switch, and equipped with
virtual second speed limiting switch: no limits
• Lift, above first speed limiting switch, and equipped with lift
limit switch: Lift disabled
• Lift, above first speed limiting switch, and equipped with lift
cutoff switch: 100 ft/min on AC lift, no limit on DC lift
Steering System No limits
How to Clear Self resetting
Tests to Run Test I23 – CAN Bus Test (Page 6-166)
NOTE: Code 5Q is recorded in the error log. The Operator Display will most likely display
Code 57.
6-52 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 5R
Code 5R
Code Title Code 5R – Secondary CAN Bus Error for BUS_E
There is a transmission error between the Vehicle Manager and
Reason the secondary CAN Bus BUS_E to which external equipment is
connected.
System Response
Alarm Sounds Yes
Operator Display Code 5R. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I23 – CAN Bus Test (Page 6-166)
Diagnosis:
• The primary Bus BUS_I and the secondary
Bus BUS_E are totally independent.
Therefore, this code cannot be caused by
devices connected to the primary bus
BUS_I.
• This code could be caused by system
noise, static discharge, or shorts to frame.
1026304B, 15 July 2007 6-53
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 5T Electrical Codes
Code 5T
Code Title Code 5T – No CAN Message from any Node
The Vehicle Manager is not receiving CAN message ACKs from
Reason
any node.
System Response
Alarm Sounds Yes
Operator Display Code 5T. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Disabled
Series CA/FA (AC lift): Lift and aux disabled; lower enabled
Hydraulic System
Series AA/BA/DA/EA (DC lift): No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I23 – CAN Bus Test (Page 6-166)
6-54 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 61
Code 61
Code Title Code 61 – Mast Switch #1 Not Crossed
1. Too much time has elapsed without crossing
mast switch #1 while a lift request is above a certain
Reason threshold.
2. Series CA/FA (AC lift): Too many height encoder pulses
were seen without detecting mast switch #1 opening.
System Response
Alarm Sounds Yes
Operator Display Code 61. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Speed limited to configured speed for the first speed limiting
Travel System
switch
Hydraulic System No limits
Steering System No limits
How to Clear Cross mast switch #1.
Tests to Run Test I02 – First Speed Limiting Switch (S12) (Page 6-154)
1026304B, 15 July 2007 6-55
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 62 Electrical Codes
Code 62
Code 62 – Lift Power Amplifier Reverted to Default
Code Title
Parameters
The lift power amplifier has detected a change in internal
Reason
software.
System Response
Alarm Sounds Yes
Operator Display Code 62
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System No limits
Steering System No limits
How to Clear Resets after 30 seconds; if not, turn key switch OFF, then ON.
Tests to Run None
NOTE: This code may appear when first turning
key switch ON after installing a new
Vehicle Manager or lift power amplifier.
Corrective Action:
• If code continues to appear infrequently,
keep running.
• If code continues to appear often, reload
FlashWare; if problem continues, replace
Lift Power Amplifier.
6-56 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 63
Code 63
Code 63 – HS Travel and First Speed Limiting Switches
Code Title
Do Not Agree
The Vehicle Manager reads the first speed limiting switch as
Reason
open when the HS travel switch reads closed.
System Response
Alarm Sounds Yes
Operator Display Code 63. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Speed limited to configured speed for the first speed limiting
Travel System
switch
Hydraulic System No limits
Steering System No limits
[VM ver. < 2.1] Turn key switch OFF, then ON.
How to Clear
[VM ver. 2.1+] Cross the first speed limiting switch .
Tests to Run Test I02 – First Speed Limiting Switch (S12) (Page 6-154)
1026304B, 15 July 2007 6-57
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 64 Electrical Codes
Code 64
Code 64 – No Pulses Seen from Height Indicator
Code Title
Encoder
With either the lift pump running or SOL2 energized, the first
Reason mast limit switch is open, but the Vehicle Manager detected no
pulses from the Height Indicator encoder.
System Response
Alarm Sounds Yes
Operator Display Code 64. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
• Below first speed limiting switch: no limits
• Above first speed limiting switch: speed limited to configured
speed for first speed limiting switch
• Above first speed limiting switch, and equipped with virtual
second speed limiting switch: speed limited to configured
speed for virtual second speed limiting switch
Travel System
• Above first speed limiting switch, and equipped with lift limit
switch: speed limited to configured speed for first speed
limiting switch
• Above first speed limiting switch, and equipped with lift
cutoff switch: speed limited to configured speed for first
speed limiting switch
• Lower and aux: no limits
• Lift, below first speed limiting switch: no limits
• Lift, above first speed limiting switch:
Series AA/BA/DA/EA (DC lift): no limits
Series CA/FA (AC lift): ES mode minimum speed
Hydraulic System • Lift, above first speed limiting switch, and equipped with
virtual second speed limiting switch: no limits
• Lift, above first speed limiting switch, and equipped with lift
limit switch: lift disabled
• Lift, above first speed limiting switch, and equipped with lift
cutoff switch: 100 ft/min on AC lift, no limit on DC lift
Steering System No limits
6-58 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 64
Code 64 – No Pulses Seen from Height Indicator
Code Title
Encoder
Lower the carriage, then lift past the first mast switch.
Troubleshoot HTI system. Code will clear when pulses are
detected. Turn key switch OFF, then ON.
How to Clear
If code is intermittent, cause could be proportional valve.
Adjust valve - see “Proportional Valve Adjustment” on
page 7-139.
Test I02 – First Speed Limiting Switch (S12) (Page 6-154)
Tests to Run
Test I42 – Lift Height (Page 6-176)
1026304B, 15 July 2007 6-59
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 66 Electrical Codes
Code 66
Code 66 – Calculated Height Greater Than Configured
Code Title
Height
The carriage height calculated by the Vehicle Manager from
Reason information from the Height Indicator is more than 6 inches
(15 cm) greater than the configured height of the lift truck.
System Response
Alarm Sounds Yes
Operator Display Code 66. Inform Service.
Travel PC Contactor Energized
Series CA/FA (AC lift): Energized
Lift PC Contactor
Series AA/BA/DA/EA (DC lift): De-energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Lift disabled once calculated height is more than 6 inches
Hydraulic System (15 cm) greater than the configured height; lower enabled; aux
enabled
Steering System No limits
How to Clear Lower the carriage below the configured maximum height.
Tests to Run Test I42 – Lift Height (Page 6-176)
Corrective Action:
• Check actual mast height against
configured height.
• Check actual fork height against indicated
fork height when HTI counting begins.
6-60 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 67
Code 67
Code 67 – Calculated Height Does Not Match First
Code Title
Speed Limiting Switch (S12)
The Vehicle Manager detected S12 closed at an incorrect
Reason
calculated height when lowering.
System Response
Alarm Sounds Yes
Operator Display Code 67. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System No limits
Steering System No limits
Lift the carriage through the first speed limiting switch height
How to Clear
or turn the key switch OFF then ON.
Tests to Run Test I02 – First Speed Limiting Switch (S12) (Page 6-154)
1026304B, 15 July 2007 6-61
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 6D Electrical Codes
Code 6D
Code Title Code 6D – Pressure Sensor Out-of-Range
Pressure sensor out-of-range. Voltage is less than 0.7V
Reason (indicating less than 300 psi) or greater than 5.0V (indicating
greater than 3999 psi).
System Response
Alarm Sounds Yes
Operator Display Code 6D. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Limited to maximum speed permitted for maximum load
Series CA/FA (AC lift): Lift speed limited to maximum speed
permitted at maximum weight
Hydraulic System Series AA/BA/DA/EA (DC lift): SOL4 de-energized on dual
pump trucks, limiting lift to single pump speed; no aux
restrictions
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test A13 – Pressure Sensor Voltage (Page 6-130)
6-62 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 6F
Code 6F
Code Title Code 6F – Lift Motor Overheated
Series CA/FA (AC lift): The lift power amplifier has detected
that the AC lift motor has overheated (greater than
300°F/149°C).
Reason
Series AA/BA/DA/EA (DC lift): The Vehicle Manager has
detected that the DC lift motor has overheated (greater than
279°F/137°C).
System Response
Alarm Sounds Yes
Code 6F. Overheated. Allow time to cool.
Operator Display
[Temperature icon is lit.]
Travel PC Contactor Energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System Lift disabled; lower enabled; aux enabled
Steering System No limits
How to Clear Allow time to cool. Self resetting.
Tests to Run Test A09 – Lift Motor Temperature (Page 6-125)
1026304B, 15 July 2007 6-63
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 6G Electrical Codes
Code 6G
Code Title Code 6G – Lift Motor Temperature Sensor Out-of-Range
Series CA/FA (AC lift): The temperature sensor voltage from
the lift motor, as seen by the lift power amplifier, is not within
acceptable limits (-58°F to +572°F or –50°C to +300°C).
Reason
Series AA/BA/DA/EA (DC lift): The temperature sensor voltage
from the lift motor, as seen by the Vehicle Manager, is not
within acceptable limits (-58°F to +572°F or –50°C to +300°C).
System Response
Alarm Sounds Yes
Code 6G. Inform Service.
Operator Display
{Temperature icon is lit.]
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Lift disabled 5 minutes after fault detected, except enabled if in
Hydraulic System cold storage environment.
Lower enabled; aux enabled
Steering System No limits
How to Clear Self resetting
Tests to Run Test A09 – Lift Motor Temperature (Page 6-125)
NOTE: Series CA/FA (AC lift): This code cannot
be caused by a bad Vehicle Manager.
6-64 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 6S
Code 6S
NOTE: Series CA/FA (AC lift)
Code 6S – Lift Power Amplifier Temperature Sensor
Code Title
Out-of-Range, Series CA/FA (AC lift)
The lift power amplifier reported to the Vehicle Manager that
Reason the temperature sensor voltage seen by the lift power amplifier
is not within acceptable limits.
System Response
Alarm Sounds Yes
Code 6S. Inform Service.
Operator Display
[Temperature icon is lit.]
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System Lift and aux slowed; lower enabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
Replace the lift power amplifier.
NOTE: This code cannot be caused by a bad
Vehicle Manager.
1026304B, 15 July 2007 6-65
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 6T Electrical Codes
Code 6T
NOTE: Series CA/FA (AC lift)
Code 6T – Lift Power Amplifier Current Calibration
Code Title
Error, Series CA/FA (AC lift)
Reason The lift power amplifier has detected an internal fault.
System Response
Alarm Sounds Yes
Operator Display Code 6T. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System Lift and aux slowed; lower enabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
Replace the lift power amplifier.
NOTE: This code cannot be caused by a bad
Vehicle Manager.
6-66 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 6U
Code 6U
NOTE: Series AA/BA/DA/EA (DC lift)
Code 6U – Excessive Lift Motor Brush Wear, Series
Code Title
AA/BA/DA/EA (DC lift)
The Vehicle Manager has detected more than +10VDC at
Reason
JPC22-15 (BrushWear1) or JPC22-16 (BrushWear2).
System Response
Alarm Sounds Yes
Operator Display Code 6U. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor De-energized (at start up only)
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
1026304B, 15 July 2007 6-67
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 6V Electrical Codes
Code 6V
NOTE: Series CA/FA (AC lift)
Code 6V – Lift Power Amplifier Failure, Series CA/FA
Code Title
(AC lift)
Reason The lift power amplifier has detected an internal fault.
System Response
Alarm Sounds Yes
Operator Display Code 6V. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System Lift disabled; lower enabled; aux disabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
Replace the lift power amplifier.
NOTE: This code cannot be caused by a bad
Vehicle Manager.
6-68 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 6W
Code 6W
NOTE: Series CA/FA (AC lift)
Code 6W – Failure Detected in Lift Motor Feedback
Code Title
Encoder, Series CA/FA (AC lift)
The lift feedback circuit, as seen by the lift power amplifier, is
Reason
not functioning.
System Response
Alarm Sounds Yes
Operator Display Code 6W. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Lift limited to approximately 10 ft/min; lower enabled, aux
Hydraulic System
slow or none, depending on the function
Steering System No limits
How to Clear Self resetting
Tests to Run Test I20 – Lift Motor Speed Sensor (Page 6-165)
NOTE: This code cannot be caused by a bad
Vehicle Manager.
1026304B, 15 July 2007 6-69
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 6X Electrical Codes
Code 6X
NOTE: Series CA/FA (AC lift)
Code 6X – Lift Power Amplifier Fault - Overcurrent,
Code Title
Series CA/FA (AC lift)
The lift power amplifier has detected greater than 675A or a
Reason
shorted output.
System Response
Alarm Sounds Yes
Operator Display Code 6X. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System Lift disabled; lower enabled; aux disabled
Steering System No limits
How to Clear Turn the key switch OFF/ON.
Tests to Run Test A20 – Lift Motor Current (Page 6-134)
NOTE: Overcurrent occurs at about 675A.
NOTE: This code cannot be caused by a bad
Vehicle Manager.
6-70 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 6Y
Code 6Y
NOTE: Series CA/FA (AC lift)
Code 6Y – Lift Power Amplifier Fault - High DC Voltage,
Code Title
Series CA/FA (AC lift)
The lift power amplifier has detected a DC input voltage
Reason
exceeding 50 volts at LPA (+) connection.
System Response
Alarm Sounds Yes
Operator Display Code 6Y. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System Lift disabled; lower enabled; aux disabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
1026304B, 15 July 2007 6-71
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 6Z Electrical Codes
Code 6Z
Code 6Z – FlashWare parameters do not match stored
Code Title
values
The height of the forks as calculated by the display is at least
Reason 6 inches higher than the maximum elevated height
programmed in the truck’s memory.
System Response
Alarm Sounds Yes
Operator Display Code 6Z. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Lift limited to 40% top speed when above
Hydraulic System
speed limiting switch #1; lower enabled; aux enabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action
Use FlashWare to verify programmed height is
correct.
6-72 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 80
Code 80
Code 80 – Primary Throttle Potentiometer
Code Title
Out-of-Range
The Vehicle Manager detected less than 0.15V or greater than
Reason
2.1V at JPC12-3.
System Response
Alarm Sounds Yes
Code 80. Inform Service.
Operator Display If equipped with optional secondary handle: Primary Handle
Error, Use Secondary Handle and Inform Service.
Without secondary handle: De-energized
Travel PC Contactor
With secondary handle: Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Without secondary handle: Shutdown
Travel System With secondary handle: Coast to 0 mph. Then 1 mph limit
using secondary handle.
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Test A04 – Primary Throttle Potentiometer (VR1) Voltage
(Page 6-122)
Tests to Run
Test A26 – Travel and Lift/Lower +5V DC Power Supply
(Page 6-137)
1026304B, 15 July 2007 6-73
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 81 Electrical Codes
Code 81
Code Title Code 81 – Lift Potentiometer Out-of-Range
The Vehicle Manager detected less than 0.15V or greater than
Reason
2.1V at JPC12-2.
System Response
Alarm Sounds Yes
Operator Display Code 81. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System Lift and lower disabled; aux enabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Test A05 – Lift/Lower Potentiometer Voltage (Page 6-123)
Tests to Run Test A26 – Travel and Lift/Lower +5V DC Power Supply
(Page 6-137)
6-74 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 83
Code 83
Code 83 – Primary Throttle Potentiometer
Code Title
Out-of-Neutral-Zone
During SelfTest, the Vehicle Manager detected less than 0.9V
Reason
or greater than 1.3V at JPC12-3 for more than 2 seconds.
System Response
Alarm Sounds Yes
Operator Display Code 83. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Disabled
Hydraulic System No limits
Steering System No limits
Release the primary travel control handle. Turn key switch
How to Clear
OFF, then ON.
Test A04 – Primary Throttle Potentiometer (VR1) Voltage
Tests to Run
(Page 6-122)
1026304B, 15 July 2007 6-75
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 84 Electrical Codes
Code 84
Code Title Code 84 – Brake Inoperable
During SelfTest, the traction motor was briefly energized and
Reason the traction power amplifier detected drive motor encoder
counts.
System Response
Alarm Sounds Yes
Operator Display Code 84. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Disabled at SelfTest
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
If brake adjustment is correct, run
Tests to Run
Test I19 – Drive Motor Speed Sensor (Page 6-164)
Corrective Action:
• Adjust brake. See “Brake Adjustment” on
page 7-96.
6-76 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 88
Code 88
Code Title Code 88 – +5VDC Power Supply Out-of-Range
The +5VDC power supply (located on the VM) for the control
Reason
handle was found to be out-of-range.
System Response
Alarm Sounds Yes
Operator Display Code 88. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System Disabled
Hydraulic System Lift, lower and aux disabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Test A26 – Travel and Lift/Lower +5V DC Power Supply
Tests to Run
(Page 6-137)
1026304B, 15 July 2007 6-77
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 8A Electrical Codes
Code 8A
Code Title Code 8A – Operator Compartment Sensor System Failure
Reason The VM senses the beams are ON with the deadman pedal UP.
System Response
Alarm Sounds Yes
Operator Display Code 8A. Inform Service.
Travel PC Contactor Energized
PC Contactor Energized
Lift (P) Contactor Energized
Performance Limits
Travel System 1 mph speed limit
Auxiliary System No limits
Lift/Lower System No limits
How to Clear Cycle the key switch.
Test I80 - Upper Beam Test
Tests to Run
Test I81 - Lower Beam Test
6-78 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 8C
Code 8C
Code Title Code 8C – Deadman Pedal Signals Do Not Agree
Voltages at the Vehicle Manager from the Deadman Switch and
Reason the Deadman Sensor indicate one is activated and the other is
not.
System Response
Alarm Sounds Yes
Operator Display Code 8C. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No speed limits; pedal plugging disabled
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Test A28 – Deadman Inductive Sensor (VR4) (Page 6-138)
Tests to Run
Test I00 – Deadman Switch (S2) (Page 6-152)
1026304B, 15 July 2007 6-79
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 8F Electrical Codes
Code 8F
Code Title Code 8F – Lift Throttle Out-of-Neutral-Zone
During SelfTest, the Vehicle Manager detected less than 0.9V
Reason
or greater than 1.3V at JPC12-2 for more than 2 seconds.
System Response
Alarm Sounds Yes
Operator Display Code 8F. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor De-energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System Lift and lower disabled; aux enabled
Steering System No limits
How to Clear Release the lift pot. Turn key switch OFF, then ON.
Tests to Run Test A05 – Lift/Lower Potentiometer Voltage (Page 6-123)
6-80 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 8G
Code 8G
Code 8G – Secondary Throttle Potentiometer
Code Title
Out-of-Range
The Vehicle Manager detected less than 0.1V or greater than
Reason
2.2V at JPC4-4.
System Response
Alarm Sounds Yes
Code 8G. Secondary Handle Error, Use Primary Handle and
Operator Display
Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Coast to 0 mph. Then 1 mph limit using primary handle.
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Test A04 – Primary Throttle Potentiometer (VR1) Voltage
(Page 6-122)
Tests to Run
Test A26 – Travel and Lift/Lower +5V DC Power Supply
(Page 6-137)
1026304B, 15 July 2007 6-81
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 8H Electrical Codes
Code 8H
Code 8H – Secondary Throttle Potentiometer
Code Title
Out-of-Neutral-Zone
During SelfTest, the Vehicle Manager detected less than 0.9V
Reason
or greater than 1.3V at JPC4-4 for more than 2 seconds.
System Response
Alarm Sounds Yes
Operator Display Code 8H. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Disabled
Hydraulic System No limits
Steering System No limits
Release the secondary travel control handle. Turn key switch
How to Clear
OFF, then ON.
Test A29 – Secondary Throttle Potentiometer (VR3) Voltage
Tests to Run
(Page 6-139)
6-82 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 8J
Code 8J
Code Title Code 8J – Ambient Temperature Sensor Out-of-Range
The voltage measured from the ambient temperature sensor is
Reason
outside the reference range.
System Response
Alarm Sounds Yes
Code 8J. Inform Service.
Operator Display
[Temperature display is “- -”]
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
No limits, except: with heated glass mast guard, 3.5 mph when
Travel System
traveling forks first
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test A36 – Ambient Temperature Sensor (Page 6-146)
NOTE: Control handle heaters will always be off
while this fault code is present.
1026304B, 15 July 2007 6-83
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 8K Electrical Codes
Code 8K
Code Title Code 8K – Deadman Sensor Out-of-Range
The voltage measured by the Vehicle Manager from the
Reason
deadman sensor is less than 2.0V or greater than 4.9V.
System Response
Alarm Sounds Yes
Operator Display Code 8K. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System 6.5 mph speed limit; deadman pedal modulation disabled
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test A28 – Deadman Inductive Sensor (VR4) (Page 6-138)
6-84 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 8L
Code 8L
Code Title Code 8L – Brake Feedback Current Out-of-Range
The current measured in the brake feedback circuit is zero, or
Reason
outside the reference range.
System Response
Alarm Sounds Yes
Operator Display Code 8L. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System 1.0 mph speed limit
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test A35 – Brake Armature (Page 6-145)
NOTE: The brake will no longer be under PWM
control; it will be either fully engaged or
fully disengaged.
1026304B, 15 July 2007 6-85
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code 8M Electrical Codes
Code 8M
Code Title Code 8M – Internal Handle Heater Failure
Reason The internal heater in the control handle has malfunctioned.
System Response
Alarm Sounds Yes
Operator Display Code 8M. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System No limits
Steering System No limits
How to Clear Self resetting
Tests to Run Test A40 – Handle Heater Reference Voltage (Page 6-149)
6-86 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code 8N
Code 8N
Code Title Code 8N – Optional Start Switch Closed at Start-Up
Reason The Vehicle Manager senses switch closed.
System Response
Alarm Sounds Yes
Operator Display Code 8N. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled
Hydraulic System Disabled
Steering System Disabled
How to Clear Open, then close the optional start switch.
Tests to Run Test I60 – Security Start Switch (S23) (option) (Page 6-177)
1026304B, 15 July 2007 6-87
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code A0 Electrical Codes
Code A0
Code A0 – Incorrect Software For Proper Lift Truck
Code Title
Operation
The software in the lift truck does not match the vehicle ID
Reason
stored in primary memory.
System Response
Alarm Sounds Yes
Operator Display Code A0. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled; brake engaged
Hydraulic System Disabled
Steering System Disabled
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
1. Verify software versions by running Config
Version.
2. Update lift truck software. See “Software
Configuration” on page 7-271.
6-88 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code AH
Code AH
Code Title Code AH – Bad Operator Display Checksum
The software checksum in the Operator Display does not
Reason
match the one in the Vehicle Manager.
System Response
Alarm Sounds Yes
Operator Display Code AH. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System 1.0 mph speed limit
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
1. If the problem is intermittent, check for
shorts to frame. See “Shorts to Frame
Test” on page 5-5.
2. Re-flash the software. See “Software
Configuration” on page 7-271.
3. Replace the Vehicle Manager.
4. If the proper software version appears on
the Operator Display, replace the Operator
Display.
1026304B, 15 July 2007 6-89
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code AJ Electrical Codes
Code AJ
Code Title Code AJ – Bad VM Flash Memory
The Vehicle Manager flash memory test during SelfTest has
Reason
failed.
System Response
Alarm Sounds Yes
Operator Display Code AJ. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled; brake engaged
Hydraulic System Disabled
Steering System Disabled
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
1. If the problem is intermittent, check for
shorts to frame. See “Shorts to Frame
Test” on page 5-5.
2. Re-flash the software. See “Software
Configuration” on page 7-271.
3. The Vehicle Manager could be
malfunctioning. Replace the Vehicle
Manager.
6-90 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code AK
Code AK
Code Title Code AK – Bad VM RAM Memory
Reason The VM RAM memory test during SelfTest has failed.
System Response
Alarm Sounds Yes
Operator Display Code AK. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled; brake engaged
Hydraulic System Disabled
Steering System Disabled
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
1. If the problem is intermittent, check for
shorts to frame. See “Shorts to Frame
Test” on page 5-5.
2. Re-flash the software. See “Software
Configuration” on page 7-271.
3. The Vehicle Manager could be
malfunctioning. Replace the Vehicle
Manager.
1026304B, 15 July 2007 6-91
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code AL Electrical Codes
Code AL
Code Title Code AL – Bad Battery Backed-Up VM RAM Memory
Reason The non-volatile RAM memory test during SelfTest has failed.
System Response
Alarm Sounds Yes
Operator Display Code AL. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled; brake engaged
Hydraulic System Disabled
Steering System Disabled
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
1. If the problem is intermittent, check for
shorts to frame. See “Shorts to Frame
Test” on page 5-5.
2. Re-flash the software. See “Software
Configuration” on page 7-271.
3. The Vehicle Manager could be
malfunctioning. Replace the Vehicle
Manager.
6-92 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code AM
Code AM
Code Title Code AM – Bad Operator Display Flash Memory
The Operator Display flash memory test during SelfTest has
Reason
failed.
System Response
Alarm Sounds Yes
Operator Display Code AM. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
• Below first speed limiting switch: no limits
• Above first speed limiting switch: speed limited to configured
speed for first speed limiting switch
• Above first speed limiting switch, and equipped with virtual
second speed limiting switch: speed limited to configured
speed for virtual second speed limiting switch
Travel System
• Above first speed limiting switch, and equipped with lift limit
switch: speed limited to configured speed for first speed
limiting switch
• Above first speed limiting switch, and equipped with lift
cutoff switch: speed limited to configured speed for first
speed limiting switch
• Lower and aux: no limits
• Lift, below first speed limiting switch: no limits
• Lift, above first speed limiting switch:
Series AA/BA/DA/EA (DC lift): no limits
Hydraulic System Series CA/FA (AC lift): 100 fpm.
• Lift, above first speed limiting switch, and equipped with
virtual second speed limiting switch: 100 fpm.
• Lift, above first speed limiting switch, and equipped with lift
limit switch: lift disabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
1026304B, 15 July 2007 6-93
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code AN Electrical Codes
Code AN
Code Title Code AN – Malfunctioning Operator Display
Reason The Operator Display is malfunctioning and must be replaced.
System Response
Alarm Sounds Yes
Operator Display Code AN. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
• Below first speed limiting switch: no limits
• Above first speed limiting switch: speed limited to configured
speed for first speed limiting switch
• Above first speed limiting switch, and equipped with virtual
second speed limiting switch: speed limited to configured
speed for virtual second speed limiting switch
Travel System
• Above first speed limiting switch, and equipped with lift limit
switch: speed limited to configured speed for first speed
limiting switch
• Above first speed limiting switch, and equipped with lift
cutoff switch: speed limited to configured speed for first
speed limiting switch
• Lower and aux: no limits
• Lift, below first speed limiting switch: no limits
• Lift, above first speed limiting switch:
Series AA/BA/DA/EA (DC lift): no limits
Hydraulic System Series CA/FA (AC lift): 100 fpm.
• Lift, above first speed limiting switch, and equipped with
virtual second speed limiting switch: 100 fpm.
• Lift, above first speed limiting switch, and equipped with lift
limit switch: lift disabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
6-94 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code EH
Code EH
Code Title Code EH – Invalid Interrupt - Operator Display
There was a software malfunction on the Operator Display
Reason
card.
System Response
Alarm Sounds Yes
Operator Display Code EH. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
• Below first speed limiting switch: no limits
• Above first speed limiting switch: speed limited to configured
speed for first speed limiting switch
• Above first speed limiting switch, and equipped with virtual
second speed limiting switch: speed limited to configured
speed for virtual second speed limiting switch
Travel System
• Above first speed limiting switch, and equipped with lift limit
switch: speed limited to configured speed for first speed
limiting switch
• Above first speed limiting switch, and equipped with lift
cutoff switch: speed limited to configured speed for first
speed limiting switch
• Lower and aux: no limits
• Lift, below first speed limiting switch: no limits
• Lift, above first speed limiting switch:
Series AA/BA/DA/EA (DC lift): no limits
Hydraulic System Series CA/FA (AC lift): 100 fpm.
• Lift, above first speed limiting switch, and equipped with
virtual second speed limiting switch: 100 fpm.
• Lift, above first speed limiting switch, and equipped with lift
limit switch: lift disabled
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action: 2. Re-flash the software. See “Software
Configuration” on page 7-271.
1. If the problem is intermittent, check for
3. The Operator Display could be
shorts to frame, static, battery
malfunctioning. Replace the Operator
leakage/shorts. See “Shorts to Frame
Display.
Test” on page 5-5.
1026304B, 15 July 2007 6-95
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code F4 Electrical Codes
Code F4
Code Title Code F4 – Vehicle Manager COP Time-out
Reason The COP circuit has timed out before a reset was generated.
System Response
Alarm Sounds Yes
Operator Display Code F4. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled; brake engaged
Hydraulic System Disabled
Steering System Disabled
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
1. If the problem is intermittent, check for
shorts to frame, static, battery
leakage/shorts. See “Shorts to Frame
Test” on page 5-5.
2. Re-flash the software. See “Software
Configuration” on page 7-271.
3. The Vehicle Manager could be
malfunctioning. Replace the Vehicle
Manager.
6-96 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code F5
Code F5
Code Title Code F5 – Bad Op Code
Bad code was detected during SelfTest. Results in total
Reason
shutdown.
System Response
Alarm Sounds Yes
Operator Display Code F5. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled; brake engaged
Hydraulic System Disabled
Steering System Disabled
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
1. If the problem is intermittent, check for
shorts to frame, static, battery
leakage/shorts. See “Shorts to Frame
Test” on page 5-5.
2. Re-flash the software. See “Software
Configuration” on page 7-271.
3. The Vehicle Manager could be
malfunctioning. Replace the Vehicle
Manager.
1026304B, 15 July 2007 6-97
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code F8 Electrical Codes
Code F8
Code Title Code F8 – Vehicle Manager COP Not Enabled
Reason Vehicle Manager COP not enabled.
System Response
Alarm Sounds Yes
Operator Display Code F8. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled; brake engaged
Hydraulic System Disabled
Steering System Disabled
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
1. If the problem is intermittent, check for
shorts to frame, static, battery
leakage/shorts. See “Shorts to Frame
Test” on page 5-5.
2. Re-flash the software. See “Software
Configuration” on page 7-271.
3. The Vehicle Manager could be
malfunctioning. Replace the Vehicle
Manager.
6-98 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code FE
Code FE
Code Title Code FE – Vehicle Manager Not Calibrated
The Vehicle Manager detected an internal calibration error.
Reason
BSOC information could be inaccurate
System Response
Alarm Sounds Yes
Operator Display Code FE. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled
Hydraulic System Disabled
Steering System Disabled
How to Clear Message clears in 30 seconds.
Tests to Run None
Corrective Action
• Turn key switch OFF, then ON.
• Make sure lift truck firmware at Vehicle
Manager version 3.3/Display Manager
version 2.4 or higher is installed.
• If code continues, replace the Vehicle
Manager.
1026304B, 15 July 2007 6-99
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code FG Electrical Codes
Code FG
Code Title Code FG – 5 and/or 12 Volt Power Supply Out-of-Range
The +5 and/or +12 volt power supply voltage is out-of-range
Reason
(less than 10.8V or greater than 13V).
System Response
Alarm Sounds Yes
Operator Display Code FG. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled; brake engaged
Hydraulic System Disabled
Steering System Disabled
How to Clear Turn key switch OFF, then ON.
Tests to Run Test A14 – Power Supply +12V DC (Page 6-131)
Corrective Action
• Make sure lift truck firmware at Vehicle
Manager version 3.3/Display Manager
version 2.4 or higher is installed.
6-100 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code FH
Code FH
Code Title Code FH – Battery Voltage Out-of-Range
Battery voltage is less than 28V or more than 45V at SelfTest.
Reason
Results in total shutdown.
System Response
Alarm Sounds Yes
Operator Display Code FH. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled; brake engaged
Hydraulic System Disabled
Steering System Disabled
How to Clear Turn key switch OFF, then ON.
Tests to Run Test A15 – Battery Voltage (Page 6-132)
Check:
Fuse FU10 could be bad.
1026304B, 15 July 2007 6-101
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code FN Electrical Codes
Code FN
Code Title Code FN – VM Did Not Power Off
The Vehicle Manager detected that B+Key was removed at
Reason
JPC14-12, but the Vehicle Manager did not power down.
System Response
Alarm Sounds Yes
Operator Display Code FN. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled; brake engaged
Hydraulic System Disabled
Steering System Disabled
How to Clear Disconnect, then re-connect battery connector.
Tests to Run Test O32 – Toggle Relays K1, K2, K3, and K4 (Page 6-203)
Diagnosis:
• Check other relays and circuits associated
with the K4 relay tips.
6-102 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code FP
Code FP
Code Title Code FP – VM Hardware Failure
Reason The Vehicle Manager detected an internal fault.
System Response
Alarm Sounds Yes
Operator Display Code FP. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled; brake engaged
Hydraulic System Disabled
Steering System Disabled
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
• Replace the Vehicle Manager.
1026304B, 15 July 2007 6-103
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code FR Electrical Codes
Code FR
Code Title Code FR – VM Config Item Out-of-Range
The value of a configurable parameter is out of the reference
Reason
range.
System Response
Alarm Sounds Yes
Code FR.
Operator Display
[Displays for 5 seconds]
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No limits
Hydraulic System No limits
Steering System No limits
Out-of-range parameter is reset after 5 seconds to the default
How to Clear
value.
Tests to Run None
6-104 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code FT
Code FT
Code Title Code FT – VM Internal Software Related Failure
A set of operational routines was performed that the Vehicle
Reason
Manager software did not recognize.
System Response
Alarm Sounds Yes
Operator Display Code FT. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor De-energized
Steer Contactor De-energized
Performance Limits
Travel System Disabled; brake engaged
Hydraulic System Disabled
Steering System Disabled
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
Document the sequence of events that occurred
just before the code was displayed. Have the
dealer service technician supply them to
Raymond Field Service.
1026304B, 15 July 2007 6-105
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code FV Electrical Codes
Code FV
Code Title Code FV – Display Internal Software Related Failure
A set of operational routines was performed that the display
Reason
software did not recognize.
System Response
Alarm Sounds Yes
Operator Display Code FV. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System No restrictions
Hydraulic System No restrictions
Steering System No restrictions
How to Clear Turn key switch OFF, then ON.
Tests to Run None
Corrective Action:
Document the sequence of events that occurred
just before the code was displayed. Have the
dealer service technician supply them to
Raymond Field Service.
6-106 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code G0
Code G0
NOTE: Series CA/FA (AC lift)
Code G0 – Steer Tiller 1 Channel A/B Fault, Series
Code Title
CA/FA (AC lift)
Steer tiller 1 is missing pulses compared to steer tiller 2, or
Reason
intermittent connect detect at JPC10-6 or JPC18-5.
System Response
Alarm Sounds Yes
Operator Display Code G0. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Full speed permitted until speed goes to 0, then 3.5 mph speed
Travel System
limit
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Test I33 – Steer Tiller Encoder 1 Connect Detect (Page 6-171)
Tests to Run
Test I35 – Steer Tiller Encoder 1 (Channel A & B) (Page 6-173)
1026304B, 15 July 2007 6-107
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code G3 Electrical Codes
Code G3
NOTE: Series CA/FA (AC lift)
Code G3 – Steer Feedback Proximity Sensor Fault,
Code Title
Series CA/FA (AC lift)
A steer motor encoder count should have put the steer
feedback proximity sensor past the steer limit flag, but the flag
Reason
was not sensed. The steer proximity sensor is either low or
high all the time.
System Response
Alarm Sounds Yes
Operator Display Code G3. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Full speed permitted until speed goes to 0, then 6.5 mph speed
Travel System
limit
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I24 – Steer Feedback Proximity Sensor (Page 6-167)
6-108 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code G4
Code G4
NOTE: Series CA/FA (AC lift)
Code G4 – Open Detected in Steer Control Circuit,
Code Title
Series CA/FA (AC lift)
The Vehicle Manager did not detect either neutral pulses at
Reason JPC6-1 or tiller encoder inputs at JPC22-5, JPC22-12,
JPC22-13, and JPC22-14.
System Response
Alarm Sounds Yes
Operator Display Code G4. Inform Service.
Travel PC Contactor De-energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Disabled
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I39 – Neutral Pulses (Page 6-175)
1026304B, 15 July 2007 6-109
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code G5 Electrical Codes
Code G5
NOTE: Series CA/FA (AC lift)
Code G5 – Short Detected in Steer Motor Encoder
Code Title
Circuit, Series CA/FA (AC lift)
A steer command or steer motor encoder pulses were detected
Reason
without steer tiller encoder pulses detected.
System Response
Alarm Sounds Yes
Operator Display Code G5. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor De-energized
Performance Limits
Travel System Moderate plug to 0 mph
Hydraulic System No limits
Steering System Disabled
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I25 – Steer Motor Encoder (Page 6-168)
Diagnosis:
Check for sources of electrical noise entering
the encoder cable.
6-110 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code G7
Code G7
NOTE: Series CA/FA (AC lift)
Code G7 – Steer Tiller 2 Channel A/B Fault, Series
Code Title
CA/FA (AC lift)
Steer tiller 2 is missing pulses compared to steer tiller 1 or
Reason
intermittent connect detect at JPC10-7 or JPC18-6.
System Response
Alarm Sounds Yes
Operator Display Code G7. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Full speed permitted until speed goes to 0, then 3.5 mph speed
Travel System
limit
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Test I34 – Steer Tiller Encoder 2 Connect Detect (Page 6-172)
Tests to Run
Test I36 – Steer Tiller Encoder 2 (Channel A & B) (Page 6-174)
1026304B, 15 July 2007 6-111
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code GD Electrical Codes
Code GD
NOTE: Series CA/FA (AC lift)
Code GD – Open Detected in Steer Motor Encoder
Code Title
Circuit, Series CA/FA (AC lift)
A steer command was issued while traveling greater than 1
Reason mph but no steer position feedback encoder pulses were
detected.
System Response
Alarm Sounds Yes
Operator Display Code GD. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Moderate plug to 1 mph speed limit
Hydraulic System No limits
Steering System Requires more tiller rotations to turn drive motor
How to Clear Turn key switch OFF, then ON.
Tests to Run Test I25 – Steer Motor Encoder (Page 6-168)
6-112 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Electrical Codes Code GE
Code GE
NOTE: Series CA/FA (AC lift)
Code Title Code GE – Steer Encoder failure
The Vehicle Manager detected either connect-detect failures or
Reason
abnormal inputs on both channels of the steer tiller encoder.
System Response
Alarm Sounds Yes
Operator Display Code GE. Inform Service.
Travel PC Contactor Energized
Lift PC Contactor Energized
Steer Contactor Energized
Performance Limits
Travel System Moderate plug to 0 mph speed limit, then disabled
Hydraulic System No limits
Steering System No limits
How to Clear Turn key switch OFF, then ON.
Test I33 – Steer Tiller Encoder 1 Connect Detect (Page 6-171)
Test I34 – Steer Tiller Encoder 2 Connect Detect (Page 6-172)
Tests to Run
Test I35 – Steer Tiller Encoder 1 (Channel A & B) (Page 6-173)
Test I36 – Steer Tiller Encoder 2 (Channel A & B) (Page 6-174)
1026304B, 15 July 2007 6-113
Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Code GE Electrical Codes
6-114 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Electrical Connections
Electrical Connections
Section 6. Electrical Tests
Terminology
Pin Identifier Lines
(black lines added for clarity)
Jack Pins
68C04013S.TIF
Figure 6-1. Molex Jack and Pin Connector
The term “connector JPx” means a mated
connector having two connector halves. One
half has male connectors, or pins (P); the other
half has female connectors, or jacks (J).
When you disconnect a mated JP connector,
you will have two connector halves. The
individual connector halves are specified by
“Jx” and “Px.” If you cannot find a connector
designated “Jx” or “Px,” look for “JPx,” and vice
versa.
For example, connector JP1 is the mated main
Operator Display connector. J1 represents the
jack connections (in the harness). P1 represents
the pin connections (on the Operator Display).
Molex connectors have ridges on the sides to
help locate pin number 1. The short side has a
single ridge at pin number 1. The long side has
1, 2, and 3 raised ridges at pin numbers 1, 2,
and 3. See Figure 6-1.
Electrical Connector Locator Chart
See legend on electrical schematic beginning on
page A-26.
1026304B, 15 July 2007 6-115
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Circuit Card Connectors
Circuit Card Connectors
Vehicle Manager
PC22 PC10 PC6 PC24 JC9 PC3
PC14 PC18 PC20 PC12 PC4
PC22 PC10 PC6 PC24 JC9 PC3
PC14 PC18 PC20 PC12 PC4
6R1019283_B.CGM
Figure 6-2. Vehicle Manager connectors
6-116 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Circuit Card Connectors
Relay/Control Fuse Panel
PF1 FU8 FU7 FU5 FU6
15A 15A
PF1
1 4
FU7
FU8
FU5
FU6
K3 K2 K4 K1
K3 K2 K4 K1
13 1 7 1 10 1
PF4 PF2 PF3
PF4 PF2 PF3
6R1022159_A.CGM
Figure 6-3. Relay/Control Fuse Panel connectors
1026304B, 15 July 2007 6-117
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Circuit Card Connectors
6-118 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Electrical Test Summary List
Section 6. Electrical Tests
Analog Tests
Test A04 – Primary Throttle Potentiometer (VR1) Voltage . . . . . . . . . . . . . . .. . . . 6-122
Test A05 – Lift/Lower Potentiometer Voltage . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-123
Test A08 – Traction Motor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-124
Test A09 – Lift Motor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-125
Test A10 – Traction Power Amplifier Heatsink Temperature . . . . . . . . . . . . .. . . . 6-128
Test A11 – Traction Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-129
Test A13 – Pressure Sensor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-130
Test A14 – Power Supply +12V DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-131
Test A15 – Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-132
Test A19 – Lift Power Amplifier Heatsink Temperature . . . . . . . . . . . . . . . . .. . . . 6-133
Test A20 – Lift Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-134
Test A22 – Primary Traction Throttle (VR1) Request . . . . . . . . . . . . . . . . . . .. . . . 6-135
Test A23 – Lift Throttle (VR2) Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-136
Test A26 – Travel and Lift/Lower +5V DC Power Supply . . . . . . . . . . . . . . . .. . . . 6-137
Test A28 – Deadman Inductive Sensor (VR4) . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-138
Test A29 – Secondary Throttle Potentiometer (VR3) Voltage . . . . . . . . . . . . .. . . . 6-139
Test A30 – Secondary Traction Throttle (VR3) Request . . . . . . . . . . . . . . . . .. . . . 6-140
Test A31 – Solenoid 5T (AUX1) Current . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-141
Test A32 – Solenoid 5B (AUX2) Current . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-142
Test A33 – Aux Dump (SOL3)/Main Relief Dump (SOL8) Current . . . . . . . . .. . . . 6-143
Test A34 – Solenoid 2 (Lift/Lower) Current . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-144
Test A35 – Brake Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-145
Test A36 – Ambient Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-146
Test A37 – Steer Power Amplifier Current . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-147
Test A39 – Analog Reference Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-148
Test A40 – Handle Heater Reference Voltage . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-149
Test A41 – Emergency Power Off (EPO) Switch . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-150
Digital Input Tests
Test I00 – Deadman Switch (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-152
Test I01 – Nested Switch (S14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-153
Test I02 – First Speed Limiting Switch (S12) . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-154
Test I06 – Reach Switch (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-156
Test I07 – Retract Switch (S5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-157
Test I08 – Tilt Up Switch (S6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-158
Test I09 – Tilt Down Switch (S7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-159
Test I10 – Sideshift Right Switch (S9) . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-160
Test I11 – Sideshift Left Switch (S8) . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-161
Test I14 – Steering Fuse (FU1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-162
Test I15 – Horn Switch (S3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-163
Test I19 – Drive Motor Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-164
Test I20 – Lift Motor Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-165
Test I23 – CAN Bus Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-166
Test I24 – Steer Feedback Proximity Sensor . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-167
Test I25 – Steer Motor Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . 6-168
1026304B, 15 July 2007 6-119
Electrical Test Summary List Model 7400/7420/7440 Reach-Fork ® Truck
Test I26 – Height Indicator Encoder . . . . . . . . . . ....................... .. 6-169
Test I27 – Secondary Horn Switch (S10) . . . . . . . ....................... .. 6-170
Test I33 – Steer Tiller Encoder 1 Connect Detect ....................... .. 6-171
Test I34 – Steer Tiller Encoder 2 Connect Detect ....................... .. 6-172
Test I35 – Steer Tiller Encoder 1 (Channel A & B) ....................... .. 6-173
Test I36 – Steer Tiller Encoder 2 (Channel A & B) ....................... .. 6-174
Test I39 – Neutral Pulses . . . . . . . . . . . . . . . . . . ....................... .. 6-175
Test I42 – Lift Height . . . . . . . . . . . . . . . . . . . . . ....................... .. 6-176
Test I60 – Security Start Switch (S23) (option) . . ....................... .. 6-177
Test I80 - OCSS Upper Beam . . . . . . . . . . . . . . . ....................... .. 6-178
Test I81 - OCSS Lower Beam . . . . . . . . . . . . . . . ....................... .. 6-180
Test I86 – Lift Height . . . . . . . . . . . . . . . . . . . . . ....................... .. 6-182
Digital Output Tests
Test O00 – Toggle the TPC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-184
Test O01 – Toggle the STR Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-185
Test O02 – Toggle the LPC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-186
Test O04 – Toggle Aux1 Directional (SOL5T) Solenoid . . . . . . . . . . . . . . . . . . . . . 6-187
Test O05 – Toggle Aux2 Directional (SOL5B) Solenoid . . . . . . . . . . . . . . . . . . . . . 6-188
Test O06 – Toggle the Reach Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-189
Test O07 – Toggle the Tilt Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-190
Test O08 – Toggle the Sideshift Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-191
Test O09 – Aux Dump (SOL3)/ Main Relief Dump (SOL8) Current . . . . . . . . . . . . 6-192
Test O11 – Toggle the Load Hold (SOL1) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 6-193
Test O12 – Ramp the Proportional Lower (SOL2) Solenoid . . . . . . . . . . . . . . . . . . 6-194
Test O18 – Toggle the Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-195
Test O19 – Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-196
Test O20 – Travel Alarm Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-197
Test O23 – Toggle Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-198
Test O25 – Toggle the 2d Pump (SOL4) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 6-199
Test O28 – Ramp the Lift Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-200
Test O29 – Ramp the Traction Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-201
Test O30 – Toggle the Brake Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-202
Test O32 – Toggle Relays K1, K2, K3, and K4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-203
Loop Back Tests
Loop Back Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-204
6-120 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests
Analog Tests
Section 6. Electrical Tests
A Diagnosis and Repair table is provided for
most tests. If a test fails, refer to the Diagnosis
and Repair table. This table provides a
step-by-step approach to diagnosing a problem
and the necessary corrective action. See the
example below.
Example Diagnosis and Repair Table
Action/
Step Meter Scale
(+) Lead (–) Lead Expected Results Step Passed Step Failed
Do the This column identifies Probe Probe The reading The next The next
testing any actions required point for point for required to consider action to be action to be
in this before testing the the the the step a success. performed if performed if
order. circuit, such as positive negative the the
disconnecting certain (+) meter (–) meter Expected Expected
connectors. If no lead. lead. Results are Results are
instructions are given, met. not met.
all circuits should be
connected.
Note: If something
was disconnected in
the prior step,
reconnect it before
performing the next
step.
This column also
identifies the required
scale on the meter for
this step.
NOTES:
1.
1026304B, 15 July 2007 6-121
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A04 – Primary Throttle Potentiometer (VR1) Voltage Analog Tests
Test A04 – Primary 2. The test is a success if the voltage
displayed is within these limits:
Throttle Potentiometer
Table 6-4.
(VR1) Voltage
Throttle Position Voltage Displayed
This test displays the voltage that the Vehicle Full Tractor-First 0.45 to 0.8V
Manager reads from the primary control handle
throttle potentiometer (VR1). Neutral 0.9 to 1.3V
NOTE: Run the Learn function after you Full Forks-First 1.4 to 1.8V
replace, repair, or adjust the throttle
assembly.
• The values should change smoothly
For information on how to use service and evenly as the handle is moved from
mode, see “Using Service Mode” on full tractor-first to full forks-first
page 6-17. direction.
• If voltages are not within reference
Run Test ranges, the test is a failure.
NOTE: This test can be run in Loop Back mode. 3. In Active Service Mode, if the voltage
See Loop Back Tests (Page 6-204). fluctuates erratically as you move the
handle back and forth, replace the control
1. The Operator Display shows the voltage
handle cable.
that the Vehicle Manager reads from the
primary throttle potentiometer (VR1). 4. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector to see if they have
been bent.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC12-3 JPC12-12 Approx. voltage: Replace VM. Step 2
Neutral:
0.9 to 1.3V
Full
tractor-first:
0.45 to 0.8V
Full forks-first:
1.4 to 1.8V
2. Meter - DC voltage. JPC12-1 JPC12-12 4.75V to 5.25V Replace VR1. Run Test A26.
6-122 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A05 – Lift/Lower Potentiometer Voltage
Test A05 – Lift/Lower 2. The test is a success if the voltage
displayed is within these limits:
Potentiometer Voltage
Table 6-5.
This test displays the voltage that the Vehicle
Throttle Position Voltage Displayed
Manager reads from the lift/lower
potentiometer (VR2). Full Lift 0.45 to 0.8V
NOTE: Run the Learn function after you Neutral 0.9 to 1.3V
replace, repair, or adjust the lift/lower
potentiometer. Full Lower 1.4 to 1.8V
For information on how to use service
mode, see “Using Service Mode” on • The values should change smoothly
page 6-17. and evenly as the handle is moved from
full lower to full lift.
Run Test • If voltages are not within reference
ranges, the test is a failure.
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204). 3. In Active Service Mode, run the test while
moving the travel pot back and forth. If the
1. The Operator Display shows the voltage voltage fluctuates erratically as you move
that the Vehicle Manager reads from the the handle back and forth, replace the
lift/lower potentiometer (VR2). control handle cable.
4. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector to see if they have
been bent.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC12-2 JPC12-12 Approx. voltage: Replace VM. Step 2
Neutral:
0.9 to 1.3V
Full lift:
0.45 to 0.8V
Full lower:
1.4 to 1.8V
2. Meter - DC voltage. JPC12-1 JPC12-12 4.75V to 5.25V Replace VR2. Run Test A26.
1026304B, 15 July 2007 6-123
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A08 – Traction Motor Temperature Analog Tests
Test A08 – Traction • Sauer Danfoss Motor: 155°C (311°F)
Motor Temperature Run Test
NOTE: For information on how to use service
This test displays the temperature of the mode, see “Using Service Mode” on
traction motor. page 6-17.
The temperature of the traction motor
Limits will be displayed on the operator
• Normal operation: ambient to 125°C display.
(258°F)
1. With the lift truck at rest and at ambient
• Speed is linearly reduced to 1.0 mph:
temperature, compare the temperatures
• Danaher Motor: Between 130°C (266°F) obtained from Test A08 and Test A36.
and 149°C (300°F)
2. If the temperatures are not within 50
• Sauer Danfoss Motor: Between 137°C degrees, then the test is a failure.
(278°F) and 155°C (311°F)
3. If the lift truck is not at ambient
• Temperature icon lights at 135°C (275°F) temperature, use the diagnosis and repair
• Fault Code 2A and travel disabled at chart to isolate the cause.
• Danaher Motor: 149°C (300°F)
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
Fault Code 2A is present and traction motor is hot to touch
1. Disconnect JPT1. JPT1-16 JPT1-17 More than1200 Step 2 Replace TPA.
Meter - Resistance. ohms
2. Repeat step 1 after Less than See section on Step 3
cooling for an hour. measurement in motor
step 1 overheating.
3. Disconnect JPT1. JPT3-2 JPT3-1 Less than Troubleshoot Replace traction
Meter - Resistance. measurement in traction motor motor
step 1 sensor wires. temperature
sensor.
Fault Code 2A is present and traction motor is not hot to touch
1. Disconnect JPT1. JPT1-16 JPT1-17 Less than 800 Replace TPA. Step 2
Meter - resistance. ohms
2. Disconnect JPT3. JPT3-2 JPT3-1 Less than 800 Troubleshoot Replace traction
Meter - resistance. ohms traction motor motor
sensor wires. temperature
sensor.
6-124 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A09 – Lift Motor Temperature
Test A09 – Lift Motor
Temperature
This test measures the temperature of the lift
motor.
Limits
AC Lift
• Normal operation: ambient to 145°C
(294°F)
• Temperature icon lights at 146°C (295°F)
• Fault Code 6F and lift shutdown at 149°C
(300°F)
DC Lift
• Normal operation, single pump:
ambient to 133°C (271°F)
• Normal operation, dual pump:
ambient to 105°C (221°F)
• Temperature icon lights at 106°C (223°F),
single and dual pump
• Fault Code 6F and lift shutdown at 137°C
(279°F), both single and dual pump
Run Test
NOTE: For information on how to use service
mode, see “Using Service Mode” on
page 6-17.
1. With the lift truck at rest and at ambient
temperature, compare the temperatures
obtained from Test A09 and Test A36.
2. If the temperatures are not within several
degrees, then the test is a failure.
3. If the lift truck is not at ambient
temperature, use the diagnosis and repair
chart to isolate the cause.
1026304B, 15 July 2007 6-125
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A09 – Lift Motor Temperature Analog Tests
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
Series CA/FA (AC lift): AC lift motor
Fault Code 6F is present and lift motor is hot to touch
1. Disconnect JPL1. JPL1-16 JPL1-17 More than 1200 Step 2 Replace LPA.
Meter - resistance. ohms
2. Repeat step 1 after Less than See section on Step 3
cooling for an hour. measurement in motor
step 1 overheating.
3. Disconnect JPL3. JPL3-2 JPL3-1 Less than Troubleshoot lift Replace lift
Meter - resistance. measurement in motor sensor motor
step 1 wires. temperature
sensor.
Series CA/FA (AC lift): AC lift motor
Fault Code 6F is present and lift motor is not hot to touch
1. Disconnect JPL1. JPL1-16 JPL1-17 Less than 800 Replace LPA. Step 2
Meter - resistance. ohms
2. Disconnect JPL1. JPL3-2 JPL3-1 Less than 800 Troubleshoot lift Replace lift
Meter - resistance. ohms motor sensor motor
wires. temperature
sensor.
6-126 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A09 – Lift Motor Temperature
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
Series AA/BA/DA/EA (DC lift): DC lift motor
Fault Code 6F is present and lift motor is hot to touch
1. Disconnect JPC24. JPC24-22 JPC24-10 More than Step 2 Replace VM.
Meter - resistance. 2200 ohms
2. Repeat step 1 after Less than Troubleshoot Step 3
cooling for an hour. measurement in cause of
step 1 overheated
motor.
3. Disconnect JPZ. JPZ-1 JPZ-2 Less than Troubleshoot lift Replace lift
Meter - resistance. measurement in motor sensor motor
step 1 wires. temperature
sensor.
Series AA/BA/DA/EA (DC lift): DC lift motor
Fault Code 6F is present and lift motor is not hot to touch
1. Disconnect JPC24. JPC24-22 JPC24-10 Less than Replace VM. Step 2
Meter - resistance. 2200 ohms
2. Disconnect JPZ. JPZ-1 JPZ-2 Less than Troubleshoot lift Replace lift
Meter - resistance. 2200 ohms motor sensor motor
wires. temperature
sensor.
1026304B, 15 July 2007 6-127
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A10 – Traction Power Amplifier Heatsink Temperature Analog Tests
Test A10 – Traction • Temperature icon lights at 90°C (194°F)
• Fault Code 1H at 115°C (239°F)
Power Amplifier
Heatsink Temperature Run Test
NOTE: For information on how to use service
This test measures the temperature of the mode, see “Using Service Mode” on
traction power amplifier heatsink. page 6-17.
The Operator Display shows the heatsink
Limits temperature that the traction power amplifier
• Normal operation: ambient to 79°C (175°F) reads.
• Fans toggle on/off at 45°C (113°F)
As drive is operated, the readings should
• Starting at 80°C (176°F), speed is linearly increase evenly over time. If not, the test is a
reduced by the Traction Power Amplifier to failure.
0.0 mph at 115°C (239°F), when traction is
disabled.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Operate truck for 15 N/A N/A Heatsink should Replace traction Run Test O23 -
to 20 minutes of heat up and amplifier. Toggle Cooling
hard operation. fans turn on at Fans.
approx. 113°F
(45°C).
6-128 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A11 – Traction Motor Current
Test A11 – Traction Diagnosis and Repair
Motor Current NOTE: Check all motor and power amplifier
connections for tightness and corrosion.
This test displays the current in the traction Check individual phase currents with a
motor power circuits. clamp-on ammeter
• The current should ramp evenly as the
Limits truck accelerates and decelerates.
• 0 to 450A while driving or plugging • Phase currents should be approximately
equal. Gross differences indicate a
• Above 130°C (266°F) current is reduced
problem.
linearly
• Maximum current up to 540A when If readings are not within reference limits, the
deadman pedal is released, unaffected and test is a failure.
unreduced by temperature
1. If any one phase differs significantly from
the other two, check power cable
Run Test continuity. Replace cables as necessary.
See “Terminal Nuts” on page 7-122.
NOTE: For information on how to use service
mode, see “Using Service Mode” on • If power cable continuity is OK,
page 6-17. troubleshoot the drive motor. See “AC
Motor Troubleshooting” on page 5-10.
This test shows better results in Active
Service. • If all phases give high readings, the
drive unit may be binding. Check drive
The Operator Display shows the current that unit.
the traction power amplifier reads from one 2. The power amplifier may be bad. Run Test
phase of the drive motor. O29 – Ramp the Traction Power Amplifier
(Page 6-201).
Table 6-6.
NOTE: For instructions on selecting Modes of
System Condition Current Displayed Operation, see “Modes of Operation” on
page 3-7.
Static at Rest less than 20 amps
Normal Operation 0 to 400A - forks-first
0 to –400A - tractor-first
Normal Plugging 450A maximum
Because Test A11 measures only one phase, the
test might not always reveal a current problem.
1026304B, 15 July 2007 6-129
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A13 – Pressure Sensor Voltage Analog Tests
Test A13 – Pressure • If the weight sensor is disconnected at the
vehicle manager, the operator display
Sensor Voltage shows 0V.
This test measures the voltage from the Run Test
pressure sensor used for load weight sensing. NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
NOTE: For information on how to use service
Use extreme caution when working mode, see “Using Service Mode” on
near the elevated forks. page 6-17.
Limits The voltage shown on the operator display
should increase and decrease in a linear
• The operator display shows the voltage fashion as the load weight is either increased or
present with various load weights. decreased. If it does not, the test is a failure. If
the weight display is inaccurate, the test is a
Table 6-7.
failure.
Load Weight Voltage
0 (no load) approx. 1.0V
4500 lbs. approx. 4.7V
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Attach pressure JPY1-2 JPY1-3 1V at 0 psi Step 2 Step 3
gauge to G1. 1VDC increase
Meter - DC voltage. per 1000 psi
2. Attach pressure JPC24-18 JPC24-6 1V at 0 psi Replace VM. Troubleshoot
gauge to G1. 1VDC increase pressure sensor
Meter - DC voltage. per 1000 psi harness.
3. Attach pressure JPY1-1 JPY1-3 10.5V to 13V Replace Troubleshoot
gauge to G1. pressure pressure sensor
Meter - DC voltage. transducer. harness.
6-130 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A14 – Power Supply +12V DC
Test A14 – Power Supply 1. The Operator Display shows the voltage
measured from the +12V power supply.
+12V DC 2. The test is a success if the voltage
displayed is within these limits:
This test displays the Vehicle Manager +12V
Table 6-8.
Power Supply voltage.
System Condition Voltage Displayed
Run Test Lift truck at rest 10.1 to 13.0V
NOTE: For information on how to use service
mode, see “Using Service Mode” on
page 6-17. • If the reading fluctuates by more than
0.8V in 10 seconds, the test is a failure.
Perform diagnosis.
Diagnosis and Repair
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC14-5 JPC14-10 10.1VDC to Step 2 Replace VM.
everything powered 13VDC
by +12V except
JPC14. This includes
the Operator Display
and the Amplifiers.
Meter - DC voltage.
2. Monitor the +12V JPC14-5 JPC14-10 10.1VDC to Go to next Troubleshoot
and reconnect each 13VDC connector. that circuit.
connector.
Troubleshoot the
circuit which, when
connected, causes
the +12V supply to
go out-of-range.
Meter - DC voltage.
1026304B, 15 July 2007 6-131
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A15 – Battery Voltage Analog Tests
Test A15 – Battery Run Test
Voltage NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
NOTE: For information on how to use service
This test displays the voltage used to calculate
mode, see “Using Service Mode” on
the battery state-of-charge.
page 6-17.
1. The battery voltage as shown on the
operator display should be 28 to 45VDC.
2. If the numbers displayed are not in this
range, the test is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. TP1 TP4 B+ Step 2 Check battery
voltage/
specific gravity.
Replace battery.
Troubleshoot/
replace battery
cables.
2. Meter - DC voltage. JPF4-1 TP4 B+ Step 3 Troubleshoot
harness TP1 to
TP4.
3. Meter - DC voltage. JPF4-7 TP4 B+ Step 4 Replace
Relay/Control
Fuse Panel.
4. Meter - DC voltage. JPC24-24 TP4 B+ Replace VM. Troubleshoot
harness from
Relay/Control
Fuse Panel to
VM.
6-132 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A19 – Lift Power Amplifier Heatsink Temperature
Test A19 – Lift Power Run Test
Amplifier Heatsink NOTE: For information on how to use service
mode, see “Using Service Mode” on
Temperature page 6-17.
The Operator Display shows the heatsink
NOTE: Series CA/FA (AC lift)
temperature that the lift power amplifier reads.
This test displays the temperature of the Lift
As the lift is operated, the readings should
Power Amplifier heatsink.
increase evenly over time. If not, the test is a
failure.
Limits
• Normal operation: ambient to 79°C (175°F) Diagnosis and Repair
• Fans toggle on/off at 45°C (113°F) 1. Check for dirt and debris in the lift power
• Starting at 80°C (176°F), speed is linearly amplifier cooling fins.
reduced to 0.0 fpm at 115°C (239°F), when 2. Check operation of the power amplifier
lift is disabled. cooling fans. Run Test O23 – Toggle Fans
• Temperature icon lights at 87°C (189°F) (Page 6-198).
• Fault Code 1V at 115°C (239°F) 3. The lift power amplifier could be
malfunctioning. Replace the lift power
amplifier.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Operate truck for 15 N/A N/A Heatsink should Replace lift Run Test O23 -
to 20 minutes of heat up and amplifier. Toggle Cooling
hard operation. fans turn on at Fans.
approx. 113°F
(45°C).
1026304B, 15 July 2007 6-133
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A20 – Lift Motor Current Analog Tests
Test A20 – Lift Motor Diagnosis and Repair
Current NOTE: Check all motor and power amplifier
connections for tightness and corrosion.
NOTE: Series CA/FA (AC lift) Check individual phase currents with a
clamp-on ammeter
This test measures the lift motor current
through the power amplifier. • The current should ramp evenly as the
truck accelerates and decelerates.
• Phase currents should be approximately
equal. Gross differences indicate a
The lift carriage and forks will move problem.
during this test. • If readings are not within reference limits,
the test is a failure.
1. If any one phase differs significantly from
the other two, check power cable
The area around the forks should be continuity. Replace cables as necessary.
clear. The ceiling clearance should allow See “Terminal Nuts” on page 7-122.
for the highest lift. • If power cable continuity is OK,
troubleshoot the lift motor. See “AC
Limits Motor Troubleshooting” on page 5-10.
• If all phases give high readings, the
• 0 to 550A lifting
mast may be binding. Check mast.
• Maximum current 675A
2. The power amplifier may be bad. Run Test
O28 – Ramp the Lift Power Amplifier
Run Test (Page 6-200).
NOTE: For information on how to use service NOTE: For instructions on selecting Modes of
mode, see “Using Service Mode” on Operation, see “Modes of Operation” on
page 6-17. page 3-7.
This test shows better results in Active
Service.
The Operator Display shows the current that
the lift power amplifier reads from one phase of
the lift motor.
Because Test A20 measures only one phase, the
test might not always reveal a current problem.
6-134 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A22 – Primary Traction Throttle (VR1) Request
Test A22 – Primary from the primary control handle throttle
potentiometer (VR1).
Traction Throttle (VR1) Acceptable values are:
Request
Table 6-9.
This test displays the percentage of primary
Throttle Position Percentage Displayed
control handle traction throttle request from
VR1 being read by the VM. Full Tractor-First 0 to +100
Neutral 0
Run Test
Full Forks-First 0 to –100
NOTE: Run the Learn function after you
replace, repair, or adjust the throttle
assembly. The values must change smoothly and evenly
as the handle moves from full tractor-first to
For information on how to use service
full forks-first.
mode, see “Using Service Mode” on
page 6-17.
If percentages are not within reference limits,
the test is a failure.
The Operator Display shows the percentage of
throttle request that the Vehicle Manager reads
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC12-3 JPC12-12 Approx. voltage: Replace VM. Step 2
Neutral: 1V
Full
tractor-first:
0.5V
Full forks-first:
1.5V
2. Meter - DC voltage. JPC12-1 JPC12-12 4.75V to 5.25V Replace VR1. Run Test A26.
1026304B, 15 July 2007 6-135
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A23 – Lift Throttle (VR2) Request Analog Tests
Test A23 – Lift Throttle Acceptable values are:
(VR2) Request Table 6-10.
Throttle Position Percentage Displayed
This test displays the percentage of lift throttle
request from VR2 being read by the VM. Full Lower 0 to –100
Neutral 0
Run Test
Full Lift 0 to +100
NOTE: Run the Learn function after you
replace, repair, or adjust the lift/lower
potentiometer. The values must change smoothly and evenly
as the handle moves from full lower to full lift.
For information on how to use service
mode, see “Using Service Mode” on If percentages are not within reference limits,
page 6-17. the test is a failure.
The Operator Display shows the percentage of
lift request that the Vehicle Manager reads from
the lift potentiometer (VR2).
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC12-2 JPC12-12 Approx. voltage: Replace VM. Step 2
Neutral: 1V
Full lift: 0.5V
Full lower: 1.5V
2. Meter - DC voltage. JPC12-1 JPC12-12 4.75V to 5.25V Replace VR2. Run Test A26.
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Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A26 – Travel and Lift/Lower +5V DC Power Supply
Test A26 – Travel and Run Test
Lift/Lower +5V DC NOTE: For information on how to use service
mode, see “Using Service Mode” on
Power Supply page 6-17.
If the operator display does not read +5VDC ±
This test measures the +5V Power Supply 0.25 volts, the test is a failure.
Voltage used for the control handle switches
and potentiometers.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC12 & PC12-1 PC12-12 4.75VDC to Step 2 Replace VM.
JPC4 (if equipped). 5.25VDC
Meter - DC voltage.
2. Connect JPC12, JPC12-1 JPC12-12 4.75VDC to Repair/replace Repair/Replace
disconnect JPC4. 5.25VDC secondary primary control
Meter - DC voltage. control handle handle and
and harness. harness.
1026304B, 15 July 2007 6-137
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A28 – Deadman Inductive Sensor (VR4) Analog Tests
Test A28 – Deadman Acceptable voltage ranges are:
Inductive Sensor (VR4) Table 6-11.
Deadman Position Displayed Voltage
This test displays the voltage that the VM reads
Released Approx. 2.5VDC
from the deadman sensor VR4 at JPC24-19.
Depressed Approx. 4.0VDC
Run Test
NOTE: This test can be run in Loop Back mode. If the displayed voltages are outside the
See Loop Back Tests (Page 6-204). reference values, the test is a failure.
NOTE: For information on how to use service As the pedal is released slowly, the displayed
mode, see “Using Service Mode” on voltage should change smoothly. If not, the test
page 6-17. is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC20-5 JPC24-7 10.5 to 13V Step 2 Replace VM.
2. Meter - DC voltage. JPDP-1 JPDP-2 10.5 to 13V Step 3 Troubleshoot
wiring.
3. Meter - DC voltage. JPDP-3 JPDP-2 Increases from Step 4 Replace sensor.
approx. 2.5V to
between 4 and
5V
4. Meter - DC voltage. JPC24-19 JPC24-7 Increases from Replace VM. Troubleshoot
approx. 2.5V to wiring.
between 4 and
5V
6-138 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A29 – Secondary Throttle Potentiometer (VR3) Voltage
Test A29 – Secondary 2. The test is a success if the voltage
displayed is within these limits:
Throttle Potentiometer
Table 6-12.
(VR3) Voltage
VR3 Throttle Position Voltage Displayed
NOTE: Only with optional secondary control
Full Tractor-First 1.4 to 1.8V
handle.
Neutral 0.9 to 1.3V
This test displays the voltage that the Vehicle
Manager reads from the optional secondary Full Forks-First 0.45 to 0.8V
control handle throttle potentiometer (VR3).
NOTE: Run the Learn function after you • The values should change smoothly
replace, repair, or adjust the throttle and evenly as the handle is moved from
assembly. full tractor-first to full forks-first
direction.
For information on how to use service
mode, see “Using Service Mode” on • If voltages are not within reference
page 6-17. ranges, the test is a failure.
Run Test
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
1. The Operator Display shows the voltage
that the Vehicle Manager reads from the
optional secondary throttle potentiometer
(VR3).
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC4-1 JPC4-2 Approx. 5V Step 2 Replace VM
2. Meter - DC voltage. JPC4-4 JPC4-2 Neutral: Replace VM. Test cable from
approx. 1V handle to VM. If
Full forks-first: OK, replace
approx. 1.5V handle or pot.
Full
tractor-first:
approx. 0.5V
1026304B, 15 July 2007 6-139
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A30 – Secondary Traction Throttle (VR3) Request Analog Tests
Test A30 – Secondary
Traction Throttle (VR3)
Request
NOTE: Only with optional secondary control
handle.
This test displays the percentage of secondary
control handle traction throttle request from
VR3 being read by the VM.
Run Test
NOTE: Run the Learn function after you
replace, repair, or adjust the throttle
assembly.
For information on how to use service
mode, see “Using Service Mode” on
page 6-17.
The Operator Display shows the percentage of
throttle request that the Vehicle Manager reads
from the secondary control handle throttle
potentiometer (VR3).
Acceptable values are:
Table 6-13.
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 is a failure.
Diagnosis and Repair
Run Test A29 – Secondary Throttle
Potentiometer (VR3) Voltage (Page 6-139).
6-140 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A31 – Solenoid 5T (AUX1) Current
Test A31 – Solenoid 5T Run Test
(AUX1) Current NOTE: For information on how to use service
mode, see “Using Service Mode” on
page 6-17.
This test displays the current that the Aux1
directional solenoid coil is drawing. You should see:
It does not prove that the Aux1 directional Table 6-14.
solenoid valve is functioning properly
Function Current
mechanically. It does not prove the condition of
the wiring or the Vehicle Manager itself. Retract Approx. 0.57A
Tilt Down/Sideshift Left Approx. 0.57A
Related Tests
• Test O04 – Toggle Aux1 Directional
(SOL5T) Solenoid (Page 6-187) Because the directional coil is proportional,
current for tilt/sideshift can be different from
the current for reach/retract.
If results do not match the preceding table, the
test is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC20. JC20-17 JC20-18 Approximately Step 2 Troubleshoot
Meter - Resistance. 40 ohms wires and coil.
2. Meter - DC voltage. PC20-17 TP4 B+ Replace VM. Troubleshoot
B+K2 from
Relay/Control
Fuse Panel.
1026304B, 15 July 2007 6-141
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A32 – Solenoid 5B (AUX2) Current Analog Tests
Test A32 – Solenoid 5B Run Test
(AUX2) Current NOTE: For information on how to use service
mode, see “Using Service Mode” on
page 6-17.
This test displays the current that the Aux2
directional solenoid coil is drawing. You should see:
It does not prove that the Aux2 directional Table 6-15.
solenoid valve is functioning properly
Function Current
mechanically. It does not prove the condition of
the wiring or the Vehicle Manager itself. Reach Approx. 0.57A
Tilt Up/Sideshift Right Approx. 0.57A
Related Tests
• Test O05 – Toggle Aux2 Directional
(SOL5B) Solenoid (Page 6-188) Because the directional coil is proportional,
current for tilt/sideshift can be different from
the current for reach/retract.
If results do not match the preceding table, the
test is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC20. JC20-19 JC20-20 Approx. 40 Step 2 Troubleshoot
Meter - Resistance. ohms wires and coil.
2. Meter - DC voltage. PC20-19 TP4 B+ Replace VM. Troubleshoot
B+K2 from
Relay/Control
Fuse Panel.
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Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A33 – Aux Dump (SOL3)/Main Relief Dump (SOL8) Current
Test A33 – Aux Dump You should see:
(SOL3)/Main Relief Table 6-16.
Dump (SOL8) Current Function Current
Any Auxiliary Function Approx. 0.8A
Activated
This test displays the current that the dump
solenoid coil is drawing.
If results do not match the preceding table, the
Run Test test is a failure.
NOTE: For information on how to use service
mode, see “Using Service Mode” on
page 6-17.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
Series CA/FA (AC lift) Solenoid 3 Current
1. Disconnect JPC20. JC20-13 JC20-12 Approx. 39 Step 2 Troubleshoot
Meter - Resistance. ohms wires and coil.
2. Meter - DC voltage. PC20-13 TP4 B+ Replace VM. Troubleshoot
B+K2 from
Relay/Control
Fuse Panel.
Series AA/BA/DA/EA (DC lift) Solenoid 8 Current
1. Disconnect JPC20. JC20-13 JC20-12 Approx. Step 2 Troubleshoot
Meter - Resistance. 39 ohms wires and coil.
2. Meter - DC voltage. PC 20-13 TP4 B+ Replace VM. Troubleshoot
B+K2 from
Relay/Control
Fuse Panel.
1026304B, 15 July 2007 6-143
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A34 – Solenoid 2 (Lift/Lower) Current Analog Tests
Test A34 – Solenoid 2 You should see:
(Lift/Lower) Current Table 6-17.
State Current
This test displays the current that the
Neutral Approx. 0.0A
proportional lift/lower solenoid coil is drawing.
Full Lower Approx. 1.3A
Run Test
NOTE: For information on how to use service If results do not match the preceding table, the
mode, see “Using Service Mode” on test is a failure.
page 6-17.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC20. JC20-15 JC20-16 Approx. Step 2 Troubleshoot
Meter - Resistance. 13 ohms wires and coil.
2. Meter - DC voltage. PC20-15 TP4 B+ Replace VM. Troubleshoot
B+K2 from
Relay/Control
Fuse Panel.
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Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A35 – Brake Armature
Test A35 – Brake You should see:
Armature Table 6-18.
State of Brake Volts
The brake coil is activated by a coil driver
Brake pulling in Approx. 0.25
located inside the Vehicle Manager. This test for 2 seconds
displays the voltage measured across that coil
driver. Deadman Pedal Approx. 9V
Depressed/Travel
Requested
Run Test
NOTE: For information on how to use service
mode, see “Using Service Mode” on If results do not match the preceding table, the
page 6-17. test is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC20. JF2-2 JC20-14 Approx. 9 ohms Step 2 Troubleshoot
Meter - Resistance. wires and coil.
2. Meter - DC voltage. PF2-2 TP4 B+ Replace VM. Troubleshoot
B+K2 from
Relay/Control
Fuse Panel.
1026304B, 15 July 2007 6-145
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A36 – Ambient Temperature Sensor Analog Tests
Test A36 – Ambient Run Test
Temperature Sensor NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
NOTE: For information on how to use service
This test displays the ambient temperature of
mode, see “Using Service Mode” on
the area around the lift truck.
page 6-17.
The Operator Display should display the room
temperature where the lift truck is located.
If not, the test is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPA. JPC24-23 JPC24-11 Approx. 5V Step 2 Replace VM.
Meter - DC voltage.
2. Meter - Resistance. JPC24-23 JPA-1 0 ohms Replace Troubleshoot
JPC24-11 JPA-2 temperature wires as
sensor. indicated by
test.
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Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A37 – Steer Power Amplifier Current
Test A37 – Steer Power You should see:
Amplifier Current Table 6-19.
State of Motor Current
NOTE: Series CA/FA (AC lift)
At rest Less than 2A
This test displays the current that the steer Clockwise (CW) Steering –30 to –50A
motor is drawing.
Counterclockwise (CCW) Steering 30 to 50A
Run Test NOTE: CW and CCW is drive unit direction.
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204). If results do not match the preceding table, the
NOTE: For information on how to use service test is a failure.
mode, see “Using Service Mode” on
page 6-17.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC6-3 TP4 At rest: Replace VM. Replace Steer
approx. 2.5V Amplifier.
Steering CCW:
less than voltage
at rest
Steering CW:
more than
voltage at rest
1026304B, 15 July 2007 6-147
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A39 – Analog Reference Voltage Analog Tests
Test A39 – Analog
Reference Voltage
NOTE: Series CA/FA (AC lift)
This test displays the voltage used by the
Vehicle Manager to verify all analog voltages.
Run Test
NOTE: For information on how to use service
mode, see “Using Service Mode” on
page 6-17.
You should see 2.4 to 2.6V. If not, the test is a
failure.
Diagnosis and Repair
Replace Vehicle Manager.
6-148 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Analog Tests Test A40 – Handle Heater Reference Voltage
Test A40 – Handle You should see:
Heater Reference Table 6-20.
Voltage Test OFF Test ON
0V Approx. 8V
NOTE: Cold Storage option only.
This test displays the voltage the Vehicle If results do not match the preceding table, the
Manager sees going through the internal test is a failure.
primary control handle heater (HTR6).
Run Test
NOTE: For information on how to use service
mode, see “Using Service Mode” on
page 6-17.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC12. JPC12-7 JPC12-12 9 to 10 ohms Step 2 Check cable
Meter - Resistance. wiring. If OK,
replace handle
or internal
heater.
2. Disconnect JPC12. JPC12-7 JPC12-12 Test ON: Make sure Replace VM.
Meter - DC voltage. on VM on VM approx. 8V option is turned
Test OFF: 0V ON in
FlashWare.
1026304B, 15 July 2007 6-149
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test A41 – Emergency Power Off (EPO) Switch Analog Tests
Test A41 – Emergency You should see:
Power Off (EPO) Switch Table 6-21.
EPO Up EPO Down
This test shows what the Vehicle Manager is
B+ 0V
reading from the EPO switch.
Run Test If results do not match the preceding table, the
test is a failure.
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
NOTE: For information on how to use service
mode, see “Using Service Mode” on
page 6-17.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPF4-12 TP4 (B–) B+ Step 2 Clean pin
connection then
replace
Relay/Control
Fuse Card.
2. Meter - DC voltage. JPF4-5 TP4 (B–) B+ Step 3 Repair or
replace wiring or
switch.
3. Meter - DC voltage. JPF4-6 TP4 (B–) B+ Step 4 Clean pin
connection then
replace
Relay/Control
Fuse Card.
4. Meter - DC voltage. JPC22-21 TP4 (B–) B+ Replace VM. Repair or
replace wiring or
switch.
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Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Input Tests
Digital Input Tests
Section 6. Electrical Tests
A Diagnosis and Repair table is provided for
most tests. If a test fails, refer to the Diagnosis
and Repair table. This table provides a
step-by-step approach to diagnosing a problem
and the necessary corrective action. See the
example below.
Example Diagnosis and Repair Table
Action/
Step Meter Scale
(+) Lead (–) Lead Expected Results Step Passed Step Failed
Do the This column identifies Probe Probe The reading The next The next
testing any actions required point for point for required to consider action to be action to be
in this before testing the the the the step a success. performed if performed if
order. circuit, such as positive negative the the
disconnecting certain (+) meter (–) meter Expected Expected
connectors. If no lead. lead. Results are Results are
instructions are given, met. not met.
all circuits should be
connected.
Note: If something
was disconnected in
the prior step,
reconnect it before
performing the next
step.
This column also
identifies the required
scale on the meter for
this step.
NOTES:
1.
1026304B, 15 July 2007 6-151
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I00 – Deadman Switch (S2) Digital Input Tests
Test I00 – Deadman The Operator Display shows the state of the
switch.
Switch (S2) Table 6-22.
This test shows what the Vehicle Manager is Operator Display
Operator Action
reading from the deadman switch (S2). Message
Off deadman Up
On deadman Down
Do not conduct this test on a ramp.
If the display does not change when you step on
Run Test the pedal, the test is a failure.
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC22 JC22-8 JC18-7 S2 closed: Step 2 Troubleshoot
and JPC 18. 0 ohms wires and
Meter - Resistance. S2 open: switch.
open circuit
2. Disconnect JPS12. JPS12-2 JPS12-3 4.5V Recheck Step 1. Replace VM.
Meter - DC voltage.
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Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Input Tests Test I01 – Nested Switch (S14)
Test I01 – Nested Switch Run Test
(S14) NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
NOTE: This test applies only to lift trucks with NOTE: For information on how to use
the nested switch option. maintenance mode, see “Using Service
Mode” on page 6-17.
This test shows what the Vehicle Manager is
reading from the nested switch (S14). The Operator Display shows the state of the
switch.
Table 6-23.
Use extreme caution when working
around an elevated mast. Operator Display
Mast Position
Message
Nested In
Unnested Out
Lift only in an area with a ceiling height
greater than the truck’s maximum
elevated height.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPS3. JPS3-6 JPS3-1 S14 open: Step 2 Troubleshoot
Meter - Resistance. open circuit wires and
S14 closed: switch.
0 ohms
2. Disconnect JPS3. TP1 (B+) JPC22-18 B+ Step 3 Replace VM.
Meter - DC voltage.
3. Disconnect JPS3. JPS3-1 TP4 B+ Recheck Step 1. Troubleshoot K2
Meter - DC voltage. circuit.
1026304B, 15 July 2007 6-153
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I02 – First Speed Limiting Switch (S12) Digital Input Tests
Test I02 – First Speed NOTE: For information on how to use
maintenance mode, see “Using Service
Limiting Switch (S12) Mode” on page 6-17.
The Operator Display shows the state of the
This test shows what the Vehicle Manager is switch.
reading from the first speed limiting mast
switch (S12). Table 6-24.
Operator Display
Mast Position
Message
Use extreme caution when working
around an elevated mast. Lowered Below
Raised Above
Run Test
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
Run this test in Active Service Mode.
Diagnosis and Repair Table (Mechanical Switch)
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC22 JPF3-8 JPC22-1 S12 open: Step 2 Troubleshoot
and JPF3. open circuit wires and
Meter - Resistance. S12 closed: switch.
0 ohms
2. Disconnect JPS4. TP1 JPF3-8 B+ Step 3 Replace
Meter - DC voltage. Relay/Control
Fuse Panel.
3. Disconnect JPS4. JPC22-1 TP4 Approx. 4.7V Replace VM. Troubleshoot
Meter - DC voltage. wires and
switch.
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Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Input Tests Test I02 – First Speed Limiting Switch (S12)
Diagnosis and Repair Table (Proximity Sensor Switch)
Action/
Step (+) Lead (–) Lead Expected Results Step Passed Step Failed
Meter Scale
1. Disconnect JPS4. JS4-1 JS4-3 10.5 to 13 volts Step 4 Step 2
Meter - DC Voltage
2. Disconnect JPS4 and JS4-1 JC20-1 0 ohms Step 3 Repair or
JPC20. replace wire.
Meter - Resistance
3. Disconnect JPS4 and JS4-3 JF3-8 0 ohms Inspect pin Repair or
JPF3. connection replace wire.
Meter - resostance to FRC.
4. Meter - resistance JPS4-1 JPS4-2 Mast lowered: Step 5 Replace
10.5 to 13 volts S12.
Mast elevated:
0 volts
5. Meter - resistance JC20-1 JC22-1 Mast lowered: Replace VM. Repair or
10.5 to 13 volts replace wire.
Mast elevated:
0 volts
1026304B, 15 July 2007 6-155
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I06 – Reach Switch (S4) Digital Input Tests
Test I06 – Reach Switch The Operator Display shows the state of the
switch:
(S4) Table 6-25.
Use this test to monitor the state of reach Reach Button Operator Display
switch (S4). This test shows what the Vehicle
Depressed In
Manager is reading from the switch.
Released Out
Run Test
NOTE: This test can be run in Loop Back mode. 1. If results do not match the preceding
See Loop Back Tests (Page 6-204). table, the test is a failure. Perform
diagnosis.
NOTE: For information on how to use
maintenance mode, see “Using Service 2. In Active Service Mode, run the test while
Mode” on page 6-17. moving the travel pot back and forth. If the
voltage fluctuates erratically as you move
This test shows better results in Active the handle back and forth, replace the
Service. control handle cable.
3. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector to see if they have
been bent.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPH12. JPC12-4 JPC12-12 More than 4V Step 2 Replace VM.
Meter - DC voltage.
2. Disconnect JPH1. JPH1-4 JPH1-12 More than 4V Step 3 Repair or
Meter - DC voltage. replace cable to
VM.
3. Meter - DC voltage. JPH1-4 JPH1-12 S4 open: Replace VM. Replace control
more than 4V handle.
S4 closed:
less than 1V
[1] NOTES: Voltage to switch being tested may drop when any other control handle switch is depressed.
6-156 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Input Tests Test I07 – Retract Switch (S5)
Test I07 – Retract Switch The Operator Display shows the state of the
switch:
(S5) Table 6-26.
Use this test to monitor the state of retract Retract Button Operator Display
switch (S5). This test shows what the Vehicle
Depressed In
Manager is reading from the switch.
Released Out
Run Test
NOTE: This test can be run in Loop Back mode. 1. If results do not match the preceding
See Loop Back Tests (Page 6-204). table, the test is a failure. Perform
diagnosis.
NOTE: For information on how to use
maintenance mode, see “Using Service 2. In Active Service Mode, run the test while
Mode” on page 6-17. moving the travel pot back and forth. If the
voltage fluctuates erratically as you move
NOTE: This test shows better results in Active the handle back and forth, replace the
Service. control handle cable.
3. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector to see if they have
been bent.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPH12. JPC12-11 JPC12-12 More than 4V Step 2 Replace VM.
Meter - DC voltage.
2. Disconnect JPH1. JPH1-11 JPH1-12 More than 4V Step 3 Repair or
Meter - DC voltage. replace cable to
VM.
3. Meter - DC voltage. JPH1-11 JPH1-12 S5 open: Replace VM. Replace control
more than 4V handle.
S5 closed:
less than 1V
[1] NOTES: Voltage to switch being tested may drop when any other control handle switch is depressed.
1026304B, 15 July 2007 6-157
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I08 – Tilt Up Switch (S6) Digital Input Tests
Test I08 – Tilt Up Switch The Operator Display shows the state of the
switch:
(S6) Table 6-27.
Use this test to monitor the state of tilt up Tilt Button Operator Display
switch (S6). This test shows what the Vehicle
Depressed In
Manager is reading from the switch.
Released Out
Run Test
NOTE: This test can be run in Loop Back mode. 1. If results do not match the preceding
See Loop Back Tests (Page 6-204). table, the test is a failure. Perform
diagnosis.
NOTE: For information on how to use
maintenance mode, see “Using Service 2. In Active Service Mode, run the test while
Mode” on page 6-17. moving the travel pot back and forth. If the
voltage fluctuates erratically as you move
NOTE: This test shows better results in Active the handle back and forth, replace the
Service. control handle cable.
NOTE: If you can enter Service Mode and use 3. If there is a problem after reconnecting the
this switch to select tests, then the control handle cable, inspect the pins in
switch is working correctly. the DB15 connector to see if they have
been bent.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPH12. JPC12-5 JPC12-12 More than 4V Step 2 Replace VM.
Meter - DC voltage.
2. Disconnect JPH1. JPH1-5 JPH1-12 More than 4V Step 3 Repair or
Meter - DC voltage. replace cable to
VM.
3. Meter - DC voltage. JPH1-5 JPH1-12 S6 open: Replace VM. Replace control
more than 4V handle.
S6 closed:
less than 1V
[1] NOTES: Voltage to switch being tested may drop when any other control handle switch is depressed.
6-158 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Input Tests Test I09 – Tilt Down Switch (S7)
Test I09 – Tilt Down The Operator Display shows the state of the
switch:
Switch (S7) Table 6-28.
Use this test to monitor the state of tilt down Tilt Button Operator Display
switch (S7). This test shows what the Vehicle
Depressed In
Manager is reading from the switch.
Released Out
Run Test
NOTE: This test can be run in Loop Back mode. 1. If results do not match the preceding
See Loop Back Tests (Page 6-204). table, the test is a failure. Perform
diagnosis.
NOTE: For information on how to use
maintenance mode, see “Using Service 2. In Active Service Mode, run the test while
Mode” on page 6-17. moving the travel pot back and forth. If the
voltage fluctuates erratically as you move
NOTE: This test shows better results in Active the handle back and forth, replace the
Service. control handle cable.
NOTE: If you can enter Service Mode and use 3. If there is a problem after reconnecting the
this switch to select tests, then the control handle cable, inspect the pins in
switch is working correctly. the DB15 connector to see if they have
been bent.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPH12. JPC12-6 JPC12-12 More than 4V Step 2 Replace VM.
Meter - DC voltage.
2. Disconnect JPH11. JPH1-6 JPH1-12 More than 4V Step 3 Repair or
Meter - DC voltage. replace cable to
VM.
3. Meter - DC voltage. JPH1-6 JPH1-12 S7 open: Replace VM. Replace control
more than 4V handle.
S7 closed:
less than 1V
[1] NOTES: Voltage to switch being tested may drop when any other control handle switch is depressed.
1026304B, 15 July 2007 6-159
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I10 – Sideshift Right Switch (S9) Digital Input Tests
Test I10 – Sideshift Right The Operator Display shows the state of the
switch:
Switch (S9) Table 6-29.
Use this test to monitor the state of sideshift Sideshift Button Operator Display
right switch (S9). This test shows what the
Depressed In
Vehicle Manager is reading from the switch.
Released Out
Run Test
NOTE: This test can be run in Loop Back mode. 1. If results do not match the preceding
See Loop Back Tests (Page 6-204). table, the test is a failure. Perform
diagnosis.
NOTE: For information on how to use
maintenance mode, see “Using Service 2. In Active Service Mode, run the test while
Mode” on page 6-17. moving the travel pot back and forth. If the
voltage fluctuates erratically as you move
NOTE: This test shows better results in Active the handle back and forth, replace the
Service. control handle cable.
3. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector to see if they have
been bent.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPH12. JPC12-9 JPC12-12 More than 4V Step 2 Replace VM.
Meter - DC voltage.
2. Disconnect JPH11. JPH1-9 JPH1-12 More than 4V Step 3 Repair or
Meter - DC voltage. replace cable to
VM.
3. Meter - DC voltage. JPH1-9 JPH1-12 S9 open: Replace VM. Replace control
more than 4V handle.
S9 closed:
less than 1V
[1] NOTES: Voltage to switch being tested may drop when any other control handle switch is depressed.
6-160 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Input Tests Test I11 – Sideshift Left Switch (S8)
Test I11 – Sideshift Left The Operator Display shows the state of the
switch:
Switch (S8) Table 6-30.
Use this test to monitor the state of sideshift left Sideshift Button Operator Display
switch (S8). This test shows what the Vehicle
Depressed In
Manager is reading from the switch.
Released Out
Run Test
NOTE: This test can be run in Loop Back mode. 1. If results do not match the preceding
See Loop Back Tests (Page 6-204). table, the test is a failure. Perform
diagnosis.
NOTE: For information on how to use
maintenance mode, see “Using Service 2. In Active Service Mode, run the test while
Mode” on page 6-17. moving the travel pot back and forth. If the
voltage fluctuates erratically as you move
NOTE: This test shows better results in Active the handle back and forth, replace the
Service. control handle cable.
3. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector to see if they have
been bent.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPH12. JPC12-8 JPC12-12 More than 4V Step 2 Replace VM.
Meter - DC voltage.
2. Disconnect JPH11. JPH1-8 JPH1-12 More than 4V Step 3 Repair or
Meter - DC voltage. replace cable to
VM.
3. Meter - DC voltage. JPH1-8 JPH1-12 S8 open: Replace VM. Replace control
more than 4V handle.
S8 closed:
less than 1V
[1] NOTES: Voltage to switch being tested may drop when any other control handle switch is depressed.
1026304B, 15 July 2007 6-161
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I14 – Steering Fuse (FU1) Digital Input Tests
Test I14 – Steering Fuse Use the following table as a guideline.
(FU1) Table 6-31.
Deadman Pedal Operator Display
This test reports the absence or presence of B+ Position Message
voltage at the load side of the steer motor (STR) Down Clsd
contactor.
Up Open
When this test is activated and the NOTE: The display will show CLSD until the
deadman pedal is depressed, the steer TPC and LPC timeout. The contactor will
motor/pump will activate. open but capacitors in the steer
amplifier take some time to bleed off.
Run Test
If the STR contactor tips do not close, run
NOTE: This test can be run in Loop Back mode. Test O01.
See Loop Back Tests (Page 6-204).
NOTE: For information on how to use If the display message does not change when
maintenance mode, see “Using Service the test is activated, the test is a failure.
Mode” on page 6-17.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Remove FU1. Fuse Fuse 0 ohms Step 2 Replace fuse
Meter - Resistance. FU1.
2. Meter - DC voltage. STR-1 STR-2 STR Tips Step 3 Replace STR
Closed: B+ contactor tips.
3. Meter - DC voltage. JPC22-19 TP4 STR Tips open: Replace VM Troubleshoot
0V wiring from VM
STR Tips closed: to contactor.
B+
6-162 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Input Tests Test I15 – Horn Switch (S3)
Test I15 – Horn Switch The Operator Display shows the state of the
switch:
(S3) Table 6-32.
Use this test to monitor the state of the horn Operator
Horn Button Audible Alarm
switch (S3). This test shows what the Vehicle Display
Manager is reading from the switch. Depressed Sounding In
Run Test Released Off Out
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204). If results do not match the preceding table, the
test is a failure. Perform diagnosis.
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
This test shows better results in Active
Service.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPH12. JPC12-10 JPC12-12 More than 4V Step 2 Replace VM.
Meter - DC voltage.
2. Disconnect JPH11. JPH1-10 JPH1-12 More than 4V Step 3 Repair or
Meter - DC voltage. replace cable to
VM.
3. Meter - DC voltage. JPH1-10 JPH1-12 S3 open: Replace VM. Replace control
more than 4V handle.
S3 closed:
less than 1V
[1] NOTES: Voltage to switch being tested may drop when any other control handle switch is depressed.
1026304B, 15 July 2007 6-163
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I19 – Drive Motor Speed Sensor Digital Input Tests
Test I19 – Drive Motor
Speed Sensor Do this test in an area free of
obstructions with ample room for
This test displays the output from the speed maneuvering.
sensor on the drive motor as seen by the
traction power amplifier. Run Test
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
“0000 to ±3450 rpm” should be displayed.
NOTE: The Operator Display shows rpm as
measured by the traction power
amplifier.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPT1. JPT1-3 JPT1-4 10.5V to 13V Step 2 Replace traction
Meter - DC voltage. power amplifier.
2. Reconnect JPT1. JPT2-1 JPT2-4 10.5V to 13V Step 3 Troubleshoot
Disconnect JPT2. wiring TPA to
Meter - DC voltage. traction motor.
3. Reconnect JPT2. JPT2-2 JPT2-4 At rest: 0 V or Step 4 Replace traction
Meter - DC voltage. 10.5V to 13V motor speed
Traveling: sensor.
approx. 5VDC
4. Meter - DC voltage. JPT2-3 JPT2-4 At rest: 0 V or Step 5 Replace traction
10.5V to 13V motor speed
Traveling: sensor.
approx. 5VDC
5. Meter - DC voltage. JPT1-5 JPT1-4 At rest: 0 V or Step 6 Troubleshoot
10.5V to 13V wiring TPA to
Traveling: traction motor.
approx. 5VDC
6. Meter - DC voltage. JPT1-6 JPT1-4 At rest: 0 V or Replace traction Troubleshoot
10.5V to 13V power amplifier. wiring TPA to
Traveling: traction motor.
approx. 5VDC
6-164 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Input Tests Test I20 – Lift Motor Speed Sensor
Test I20 – Lift Motor
Speed Sensor Do this test in an area free of
obstructions with ample room for lifting.
NOTE: Series CA/FA (AC lift)
Run Test
This test displays the input from the speed
sensor on the lift motor as seen by the lift power NOTE: For information on how to use
amplifier. maintenance mode, see “Using Service
Mode” on page 6-17.
This test shows best results in Active
Service.
“0000 to ±2340 rpm” should be displayed.
NOTE: The Operator Display shows rpm as
measured by the lift power amplifier.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPT1. JPL1-3 JPL1-4 10.5V to 13V Step 2 Replace lift
Meter - DC voltage. power amplifier.
2. Reconnect JPT1. JPL2-1 JPL2-4 10.5V to 13V Step 3 Troubleshoot
Disconnect JPT2. wiring LPA to lift
Meter - DC voltage. motor.
3. Reconnect JPT2. JPL2-2 JPL2-4 At rest: 0 V or Step 4 Replace
Meter - DC voltage. 10.5V to 13V lift motor
Lifting: approx. speed sensor.
5VDC
4. Meter - DC voltage. JPL2-3 JPL2-4 At rest: 0 V or Step 5 Replace
10.5V to 13V lift motor
Lifting: approx. speed sensor.
5VDC
5. Meter - DC voltage. JPL1-5 JPL1-4 At rest: 0 V or Step 6 Troubleshoot
10.5V to 13V wiring LPA to lift
Lifting: approx. motor.
5VDC
6. Meter - DC voltage. JPL1-6 JPL1-4 At rest: 0 V or Replace lift Troubleshoot
10.5V to 13V power amplifier. wiring LPA to lift
Lifting: approx. motor.
5VDC
1026304B, 15 July 2007 6-165
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I23 – CAN Bus Test Digital Input Tests
Test I23 – CAN Bus Test The Operator Display shows:
• T if the Traction Power Amplifier is
communicating with the Vehicle Manager
This test indicates whether the Vehicle Manager
is communicating with the Traction Power • L if the Lift Power Amplifier is
Amplifier (TA) and Lift Power Amplifier (LA) and communicating with the Vehicle Manager
Operator’s Display. • V if the Operator Display is
communicating with the Vehicle Manager
Run Test
If either (T), (L) or (V) is missing, the test is a
NOTE: For information on how to use failure.
maintenance mode, see “Using Service
Mode” on page 6-17.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
Series CA/FA (AC lift)
1. Disconnect VM and JPL1-15 JPL1-23 Approx. Step 2 Test wires from
LA. 38 k ohms LA to TA. If OK,
Meter - Resistance. replace TA.
2. JPL1-22 JPL1-14 Approx. Step 3 Test wires from
120 ohms LA to display. If
OK, replace
display.
3. Disconnect TA and JPD1-2 JPD1-3 Approx. Step 4 Test wires from
display. 38 k ohms display to LA. If
Meter - Resistance. OK, replace LA.
4. JPD1-6 JPD1-7 Approx. Call Technical Test wires from
120 ohms Support. display to VM. If
OK, replace VM.
Series AA/BA/DA/EA (DC lift)
1. Disconnect TA and JPT1-23 JPT1-15 Approx. Step 2 Test wires from
display. 120 ohms TA to display. If
Meter - Resistance. OK, replace
display.
2. Disconnect Display. JPD1-2 JPD1-3 Approx. Step 3 Test wires from
Meter - Resistance. 38 k ohms display to TA. If
OK, replace TA.
3. Disconnect TA and JPD1-6 JPD1-7 Approx. Call Technical Test wires from
display. 120 ohms Support. display to VM. If
Meter - Resistance. OK, replace VM.
6-166 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Input Tests Test I24 – Steer Feedback Proximity Sensor
Test I24 – Steer You should see:
Feedback Proximity Table 6-33.
Sensor Sensor Location Operator Display
Over Metal On
NOTE: Series CA/FA (AC lift)
Not Over Metal Off
This test reads the input to the Vehicle Manager
from the Steer Feedback Proximity Sensor. If results do not match the preceding table, the
test is a failure.
Run Test
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC20-9 JPC20-11 12V Step 2 Replace VM.
2. Meter - DC voltage. JPST-1 JPST-3 12V Step 3 Repair or
replace wiring.
3. Meter - DC voltage. JPST-2 JPST-3 Sensor over Step 4 Replace sensor.
metal:10V
Sensor not over
metal: <1V
4. Meter - DC voltage. JPC22-22 JPC22-11 Sensor over Replace VM. Repair or
metal: 10V replace wiring.
Sensor not over
metal: <1V
1026304B, 15 July 2007 6-167
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I25 – Steer Motor Encoder Digital Input Tests
Test I25 – Steer Motor Run Test
Encoder NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
NOTE: Series CA/FA (AC lift)
You should see “0 to 255” while steering. If not,
This test displays the encoder counts from the the test is a failure.
steer motor encoder.
Diagnosis and Repair Table
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC20-7 JPC10-9 12V Step 2 Replace VM.
2. Meter - DC voltage. JPE4-1 JPE4-4 12V Step 3 Troubleshoot
wiring to VM.
3. Meter - DC voltage. JPE4-3 JPE4-4 Step 4 Replace steer
motor encoder.
4. Meter - DC voltage. JPE4-2 JPE4-4 Step 5 Replace steer
Steering: motor encoder.
5. Meter - DC voltage. JPC22-10 JPC10-9 approx. 1.8V Step 6 Troubleshoot
Not steering: 0 wiring to
or 4.5V encoder.
6. Meter - DC voltage. JPC22-9 JPC10-9 Replace VM. Troubleshoot
wiring to
encoder.
6-168 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Input Tests Test I26 – Height Indicator Encoder
Test I26 – Height Run Test
Indicator Encoder NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
This test reads the input from the height
encoder to the operator’s display. Above free lift: counts increase “0 to 255” lifting
counts decrease “255 to 0” lowering
If not, the test is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPD2-1 JPD2-2 10.5 to 13V Step 2 Replace
Operator
Display.
2. Meter - DC voltage. JPE3-1 JPE3-4 10.5 to 13V Step 3 Repair or
replace wiring.
3. Meter - DC voltage. JPE3-3 JPE3-4 Step 4 Replace height
(Channel encoder.
A)
Not lifting:
4. Meter - DC voltage. JPE3-2 JPE3-4 below freelift = Step 5 Replace height
(Channel approx. 5 or 0V; encoder.
B) above freelift =
5. Meter - DC voltage. JPD2-3 JPD2-2 approx. 5 or 0V; Step 6 Repair or
(Channel lifting above replace wiring.
A) freelift = approx.
2.3V
6. Meter - DC voltage. JPD2-4 JPD2-2 Replace Repair or
(Channel Operator replace wiring.
B) Display.
1026304B, 15 July 2007 6-169
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I27 – Secondary Horn Switch (S10) Digital Input Tests
Test I27 – Secondary You should see:
Horn Switch (S10) Table 6-34.
Operator
Horn Button Audible Alarm
NOTE: Only with optional secondary control Display
handle
Depressed Sounding In
This test shows what the Vehicle Manager is Released Off Out
reading from S10.
Run Test If results do not match the preceding table, the
test is a failure.
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC4-1 JPC4-2 More than 4V Step 2 If travel
functions OK,
repair wire
connection at
VM. If travel
does not
function,
replace VM.
2. Meter - DC voltage. JPH3-1 JPH3-2 More than 4V Step 3 Repair wiring to
VM.
3. Meter - DC voltage. JPH3-3 JPH3-2 S10 open: Step 4 Replace switch
more than 4V S10.
S10 closed:
less than 1V
4. Meter - DC voltage. JPC4-3 JPC4-2 S10 open: Replace VM. Repair wiring to
more than 4V switch S10.
S10 closed:
less than 1V
6-170 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Input Tests Test I33 – Steer Tiller Encoder 1 Connect Detect
Test I33 – Steer Tiller You should see:
Encoder 1 Connect Detect Table 6-35.
Connection Status Operator Display
NOTE: Series CA/FA (AC lift)
Connected Yes
This test verifies the Vehicle Manager sees the Not Connected No
12V circuit connected to the Steer Encoder
Channel 1.
If results do not match the preceding table, the
Run Test test is a failure.
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC10-6 JPC18-5 10.5 to 13V Step 2 Replace VM.
2. Meter - DC voltage. JPE1-1 JPE1-4 10.5 to 13V Replace steer Repair wiring
tiller encoder. from VM.
1026304B, 15 July 2007 6-171
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I34 – Steer Tiller Encoder 2 Connect Detect Digital Input Tests
Test I34 – Steer Tiller You should see:
Encoder 2 Connect Detect Table 6-36.
Connection Status Operator Display
NOTE: Series CA/FA (AC lift)
Connected Yes
This test verifies the Vehicle Manager sees the Not Connected No
12V circuit connected to the Steer Encoder
Channel 2.
If results do not match the preceding table, the
Run Test test is a failure.
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC10-7 JPC18-6 10.5 to 13V Step 2 Replace VM.
2. Meter - DC voltage. JPE2-1 JPE2-4 10.5 to 13V Replace steer Repair wiring
tiller encoder. from VM.
6-172 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Input Tests Test I35 – Steer Tiller Encoder 1 (Channel A & B)
Test I35 – Steer Tiller Run Test
Encoder 1 NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
(Channel A & B) NOTE: For information on how to use
maintenance mode, see “Using Service
NOTE: Series CA/FA (AC lift) Mode” on page 6-17.
This test monitors input to Vehicle Manager Count should increase CW; decrease CCW. If
from Channel 1. not, the test is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC10-6 JPC18-5 10.5 to 13V Step 2 Replace VM.
2. Meter - DC voltage. JPE1-1 JPE1-4 10.5 to 13V Step 3 Repair wiring
from VM.
3. Meter - DC voltage. JPE1-3 JPE1-4 Step 4 Replace steer
tiller encoder.
4. Meter - DC voltage. JPE1-2 JPE1-4 Step 5 Replace steer
Turning tiller: tiller encoder.
5. Meter - DC voltage. JPC22-5 JPC18-5 approx 2.5V Step 6 Repair or
replace wiring.
6. Meter - DC voltage. JPC22-12 JPC18-5 Replace VM. Repair or
replace wiring.
1026304B, 15 July 2007 6-173
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I36 – Steer Tiller Encoder 2 (Channel A & B) Digital Input Tests
Test I36 – Steer Tiller Run Test
Encoder 2 NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-204).
(Channel A & B) NOTE: For information on how to use
maintenance mode, see “Using Service
NOTE: Series CA/FA (AC lift) Mode” on page 6-17.
This test monitors input to Vehicle Manager Count should increase CW; decrease CCW. If
from Channel 2. not, the test is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC10-7 JPC18-6 10.5 to 13V Step 2 Replace VM.
2. Meter - DC voltage. JPE2-1 JPE2-4 10.5 to 13V Step 3 Repair wiring
from VM.
3. Meter - DC voltage. JPE2-3 JPE2-4 Step 4 Replace steer
tiller encoder.
4. Meter - DC voltage. JPE2-2 JPE2-4 Step 5 Replace steer
Turning tiller: tiller encoder.
5. Meter - DC voltage. JPC22-13 JPC18-6 approx 2.5V Step 6 Repair or
replace wiring.
6. Meter - DC voltage. JPC22-14 JPC18-6 Replace VM. Repair or
replace wiring.
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Digital Input Tests Test I39 – Neutral Pulses
Test I39 – Neutral Pulses You should see:
Table 6-37.
NOTE: Series CA/FA (AC lift)
Deadman Pedal Operator Display
This test displays the neutral pulses seen by
Depressed Toggles between On
the Vehicle Manager from the Steer Power
and Off
Amplifier.
Released >15 sec = On or Off
Run Test
NOTE: This test can be run in Loop Back mode. If results do not match the preceding table, the
See Loop Back Tests (Page 6-204). test is a failure.
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPC6-6 JPC6-4 10.5 to 13V Step 2 Replace VM.
2. Meter - DC voltage. JPC6-1 JPC6-4 Deadman Pedal Replace VM. Repair wiring or
Up: more than replace Steer
4V Power Amplifier.
1026304B, 15 July 2007 6-175
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I42 – Lift Height Digital Input Tests
Test I42 – Lift Height maintenance mode, see “Using Service
Mode” on page 6-17.
NOTE: On VM versions below 3.7. At VM You should see: below freelift = 0; height
version 3.7 and above, this test is increase going up; height decrease going down
renumbered as Test I86.
If not, the test is a failure.
This test displays fork height above free lift.
Run Test
NOTE: This test cannot be run in Active Service
Mode.
For information on how to use
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPD-2. JPD2-1 JPD2-2 10.5 to 13V Step 2 Replace display.
Meter - DC voltage.
2. Meter - DC voltage. JPE3-1 JPE3-4 10.5 to 13V Step 3 Troubleshoot
wiring.
3. Meter - DC voltage. JPE3-3 JPE3-4 Step 4 Replace encoder.
4. Meter - DC voltage. JPE3-2 JPE3-4 Step 5 Replace encoder.
5. Meter - DC voltage. JPD2-3 JPD2-2 Lifting: approx. Step 6 Troubleshoot
2.4V wiring.
6. Meter - DC voltage. JPD2-4 JPD2-2 Replace display. Troubleshoot
wiring.
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Digital Input Tests Test I60 – Security Start Switch (S23) (option)
Test I60 – Security Start You should see:
Switch (S23) (option) Table 6-38.
Switch Status Operator Display
This test shows what the Vehicle Manager reads
Depressed In
from S23.
Released Out
Run Test
NOTE: This test can be run in Loop Back mode. If results do not match the preceding table, the
See Loop Back Tests (Page 6-204). test is a failure.
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC10. JPC10-2 JPC10-4 >4.0V Step 2 Verify option is
Meter - DC voltage. ON.
2. Meter - DC voltage. JPC10-2 JPC10-4 S23 open = Replace VM. Troubleshoot
>4.0V switch and
S23 closed = 0V wires.
1026304B, 15 July 2007 6-177
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I80 - OCSS Upper Beam Digital Input Tests
Test I80 - OCSS Upper
Beam Table 6-39.
Deadman Pedal Display
This test verifies the upper beam is working
properly. Down On
NOTE: This test must be run in Maintenance Up Off
Mode. For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17. If results do not match Table 6-39, the test has
failed. Perform Diagnosis and Repair.
Run Test
Diagnosis and Repair
Make sure the beam is not blocked by objects,
debris, or dirt. The Operator Display shows the Remove sensor housing covers. Turn key switch
state of the beam: ON and verify LEDs are illuminated as follows:
Deadman Pedal
LED Status
Position
Receiver Up or Down Green ON +12V present at RCVR_1
(3 wires)
Down Yellow ON Receiver is receiving light beam
(properly aligned)
Emitter Down Green ON +12V present at EMTR_1
(2 wires)
If the LEDs do not illuminate as described
above, troubleshoot as follows:
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
Fault: All LEDS not illuminated
1 Deadman pedal JX1-1 JX1-4 10.7 Replace Expander Step 2
down, JPX1 to Module.
disconnected/ 13V
Voltage
2 Deadman pedal PD1-1 PT1-8 Replace harness Troubleshoot VM.
down, JPX1 [CA] between Expander
disconnected/ Module and OD/PA
Voltage PT1-7 JX1 to JD1-1/JT1.
[AA/BA]
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Digital Input Tests Test I80 - OCSS Upper Beam
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
Fault: EMITTER - Green LED not illuminated
1 Deadman pedal JCS1-1 JCS1-2 10.7 Replace Emitter Step 2
down, JPCS1 to harness
disconnected/ 13V PCS1.
Voltage
2 Deadman pedal PX2-4 PX2-9 Replace harness Replace Expander
down, JPX2 between Expander Module.
disconnected/ Module and Emitter
Voltage harness
JX2 to JCS1.
Fault: RECEIVER - Green LED not illuminated
1 Deadman pedal JCS2-1 JCS2-4 10.7 Replace Receiver Step 2
up, JPCS2 to harness
disconnected/ 13V PCS2.
Voltage
2 Deadman pedal PX2-1 PX2-6 Replace harness Replace Expander
up, JPX2 between Expander Module.
disconnected/ Module and Receiver
Voltage harness
JX2 to JCS2.
Fault: RECEIVER - Yellow LED not illuminated
1 JPCS2 & JPX2 JCS2-2 PX2-2 0 ohms Step 2 Replace harness
disconnected/ between Expander
Resistance Module and Receiver
harness
JX2 to JPCS2.
2 Make sure Emitter is not obscured (dirty) and is Step 3 Clean Emitter eye
aligned properly and/or align
properly.
3 JPX2 PX2-2 PX2-6 Approx. Replace Receiver Replace Expander
disconnected/ 5V harness Module.
Voltage PCS2.
Fault Code 58 - Previous Tests Pass
1 Disconnect JX1-5 JT1-15 0 ohms Step 2 Repair/Replace
harness at JPX1 (AC Lift) harness JX1-JT1.
and JPT1/ JT1-14
Resistance (DC Lift)
2 Disconnect JX1-2 JT1-23 0 ohms Replace Expander Repair Replace
harness at JPX1 (AC Lift) Module. harness JX1-JT1.
and JPT1/ JT1-22
Resistance (DC Lift)
1026304B, 15 July 2007 6-179
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I81 - OCSS Lower Beam Digital Input Tests
Test I81 - OCSS Lower
Beam Table 6-40.
Deadman Pedal Display
This test verifies the lower beam is working
properly. Down On
NOTE: This test must be run in Maintenance Up Off
Mode. Refer to “Using Maintenance
Mode” in the Maintenance Manual.
If results do not match Table 6-40, the test has
failed. Perform Diagnosis and Repair.
Run Test
Make sure the beam is not blocked by objects, Diagnosis and Repair
debris, or dirt. The Operator Display shows the
state of the beam: Remove sensor housing covers. Turn key switch
ON and verify LEDs are illuminated as follows:
Deadman Pedal
LED Status
Position
Receiver Up or Down Green ON +12V present at RCVR_2
(3 wires)
Down Yellow ON Receiver is receiving light beam
(properly aligned)
Emitter Down Green ON +12V present at EMTR_2
(2 wires)
If the LEDs do not illuminate as described
above, troubleshoot as follows:
Action/ Expected
Step Meter Scale
(+) Lead (–) Lead Results
Step Passed Step Failed
Fault: All LEDS not illuminated
1 Deadman pedal JX1-1 JX1-4 Replace Expander Step 2
down, JPX1 Module.
disconnected/ 10.7
Voltage to
13V
2 Deadman pedal PD1-1 PT1-8 Replace harness Troubleshoot VM.
down, JPX1 [CA] between Expander
disconnected/ Module and OD/TPA
Voltage PT1-7 JX1 to JD1-1/JT1.
[AA/BA]
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Digital Input Tests Test I81 - OCSS Lower Beam
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
Fault: EMITTER - Green LED not illuminated
1 Deadman pedal JCS3-1 JCS3-2 10.7 Replace Emitter Step 2
down, JPCS3 to harness
disconnected/ 13V PCS3.
Voltage
2 Deadman pedal PX2-5 PX2-10 Replace harness Replace Expander
down, JPX2 between Expander Module.
disconnected/ Module and Emitter
Voltage harness
PX2 to JCS1.
Fault: RECEIVER - Green LED not illuminated
1 Deadman pedal JCS4-1 JCS4-4 10.7 Replace Receiver Step 2
up, JPCS4 to harness
disconnected/ 13V PCS4.
Voltage
2 Deadman pedal PX2-3 PX2-8 Replace harness Replace Expander
up, JPX2 between Expander Module.
disconnected/ Module and Receiver
Voltage harness
JX2 to JPCS4.
Fault: RECEIVER - Yellow LED not illuminated
1 JPCS4 & JPX2 JCS4-3 PX2-7 0 ohms Step 2 Replace harness
disconnected/ between Expander
Resistance Module and Receiver
harness
JX2 to JCS4.
2 Make sure Emitter is not obscured (dirty) and is Step 3 Clean Emitter eye
aligned properly and/or align
properly.
3 JPX2 PX2-7 PX2-8 Approx. Replace Receiver Replace Expander
disconnected/ 5V harness Module.
Voltage PCS4.
Fault Code 58 - Previous Tests Pass
1 Disconnect JX1-5 JT1-15 0 ohms Step 2 Repair/Replace
harness at JPX1 (AC Lift) harness JX1-JT1.
and JPT1/ JT1-14
Resistance (DC Lift)
2 Disconnect JX1-2 JT1-23 0 ohms Replace Expander Repair Replace
harness at JPX1 (AC Lift) Module. harness JX1-JT1.
and JPT1/ JT1-22
Resistance (DC Lift)
1026304B, 15 July 2007 6-181
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test I86 – Lift Height Digital Input Tests
Test I86 – Lift Height
NOTE: On VM versions 3.7 and above. At VM
versions below 3.7, this test is
numbered Test I42.
This test displays fork height above free lift.
Run Test
NOTE: This test cannot be run in Active Service
Mode.
For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
You should see: below freelift = 0; height
increase going up; height decrease going down
If not, the test is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPD-2. JPD2-1 JPD2-2 10.5 to 13V Step 2 Replace display.
Meter - DC voltage.
2. Meter - DC voltage. JPE3-1 JPE3-4 10.5 to 13V Step 3 Troubleshoot
wiring.
3. Meter - DC voltage. JPE3-3 JPE3-4 Step 4 Replace encoder.
4. Meter - DC voltage. JPE3-2 JPE3-4 Step 5 Replace encoder.
5. Meter - DC voltage. JPD2-3 JPD2-2 Lifting: approx. Step 6 Troubleshoot
2.4V wiring.
6. Meter - DC voltage. JPD2-4 JPD2-2 Replace display. Troubleshoot
wiring.
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Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Output Tests
Digital Output Tests
Section 6. Electrical Tests
A Diagnosis and Repair table is provided for
most tests. If a test fails, refer to the Diagnosis
and Repair table. This table provides a
step-by-step approach to diagnosing a problem
and the necessary corrective action. See the
example below.
Example Diagnosis and Repair Table
Action/
Step Meter Scale
(+) Lead (–) Lead Expected Results Step Passed Step Failed
Do the This column identifies Probe Probe The reading The next The next
testing any actions required point for point for required to consider action to be action to be
in this before testing the the the the step a success. performed if performed if
order. circuit, such as positive negative the the
disconnecting certain (+) meter (–) meter Expected Expected
connectors. If no lead. lead. Results are Results are
instructions are given, met. not met.
all circuits should be
connected.
Note: If something
was disconnected in
the prior step,
reconnect it before
performing the next
step.
This column also
identifies the required
scale on the meter for
this step.
NOTES:
1.
1026304B, 15 July 2007 6-183
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test O00 – Toggle the TPC Contactor Digital Output Tests
Test O00 – Toggle the Run Test
TPC Contactor NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
This test turns the TPC contactor ON and OFF.
Use the ENTER button to toggle the test ON and
OFF. The operator display shows ON or OFF.
Jack the drive wheels off the floor for
If the contactor does not cycle in/out when the
this test.
test is toggled, then the test is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPS1 JPS1-10 JPS1-8 Approximately Step 2 Troubleshoot
from contactor 38 ohms wires and coil.
panel.
Meter - Resistance.
2. Meter - DC voltage. JPS1-10 TP4 B+ Step 3 Troubleshoot K2
relay and
relay/control
fuse panel.
3. Meter - DC voltage. B+ JPS1-8 Test ON = B+ Test contactor Test wire to TA.
Test OFF = 0V for binding. If OK, replace
TA.
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Digital Output Tests Test O01 – Toggle the STR Contactor
Test O01 – Toggle the
STR Contactor
This test turns the STR contactor ON and OFF.
DO NOT attempt to drive the truck while
conducting this test.
Run Test
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
Use the ENTER button to toggle the test ON and
OFF. The operator display shows ON or OFF.
If the contactor does not cycle in/out when the
test is toggled, then the test is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPS1. JPS1-10 JPS1-11 Approximately Step 2 Trouble shoot
Meter - Resistance. 40 ohms wires and coil.
2. Meter - DC voltage. JPS1-10 TP4 B+ Step 4 Step 3
3. Meter - DC voltage. JPF2-1 TP4 B+ Troubleshoot Replace
wire to JPS1-10. Relay/Control
Fuse Panel.
4. Meter - DC voltage. B+ JPS1-11 OFF: 0V Test contactor Step 5
ON: approx. 24V for binding.
5. Meter - DC voltage. B+ JPC18-11 OFF: 0V Troubleshoot Replace VM.
ON: approx. 24V wire to JPS1-11.
1026304B, 15 July 2007 6-185
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test O02 – Toggle the LPC Contactor Digital Output Tests
Test O02 – Toggle the
LPC Contactor
This test turns the LPC contactor ON and OFF.
Ceiling height must be higher than the
maximum elevated height of the lift
truck under test.
The lift system on a truck with DC lift
might not act as expected during this
test. If the STR contactor is shorted, the
carriage will lift when the LPC contactor
is toggled ON.
This will not happen on a truck with AC
lift, because the AC lift motor will not
turn without power from the lift power
amplifier.
Run Test
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
Use the ENTER button to toggle the test ON and
OFF. The operator display shows ON or OFF.
If the contactor does not cycle in/out when the
test is toggled, then the test is a failure.
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Digital Output Tests Test O04 – Toggle Aux1 Directional (SOL5T) Solenoid
Test O04 – Toggle Aux1
Directional (SOL5T)
Solenoid
See Test A31 – Solenoid 5T (AUX1) Current
(Page 6-141).
1026304B, 15 July 2007 6-187
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test O05 – Toggle Aux2 Directional (SOL5B) Solenoid Digital Output Tests
Test O05 – Toggle Aux2
Directional (SOL5B)
Solenoid
See Test A32 – Solenoid 5B (AUX2) Current
(Page 6-142).
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Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Output Tests Test O06 – Toggle the Reach Solenoid
Test O06 – Toggle the 1. Turn the key switch OFF and disconnect
the battery connector.
Reach Solenoid 2. Disconnect wire REACH-1 from the reach
solenoid.
This test turns the reach solenoid ON and OFF, 3. Connect a digital ammeter in series with
verifying its correct operation electrically. the reach solenoid coil, positive lead (+) to
the wire removed and the negative lead (–)
A successful test proves that the reach solenoid to terminal REACH-1 on the solenoid.
coil, wiring, and related circuitry in the vehicle 4. Reconnect the battery connector and turn the
manager are functioning correctly. key switch ON.
It does not prove that the reach solenoid valve is 5. Run Test O06 and toggle the solenoid coil
functioning properly mechanically. ON. Use the ENTER button to toggle the
test ON and OFF. The operator display
NOTE: If the horn does not work and the truck shows ON or OFF. The ammeter must read
will not lower, test the B+K2 circuit for approx. 560 milliamps.
battery positive before running this test.
a. If the ammeter reading is correct, the
solenoid coil is functioning properly
Run Test electrically.
NOTE: For information on how to use b. If the solenoid is not working properly,
maintenance mode, see “Using Service check for a mechanical problem in the
Mode” on page 6-17. valve, such as binding or
contamination.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC18 JPF2-8 JPC18-12 Approx. Step 2 Troubleshoot
and JPF2. 41 ohms coil and wires.
Meter - Resistance.
2. Meter - DC voltage. JPF2-8 TP4 B+ Replace VM. Troubleshoot K2
circuit.
1026304B, 15 July 2007 6-189
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test O07 – Toggle the Tilt Solenoid Digital Output Tests
Test O07 – Toggle the Tilt 1. Turn the key switch OFF and disconnect
the battery connector.
Solenoid 2. Disconnect wire TILT-1 from the tilt
solenoid.
This test turns the tilt solenoid ON and OFF, 3. Connect a digital ammeter in series with
verifying its correct operation electrically. the tilt solenoid coil, positive lead (+) to the
wire removed and the negative lead (–) to
A successful test proves that the tilt solenoid terminal TILT-1 on the solenoid.
coil, wiring, and related circuitry in the vehicle 4. Reconnect the battery connector and turn the
manager are functioning correctly. key switch ON.
It does not prove that the tilt solenoid valve is 5. Run Test O07 and toggle the solenoid coil
functioning properly mechanically. ON. Use the ENTER button to toggle the
test ON and OFF. The operator display
NOTE: If the horn does not work and the truck shows ON or OFF. The ammeter must read
will not lower, test the B+K2 circuit for approx. 560 milliamps.
battery positive before running this test.
a. If the ammeter reading is correct, the
solenoid coil is functioning properly
Run Test electrically.
NOTE: For information on how to use b. If the solenoid is not working properly,
maintenance mode, see “Using Service check for a mechanical problem in the
Mode” on page 6-17. valve, such as binding or
contamination.
NOTE: This test is available only if the tilt
option is configured for the lift truck.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC18 JPF2-8 JPC18-15 Approx. Step 2 Troubleshoot
and JPF2. 41 ohms coil and wires.
Meter - Resistance.
2. Meter - DC voltage. JPF2-8 TP4 B+ Replace VM. Troubleshoot K2
circuit.
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Digital Output Tests Test O08 – Toggle the Sideshift Solenoid
Test O08 – Toggle the 1. Turn the key switch OFF and disconnect
the battery connector.
Sideshift Solenoid 2. Disconnect wire SIDESHIFT-1 from the
sideshift solenoid.
This test turns the sideshift solenoid ON and 3. Connect a digital ammeter in series with
OFF, verifying its correct operation electrically. the sideshift solenoid coil, positive lead (+)
to the wire removed and the negative lead
A successful test proves that the sideshift (–) to terminal SIDESHIFT-1 on the
solenoid coil, wiring, and related circuitry in the solenoid.
vehicle manager are functioning correctly. 4. Reconnect the battery connector and turn the
key switch ON.
It does not prove that the sideshift solenoid
valve is functioning properly mechanically. 5. Run Test O08 and toggle the solenoid coil
ON. Use the ENTER button to toggle the
NOTE: If the horn does not work and the truck test ON and OFF. The operator display
will not lower, test the B+K2 circuit for shows ON or OFF. The ammeter must read
battery positive before running this test. approx. 560 milliamps.
a. If the ammeter reading is correct, the
Run Test solenoid coil is functioning properly
electrically.
NOTE: For information on how to use
maintenance mode, see “Using Service b. If the solenoid is not working properly,
Mode” on page 6-17. check for a mechanical problem in the
valve, such as binding or
NOTE: This test is available only if the sideshift
contamination.
option is configured for the lift truck.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC18 JPF2-8 JPC18-14 Approx. Step 2 Troubleshoot
and JPF2. 41 ohms coil and wires.
Meter - Resistance.
2. Meter - DC voltage. JPF2-8 TP4 B+ Replace VM. Troubleshoot K2
circuit.
1026304B, 15 July 2007 6-191
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test O09 – Aux Dump (SOL3)/ Main Relief Dump (SOL8) Current Digital Output Tests
Test O09 – Aux Dump
(SOL3)/ Main Relief
Dump (SOL8) Current
See Test A33 – Aux Dump (SOL3)/Main Relief
Dump (SOL8) Current (Page 6-143).
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Digital Output Tests Test O11 – Toggle the Load Hold (SOL1) Solenoid
Test O11 – Toggle the 1. Turn the key switch OFF and disconnect
the battery connector.
Load Hold (SOL1) 2. Disconnect wire SOL1-1 from the load
hold solenoid.
Solenoid 3. Connect a digital ammeter in series with
the load hold solenoid coil, positive lead (+)
This test turns the load hold solenoid ON and to the wire removed and the negative
OFF, verifying its correct operation electrically. lead (–) to terminal SOL1-1 on the
solenoid.
A successful test proves that the load hold
4. Reconnect the battery connector and turn the
solenoid coil, wiring, and related circuitry in the
key switch ON.
vehicle manager are functioning correctly.
5. Run Test O11 and toggle the solenoid coil
It does not prove that the load hold solenoid ON. Use the ENTER button to toggle the
valve is functioning properly mechanically. test ON and OFF. The operator display
shows ON or OFF. The ammeter must read
NOTE: If the horn does not work and the truck approx. 800 milliamps.
will not lower, test the B+K2 circuit for
battery positive before running this test. a. If the ammeter reading is correct, the
solenoid coil is functioning properly
electrically.
Run Test
b. If the solenoid is not working properly,
NOTE: For information on how to use check for a mechanical problem in the
maintenance mode, see “Using Service valve, such as binding or
Mode” on page 6-17. contamination.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPC18 JPF2-5 JPC18-10 Approx. Step 2 Troubleshoot
and JPF2. 30 ohms coil and wires.
Meter - Resistance.
2. Meter - DC voltage. JPF2-5 TP4 B+ Replace VM. Troubleshoot K2
circuit.
1026304B, 15 July 2007 6-193
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test O12 – Ramp the Proportional Lower (SOL2) Solenoid Digital Output Tests
Test O12 – Ramp the
Proportional Lower
(SOL2) Solenoid
See Test A34 – Solenoid 2 (Lift/Lower) Current
(Page 6-144).
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Digital Output Tests Test O18 – Toggle the Horn
Test O18 – Toggle the Run Test
Horn NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
This test turns the truck’s horn ON and OFF.
1. Run this test in Active Service Mode while
NOTE: If the horn does not work and the truck taking readings,
will not lower, test the B+K2 circuit for
2. Use the ENTER button to toggle the test
battery positive before running this test.
ON and OFF. The operator display shows
ON or OFF.
3. When the ENTER key is pressed the horn
must sound. If it does not sound, then this
test is a failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. H2 TP4 B+ Step 2 Troubleshoot
wires and
Relay/Control
Fuse Panel.
2. Meter - DC voltage. TP1 H1 B+ Replace horn. Step 3
3. Meter - DC voltage. TP1 JPC18-16 B+ Trouble wires to Replace VM.
horn.
1026304B, 15 July 2007 6-195
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test O19 – Audible Alarm Digital Output Tests
Test O19 – Audible Run Test
Alarm NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
This test turns on the operator display alarm by
gradually increasing the PWM voltage. If the sonalert does not sound when you
depress the ENTER button, then this test is a
failure.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. JPD3-1 JPD3-2 Test ON: Step 2 Replace
approx. 10V for Operator
1 second Display card.
Test OFF: 0V
2. Meter - DC voltage. Sounder Sounder Replace Troubleshoot
B1 B2 sounder. wiring to
sounder.
6-196 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Output Tests Test O20 – Travel Alarm Test
Test O20 – Travel Alarm Run Test
Test NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
NOTE: Only with Travel Alarm option
Use the ENTER button to toggle the test ON and
This test toggles the travel alarm ON and OFF. OFF. The operator display shows ON or OFF.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. H2+ H2- Approx. B+ Replace travel Step 2
alarm.
2. Meter - DC voltage. H2+ TP4 B+ Step 3 Troubleshoot
FU9 and wiring.
3. Meter - DC voltage. TP1 JPC18-18 B+ Troubleshoot Replace VM.
wiring to horn.
1026304B, 15 July 2007 6-197
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test O23 – Toggle Fans Digital Output Tests
Test O23 – Toggle Fans Use the TILT UP/DOWN buttons to toggle the
test ON and OFF. The operator display shows
ON or OFF.
This test toggles the power amplifier fans and
motor compartment cooling fans ON and OFF. NOTE: Upon exiting this test, the power
amplifier fans will remain in the ON or
NOTE: If the horn does not work and the truck OFF state last chosen, until the
will not lower, test the B+KA circuit for technician exits Program Mode. This
battery positive before running this test. permits running Test O23 in
conjunction with Test A27.
Run Test
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Meter - DC voltage. TP1 JPC18-17 OFF: 0V Step 2 Replace VM.
ON: B+
2. Meter - DC voltage. JPF2-3 TP4 B+ Troubleshoot Troubleshoot K2
wires and fans. circuitry.
6-198 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Output Tests Test O25 – Toggle the 2d Pump (SOL4) Solenoid
Test O25 – Toggle the 2d 1. Turn the key switch OFF and disconnect
the battery connector.
Pump (SOL4) Solenoid 2. Disconnect wire SOL4-1 from the 2d Pump
solenoid.
NOTE: Only with Series BA/EA (DC dual pump 3. Connect a digital ammeter in series with
lift) the 2d Pump solenoid coil, positive lead (+)
to the wire removed and the negative
This test turns the 2d Pump solenoid ON and lead (–) to terminal SOL4-1 on the
OFF, verifying its correct operation electrically. solenoid.
4. Reconnect the battery connector and turn the
A successful test proves that the 2d Pump
key switch ON.
solenoid coil, wiring, and related circuitry in the
vehicle manager are functioning correctly. 5. Run Test O25 and toggle the solenoid coil
ON. Use the ENTER button to toggle the
It does not prove that the 2d Pump solenoid test ON and OFF. The operator display
valve is functioning properly mechanically. shows ON or OFF. The ammeter must read
650 to 900 milliamps.
NOTE: If the horn does not work and the truck
will not lower, test the B+KA circuit for a. If the ammeter reading is correct, the
battery positive before running this test. solenoid coil is functioning properly
electrically.
Run Test b. If the solenoid is not working properly,
check for a mechanical problem in the
NOTE: For information on how to use valve, such as binding or
maintenance mode, see “Using Service contamination.
Mode” on page 6-17.
Diagnosis and Repair Table
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-9.
Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
1. Disconnect JPF2 JPF2-5 JPC18-1 40 ohms Step 2 Troubleshoot
and JPC18. solenoid coil and
Meter - Resistance. wiring.
2. Meter - DC voltage. JPC18-1 B– B+ Replace VM. Troubleshoot K2
relay circuit.
1026304B, 15 July 2007 6-199
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test O28 – Ramp the Lift Power Amplifier Digital Output Tests
Test O28 – Ramp the Lift Diagnosis and Repair
Power Amplifier
NOTE: Series CA/FA (AC lift) Use correct electrostatic discharge
precautions. See “Static Precautions” on
This test turns on the lift power amplifier by page 2-9.
gradually increasing the command to it through
the CAN bus. This test verifies that the lift 1. If the RPM request on the display changes
power amplifier can generate current. and the amperage and RPM on the display
does not, replace the lift power amplifier.
See “Power Amplifier, Lift Series CA/FA
(AC lift)” on page 7-110.
Prolonged application of the current to
2. If the RPM request on the display is
the motor without movement will cause
greater than zero and the amperage on the
damage to the motor.
display ramps up, but the motor does not
turn, troubleshoot the motor, associated
wiring and pump. Check also for
mechanical binding in the mast.
The lift motor might rotate during this
test. Jack the drive wheels up and make
sure truck is in an area with sufficient
overhead clearance for lifting the mast.
Run Test
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
The Operator Display first shows the current
RPM request.
Use the tilt down button to increase the RPM
request by 25 RPM increments, from a
minimum of 775 RPM to a maximum of
1500 RPM.
Once the maximum RPM request is reached,
pressing tilt down again resets the request to
775. To prevent lift pump damage due to very
low RPM, the minimum lift motor speed request
is 775 RPM. Tilt up resets the request to 0.
Use the horn button to stop the motor, reset the
RPM request to 0, de-energize the lift contactor,
and prompt for quitting the test. Press the horn
button a second time to exit the test. If instead,
you press tilt up, tilt down, sideshift left, or
sideshift right, the test is still active with the
request set to 0.
6-200 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Output Tests Test O29 – Ramp the Traction Power Amplifier
Test O29 – Ramp the Diagnosis and Repair
Traction Power Amplifier
Use correct electrostatic discharge
This test turns on the traction power amplifier
precautions. See “Static Precautions” on
by gradually increasing the command to it
page 2-9.
through the CAN bus. This test verifies that the
traction power amplifier can generate current.
1. If the RPM request on the display changes
and the amperage and RPM on the display
does not, replace the power amplifier. See
Prolonged application of the current to “Power Amplifier, Traction” on page 7-110.
the motor without movement will cause 2. If the RPM request on the display is
damage to the motor. greater than zero and the amperage on the
display ramps up but the motor does not
turn, troubleshoot the motor, associated
wiring, drive unit, and brake assembly.
The traction motor might rotate during
this test. Jack the drive wheels up or
allow sufficient room for maneuvering.
Run Test
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
NOTE: The deadman pedal must be depressed
for the brake to release.
The Operator Display first shows the current
RPM request.
Use the tilt down button to increase the RPM
request by 25 RPM increments, from a
minimum of 25 RPM to a maximum of 750
RPM.
Once the maximum RPM request is reached,
pressing tilt down again resets the request to 0.
Tilt up also resets the request to 0.
Use the horn button to stop the motor, reset the
RPM request to 0, and prompt for quitting the
test. Press the horn button a second time to exit
the test. If instead, you press tilt up, tilt down,
sideshift left, or sideshift right, the test is still
active with the request set to 0.
1026304B, 15 July 2007 6-201
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Test O30 – Toggle the Brake Coil Digital Output Tests
Test O30 – Toggle the
Brake Coil
This test activates the brake coil.
Run Test
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
Step on the deadman pedal.
Press the ENTER button to toggle the test.
You should see:
Table 6-41.
Test Status Brake Status
Test ON Brake Released)
Test OFF Brake Applied
If results do not match the preceding table, the
test is a failure.
6-202 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Output Tests Test O32 – Toggle Relays K1, K2, K3, and K4
Test O32 – Toggle Relays
K1, K2, K3, and K4
This test toggles the relays on and off.
Run Test
NOTE: For information on how to use
maintenance mode, see “Using Service
Mode” on page 6-17.
Press the ENTER button to toggle the test.
You should see:
Table 6-42.
Test Status Relay Status
ON Tips closed
OFF Tips open
If results do not match the preceding table, the
test is a failure.
1026304B, 15 July 2007 6-203
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Loop Back Tests Digital Output Tests
Loop Back Tests
The Loop Back Test (LBT) feature is standard on
the Model 7400/7420/7440 Reach-Fork ®
Truck. This feature allows you to toggle inputs
and monitor their respective values on the
Operator Display.
Access this feature via the Superword level. It is
nested inside the Service submenu.
Upon entering the Loop Back Test, the screen
will show the status of the LBT (defaults to
Disabled) and the first three entries. You can
scroll through the list, locating the test of
interest.
The layout for the tests is very similar to the
standard Analog and Digital Input tests. The
major difference is that the LBT references a
connector on the Vehicle Manager. Disconnect
this connector from the Vehicle Manager prior
to enabling the LBT function. Then observe the
reading indicated in Table 6-43 under “Disabled
Value”. Next, apply the LBT voltage by pressing
the Enter key on the display keypad. The status
of the LBT will read “LOOP BACK ENABLED”.
Observe the reading in Table 6-43 column
“Enabled Value” for the particular test.
NOTE: When testing any of the entries where
JPC-22 is to be disconnected, the truck
will restart after LBT is toggled from
Enabled to Disabled. The reason for this
is that the EPO is wired to JPC-22.
Toggling the input simulates the EPO
engaged then disengaged, thus
restarting the vehicle.
If any loop back test fails, replace the Vehicle
Manager.
When exiting the LBT, the truck will restart
when the Service submenu is exited.
6-204 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Digital Output Tests Loop Back Tests
Table 6-43. Loop Back Tests
Test Connector Disabled Value Enabled Value
Test A04 – Primary Throttle Potentiometer (VR1) Voltage JPC-12 0.00 5.0V ±0.2V
(Page 6-122)
Test A05 – Lift/Lower Potentiometer Voltage JPC-12 0.00 5.00V ±0.2V
(Page 6-123)
Test A13 – Pressure Sensor Voltage (Page 6-130) JPC-24 0.00 5.00V ±0.2V
Test A15 – Battery Voltage (Page 6-132) JPC-24 0.00 35.00 V ±2V
Test A28 – Deadman Inductive Sensor (VR4) JPC-24 0.00 5.00 V ±0.2V
(Page 6-138)
Test A29 – Secondary Throttle Potentiometer (VR3) JPC-04 0.00 5.00 V ±0.2V
Voltage (Page 6-139)
Test A36 – Ambient Temperature Sensor (Page 6-146) JPC-24 400 to 460°F/ 44°F/6°C
204 to 238°C ±10°F/6°C
Test A37 – Steer Power Amplifier Current (Page 6-147) JPC-6 550A ±20A 100A ±10A
Test A41 – Emergency Power Off (EPO) Switch JPC-22 Down Up
(Page 6-150)
Test I00 – Deadman Switch (S2) (Page 6-152) JPC-22 Up Down
Test I01 – Nested Switch (S14) (Page 6-153) JPC-22 Out In
Test I02 – First Speed Limiting Switch (S12) JPC-22 Above Below
(Page 6-154)
Test I06 – Reach Switch (S4) (Page 6-156) JPC-12 Out In
Test I07 – Retract Switch (S5) (Page 6-157) JPC-12 Out In
Test I08 – Tilt Up Switch (S6) (Page 6-158) JPC-12 Out In
Test I09 – Tilt Down Switch (S7) (Page 6-159) JPC-12 Out In
Test I10 – Sideshift Right Switch (S9) (Page 6-160) JPC-12 Out In
Test I11 – Sideshift Left Switch (S8) (Page 6-161) JPC-12 Out In
Test I14 – Steering Fuse (FU1) (Page 6-162) JPC-22 Blown OK
Test I15 – Horn Switch (S3) (Page 6-163) JPC-12 Out In
Test I24 – Steer Feedback Proximity Sensor (Page 6-167) JPC-22 Off On
Test I27 – Secondary Horn Switch (S10) (Page 6-170) JPC-04 Out In
Test I33 – Steer Tiller Encoder 1 Connect Detect JPC-10 No Yes
(Page 6-171)
Test I34 – Steer Tiller Encoder 2 Connect Detect JPC-10 No Yes
(Page 6-172)
Test I35 – Steer Tiller Encoder 1 (Channel A & B) JPC-22 High Low
(Page 6-173)
1026304B, 15 July 2007 6-205
Section 6. Electrical Tests Model 7400/7420/7440 Reach-Fork ® Truck
Loop Back Tests Digital Output Tests
Table 6-43. Loop Back Tests
Test I36 – Steer Tiller Encoder 2 (Channel A & B) JPC-22 High Low
(Page 6-174)
Test I39 – Neutral Pulses (Page 6-175) JPC-6 On Off
Test I60 – Security Start Switch (S23) (option) JPC-10 Out In
(Page 6-177)
6-206 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Section 7. Component Procedures
1026304B, 15 July 2007 7-1
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Component Locator Photos. . . . . 7-7
Steering and Controls . . . . . . . . 7-39
Mast and Standard Reach Carriage . . . . . . 7-7
Tractor, AC Lift, Fore-Aft Stance . . . . . . . . 7-8 Steering and Controls Component Procedures
Tractor, DC Lift, Side Stance . . . . . . . . . . 7-15 Summary . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Mast with Standard Reach Carriage . . . . 7-20 EPO Switch . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Underside Components . . . . . . . . . . . . . . 7-21 Operator Display . . . . . . . . . . . . . . . . . . . . 7-40
Hydraulic Steering Motor
Covers and Finish. . . . . . . . . . . 7-23 Series AA/BA/DA/EA (DC lift) . . . . . . . . 7-40
Steer Contactor . . . . . . . . . . . . . . . . . . . . . 7-41
Cover Removal Sequence . . . . . . . . . . . . 7-24
Steer Motor, Electric
Covers Component Procedures Summary 7-24
Series CA/FA (AC lift) . . . . . . . . . . . . . . . 7-41
Cover, Control Handle, Primary . . . . . . . . 7-24
Steer Power Amplifier
Cover, Control Handle, Secondary . . . . . . 7-24
Series CA/FA (AC lift) . . . . . . . . . . . . . . . 7-41
Cover, Control Handle, Filler . . . . . . . . . . 7-25
Steering Orbitrol
Cover, Left Front . . . . . . . . . . . . . . . . . . . 7-25
Series AA/BA/DA/EA (DC lift) . . . . . . . . 7-42
Cover, Right Front . . . . . . . . . . . . . . . . . . 7-25
Steering Wheel . . . . . . . . . . . . . . . . . . . . . 7-42
Cover, Right Side . . . . . . . . . . . . . . . . . . . 7-25
Steering Encoder . . . . . . . . . . . . . . . . . . . 7-43
Cover, Steering . . . . . . . . . . . . . . . . . . . . 7-25
Steer Limit Switch (S11) . . . . . . . . . . . . . . 7-44
Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Steerable Caster . . . . . . . . . . . . . . . . . . . . 7-45
Cover Drawings, All Series . . . . . . . . . . . 7-27
Steering Linkage . . . . . . . . . . . . . . . . . . . 7-48
Cover Drawings,
Control Handle . . . . . . . . . . . . . . . . . . . . . 7-49
Series AA/BA/CA (Fore-Aft Stance) . . . . 7-28
Cover Drawings, Drive and Brake . . . . . . . . . . . . 7-75
Series DA/EA/FA (Side Stance) . . . . . . 7-31
Decals and Plates . . . . . . . . . . . . . . . . . . 7-33 Drive and Brake Component Procedures
Summary . . . . . . . . . . . . . . . . . . . . . . . . 7-76
Deadman Pedal Assembly . . . . . . . . . . . . . 7-76
Deadman Sensor VR4 . . . . . . . . . . . . . . . . 7-76
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Drive Wheel and Tire . . . . . . . . . . . . . . . . . 7-78
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Brake, Electric . . . . . . . . . . . . . . . . . . . . . 7-95
Deadman Switch (S2) . . . . . . . . . . . . . . . 7-102
Inertial Dampener . . . . . . . . . . . . . . . . . 7-103
7-2 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Electrical Components . . . . . . 7-107 Hydraulic Components . . . . . . . . . . . . . 7-129
Electrical Component Procedures Hydraulic Component Procedures
Summary . . . . . . . . . . . . . . . . . . . . . . 7-108 Summary . . . . . . . . . . . . . . . . . . . . . . . 7-130
Auxiliary Motor Auxiliary Pump
Series AA/BA/DA/EA (DC lift) . . . . . . . 7-108 Series AA/BA/DA/EA (DC lift). . . . . . . . 7-130
Battery Gate Inspection . . . . . . . . . . . . . 7-108 Counterbalance Valve CB-1 and CB-2
Battery Rollers, Inspection . . . . . . . . . . . 7-108 Deep-Reach. . . . . . . . . . . . . . . . . . . . . . 7-130
Fan, Tractor Compartment Cooling (FAN-FW) Valve CE1 Series AA/BA/DA/EA (DC lift) 7-130
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109 Clogged Filter Switch CFS-1 . . . . . . . . . . 7-130
Fan, Lift Motor (FAN-LM) . . . . . . . . . . . . 7-109 Check Valve CV-1 . . . . . . . . . . . . . . . . . . 7-130
Fan, Drive Motor (FAN-DU). . . . . . . . . . . 7-109 Check Valve CV-2
Fan, Traction Power Amplifier (FAN-2) . . 7-109 Series AA/BA/DA/EA (DC lift). . . . . . . . 7-130
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109 Check Valve CV-3 Deep-Reach . . . . . . . . 7-130
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . 7-131
HTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109 Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . 7-131
Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . 7-109 Load Shuttle LS-1 . . . . . . . . . . . . . . . . . . 7-131
AC Motors . . . . . . . . . . . . . . . . . . . . . . . 7-109 Manifold, Main . . . . . . . . . . . . . . . . . . . . 7-132
DC Motors . . . . . . . . . . . . . . . . . . . . . . . 7-109 Priority-on-Demand Valve POD-1. . . . . . . 7-132
Power Amplifier, Lift Pressure Switch, HTI . . . . . . . . . . . . . . . . 7-132
Series CA/FA (AC lift). . . . . . . . . . . . . . 7-110 Pressure Transducer CYL-P . . . . . . . . . . . 7-132
Power Amplifier, Traction . . . . . . . . . . . . 7-110 Relief Valve REL-1
Relays, Relay/Control Fuse Panel. . . . . . 7-111 Series AA/BA/DA/EA (DC lift). . . . . . . . 7-132
Static Strap . . . . . . . . . . . . . . . . . . . . . . 7-111 Relief Valve REL-2 Series CA/FA (AC lift) . 7-132
Series CA/FA (AC lift) . . . . . . . . . . . . . . . 7-111 Relief Valve REL-3 Deep-Reach only . . . . 7-132
Series CA/FA (AC lift) . . . . . . . . . . . . . . . 7-111 Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . 7-133
Switch S18 (HTI pressure) . . . . . . . . . . . 7-111 Hydraulic System Bleeding . . . . . . . . . . . 7-134
Switch S19 (Clogged Filter) . . . . . . . . . . . 7-112 Hydraulic Filter . . . . . . . . . . . . . . . . . . . 7-135
Temperature Sensor, Ambient (T) . . . . . . 7-112 Lift Pressure Adjustment . . . . . . . . . . . . 7-137
Temperature Sensor, DC Lift Motor . . . . 7-112 Manual Lowering of Fork Carriage . . . . . 7-138
Travel Light . . . . . . . . . . . . . . . . . . . . . . 7-112 Proportional Valve Adjustment . . . . . . . . 7-139
Vehicle Manager. . . . . . . . . . . . . . . . . . . 7-112 Auxiliary Pressure Adjustment . . . . . . . . 7-140
Battery Procedures . . . . . . . . . . . . . . . . 7-113 Manifold, Main, AC Lift, Model 7400 . . . . 7-141
Wiring and Harness Connectors . . . . . . 7-116 Manifold, Main, AC Lift,
Contactor Panel . . . . . . . . . . . . . . . . . . . 7-121 Model 7420/7440 . . . . . . . . . . . . . . . . 7-143
Motors . . . . . . . . . . . . . . . . . . . . . . . . . 7-122 Manifold, Main, DC Lift, Model 7400 . . . . 7-145
Temperature .Sensor, AC Motor, LMT/TMT Manifold, Auxiliary (Single Reach) . . . . . . 7-147
(Danaher Motor) . . . . . . . . . . . . . . . . . 7-123 Manifold, Reach (Deep-Reach ®) . . . . . . . . 7-149
Speed Sensor, AC Motor (Danaher Motor) 7-124 Manifold, Tilt/Sideshift (Deep-Reach ®) . . . 7-151
Steer Manager . . . . . . . . . . . . . . . . . . . . 7-126 Manifold Solenoids, Fittings,
Cold Storage Conditioning . . . . . . . . . . . 7-127 and Attachments . . . . . . . . . . . . . . . . . 7-152
1026304B, 15 July 2007 7-3
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic Components, Mast, Chain, Hose, Cable . . . . 7-187
Cylinder. . . . . . . . . . . . . . . . . 7-155 Mast, Chain, Hose, Cable Component
Hydraulic Component (Cylinder) Procedures Procedures Summary . . . . . . . . . . . . . . 7-188
Summary . . . . . . . . . . . . . . . . . . . . . . .7-156 Baseleg . . . . . . . . . . . . . . . . . . . . . . . . . . 7-188
Cylinder, Main Lift . . . . . . . . . . . . . . . . . .7-156 Pulleys, Over-the-Mast . . . . . . . . . . . . . . 7-190
Cylinder, Main Lift, Lowering Cushion . . .7-156 Stops, Carriage . . . . . . . . . . . . . . . . . . . . 7-190
Cylinder, Sideshift . . . . . . . . . . . . . . . . . .7-156 Baseleg . . . . . . . . . . . . . . . . . . . . . . . . . 7-191
Lift Cylinder, Free Lift, Remove/Install . .7-157 Bearings, Reach Carriage . . . . . . . . . . . . 7-193
Lift Cylinder, Free Lift, Bearing Shimming, Mast Telescopics . . . 7-194
Exploded Parts Drawing . . . . . . . . . . . .7-161 Bow Pads . . . . . . . . . . . . . . . . . . . . . . . . 7-196
Lift Cylinder, Free Lift, Seal Repacking . .7-164 Carriage . . . . . . . . . . . . . . . . . . . . . . . . . 7-198
Lift Cylinder, Main, Remove/Install . . . . .7-167 Chain Anchors . . . . . . . . . . . . . . . . . . . . 7-201
Lift Cylinder, Main Lift, Chains . . . . . . . . . . . . . . . . . . . . . . . . . . 7-208
Exploded Parts Drawing . . . . . . . . . . . .7-172 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-213
Lift Cylinder, Main, Seal Repacking . . . . .7-174 Height Encoder Belt . . . . . . . . . . . . . . . . 7-214
Lift Cylinder Lowering Cushion . . . . . . . .7-176 Hose, Main Lift . . . . . . . . . . . . . . . . . . . . 7-219
Reach Cylinder . . . . . . . . . . . . . . . . . . . .7-179 Hose and Cable, Over-the-Mast . . . . . . . 7-220
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . .7-182 Cable, Over-the-Mast . . . . . . . . . . . . . . . 7-229
Flow Limiter, Main Lift . . . . . . . . . . . . . .7-184 Hose/Tubing, Free Lift Feed . . . . . . . . . . 7-234
Flow Limiter, Free Lift . . . . . . . . . . . . . . .7-185 Mast, Model 7400
(Complete Disassembly) . . . . . . . . . . . . 7-235
Mast, Model 7400 (Complete Assembly) . 7-239
Mast, Model 7420
(Complete Disassembly) . . . . . . . . . . . . 7-247
Mast, Model 7420 (Complete Assembly) . 7-252
Mast, Model 7440
(Complete Disassembly) . . . . . . . . . . . . 7-258
Mast, Model 7440 (Complete Assembly) . 7-262
7-4 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Software Configuration . . . . . 7-271 Options . . . . . . . . . . . . . . . . . 7-273
Options Component Procedures
Summary . . . . . . . . . . . . . . . . . . . . . . . 7-274
Operator Compartment Sensor System . . 7-275
Vantage Point . . . . . . . . . . . . . . . . . . . . . 7-294
1026304B, 15 July 2007 7-5
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
7-6 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Component Locator Photos Mast and Standard Reach Carriage
Component Locator Photos
Section 7. Component Procedures
Mast and Standard Reach Carriage
Main Lift
Chain
Overhead
Free Lift Guard
Cylinder &
Chain
Main Lift
Cylinder
Mast Guard
Operator
Manual
Lift Motor & Location
Power Amp
Fans
Load
Backrest
Battery
Reach
Fork Scissor
Carriage Mechanism
(integral
sideshift)
Battery
Load Baseleg
Gate
Wheel
Forks
76353_117G.jpg
Figure 7-1. Mast and Carriage, R45TT
1026304B, 15 July 2007 7-7
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Tractor, AC Lift, Fore-Aft Stance Component Locator Photos
Tractor, AC Lift, Fore-Aft Stance
Overhead
Guard
Warning Mast Guard
Decal (Mesh or
Glass)
Operator
Manual Primary
Pocket Control
(on Mast) Handle
Hydraulic
Fluid Filler
Cap
Spec Plate
(not visible)
Deadman
Pedal
Brake
Drive
Motor
Drive
Unit
Steer Caster
(not visible)
Drive
Wheel
7DSC_898a.jpg
Figure 7-2. Mast and Tractor, AC Lift, Fore-Aft Stance (Series CA shown)
7-8 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Component Locator Photos Tractor, AC Lift, Fore-Aft Stance
Operator
Display
Primary
Control
Handle
Main
Hydraulic
Manifold
Reservoir
Relay/
Control
Fuse Panel
Electric
Steer Vehicle
Motor Manager
Horn Contactor/
Fuse Panel
Brake Traction
Power
Amplifier
Drive
Motor
Spec Plate
(not visible)
Drive Unit
(not visible)
Deadman
Pedal
Tractor
Cooling
Fan
Steer Idler
(not visible)
Drive Wheel
7DSC_901a.jpg
Figure 7-3. Tractor, AC Lift, Fore-Aft Stance (Series CA shown)
1026304B, 15 July 2007 7-9
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Tractor, AC Lift, Fore-Aft Stance Component Locator Photos
Hydraulic
Reservoir
Sight
Glass
Horn
Electric
Steer
Motor
Brake
Drive
Motor
Drive
Unit
7DSC_908a.jpg
Figure 7-4. Motor Compartment, AC Lift, Fore-Aft Stance (Series CA shown)
7-10 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Component Locator Photos Tractor, AC Lift, Fore-Aft Stance
Optional
Primary Secondary
Control Control
Handle Handle
Vehicle
Manager
Contactor/
Fuse Panel
Traction
Spec Plate Power
Amplifier
Inertial
Dampener
Traction
Power ESD Jack
Amplifier
Cooling Fan
7DSC_911a.jpg
Figure 7-5. Electronics Compartment, AC Lift, Fore-Aft Stance (Series CA shown)
1026304B, 15 July 2007 7-11
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Tractor, AC Lift, Fore-Aft Stance Component Locator Photos
Key Switch
Relay/ Operator Emergency Lift Pump
Control Display Power Off
Fuse Panel Knob
Primary
Control
Handle
7DSC_920a.jpg
Figure 7-6. Tractor Deck, Operator View, AC Lift, Fore-Aft Stance (Series CA shown)
7-12 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Component Locator Photos Tractor, AC Lift, Fore-Aft Stance
Lift Power
Amplifier
Operator
Display
Lift Pump
Lift Motor
Emergency
Power Off
Knob
Steer Power
Amplifier
TP4
7DSC_939a.jpg
Figure 7-7. Tractor Deck, EPO, AC Lift, Fore-Aft Stance (Series CA shown)
1026304B, 15 July 2007 7-13
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Tractor, AC Lift, Fore-Aft Stance Component Locator Photos
Main Safety Lift Motor Operator Primary Optional
Decal Display Control Secondary
Handle Control Handle
Lift Power Hydraulic Main Steering
Amplifier Fluid Filler Manifold Wheel
Cap
7DSC_935a.jpg
Figure 7-8. Tractor Deck, Lift Power Amplifier, AC Lift, Fore-Aft Stance (Series CA shown)
7-14 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Component Locator Photos Tractor, DC Lift, Side Stance
Tractor, DC Lift, Side Stance
Overhead
Guard
Mast Guard
(Mesh or
Warning Decal Glass)
Primary
Control
Handle
Operator Manual
Pocket (on Mast)
Hydraulic Fluid
Filler Cap
Spec Plate
Deadman
Pedal
Brake
Drive
Motor
Drive
Unit Steer Caster
(not visible)
Drive
Wheel
7DSC_854a.JPG
Figure 7-9. Tractor, DC Lift, Side Stance (Series DA/EA)
1026304B, 15 July 2007 7-15
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Tractor, DC Lift, Side Stance Component Locator Photos
Emergency
Power Off
Button
Steering
Operator Wheel
Display
Relay/
Control
Main
Hydraulic Fuse Panel
Manifold
Fluid
Reservoir
Sight Glass
Steering
Orbitrol Vehicle
Manager
Aux
Motor/
Contactor
Pump
Fuse Panel
Horn
Traction
Brake Power
Amplifier
Drive Spec Plate
Motor
Traction
Power
Amplifier
Cooling Fan
Drive Deadman
Unit Pedal
Steer Idler
(not visible)
Drive Wheel Hydraulic
Steer Motor
7DSC_0837a.JPG
Figure 7-10. Tractor, DC Lift, Side Stance (Series DA/EA)
7-16 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Component Locator Photos Tractor, DC Lift, Side Stance
Steering
Wheel
Main
Hydraulic Fluid
Manifold
Fluid
Reservoir Sight
Reservoir
Glass
Steering
Orbitrol
Reservoir
Horn Aux Motor
Brake
Aux Pump
Drive
Motor
Hydraulic
Steer Motor
Drive
Unit
Motor
Compartment
Cooling Fan
7DSC_0843a.jpg
Figure 7-11. Motor Compartment, DC Lift, Side Stance (Series DA/EA)
1026304B, 15 July 2007 7-17
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Tractor, DC Lift, Side Stance Component Locator Photos
Relay/
Control
Fuse Panel
Vehicle
Manager
Contactor
Fuse Panel
Traction
Power
Amplifier
Traction
Power
Amplifier
Cooling Fan
ESD
Ground Jack
7DSC_848a.JPG
Figure 7-12. Electronics Compartment, DC Lift, Side Stance (Series DA/EA)
7-18 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Component Locator Photos Tractor, DC Lift, Side Stance
Lift Motor Emergency Lift Pump
Operator
Display Power Off
Knob
Main Control TP4
Hydraulic Steering
Fluid Filler Orbitrol Manifold Handle
Cap
7DSC_0866.JPG
Figure 7-13. Tractor Deck, DC Lift, Side Stance (Series DA shown)
1026304B, 15 July 2007 7-19
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast with Standard Reach Carriage Component Locator Photos
Mast with Standard Reach Carriage
Ambient
Temperature Free Lift
Sensor Cylinder
Chain
Anchor
Hose
Retainer/
Guide
Hose
Tensioning
Spring
Bleed Screw
Carriage
Stop
Aux
Manifold
Reach
Cylinder
Tilt Cylinder
7DSC_0873a.JPG
Figure 7-14. Standard Reach Carriage, Operator View (Mast Guard removed for clarity)
7-20 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Component Locator Photos Underside Components
Underside Components
Static
Strap
Steering
Linkage
A-frame
Steerable Drive Wheel
Caster
7P5180009.TIF
Figure 7-15. Underside Components
1026304B, 15 July 2007 7-21
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Underside Components Component Locator Photos
7-22 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Covers and Finish
Covers and Finish
Section 7. Component Procedures
1026304B, 15 July 2007 7-23
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Cover Removal Sequence Covers and Finish
Cover Removal
Sequence
Table 7-1. Cover Removal Sequence
Fore-Aft Stance Side Stance
Right Side Cover Right Side Cover
[Open the Motor Compartment Door] [16 in. battery compartment: remove mast guard]
Top Cover [Open the Motor Compartment Door]
Steering Wheel Cover Top Cover, Display
[Steering Wheel] [Control Handle]
Steering Cover Top Cover, Elbow
Secondary Control Handle Cover or Filler [Steering Wheel]
[Primary Control Handle] Steering Cover
Primary Control Handle Cover Left Front and Right Front Covers
Left Front and Right Front Covers
Covers Component
Procedures Summary
Table 7-2. Covers Component Procedures Summary
Procedure Thread-Locking
Component /Photo or Compound/ Helpful Hints
Drawing Torque Values
Cover, Control Drawing: N/A Series AA/BA/CA (Fore-Aft Stance):
Handle, Primary Series Gives access to:
AA/BA/CA • Lift pump
(Fore-Aft • Steer Manager
Stance):
Remove secondary control handle cover first,
page 7-28
then remove primary control handle. Use
5mm long Allen wrench to reach control
handle set screw from underside, battery
compartment.
Cover, Control Drawing: N/A Series AA/BA/CA (Fore-Aft Stance):
Handle, Series Gives access to:
Secondary AA/BA/CA • Secondary control handle harness
(Fore-Aft • Vehicle Manager mounting bolt
Stance):
Remove right side cover first.
page 7-28
7-24 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Covers and Finish Covers Component Procedures Summary
Table 7-2. Covers Component Procedures Summary
Procedure Thread-Locking
Component /Photo or Compound/ Helpful Hints
Drawing Torque Values
Cover, Control Drawing: N/A Series AA/BA/CA (Fore-Aft Stance):
Handle, Filler Series Gives access to:
AA/BA/CA • Vehicle Manager mounting bolt
(Fore-Aft Remove right side cover first.
Stance):
page 7-28
Cover, Left Front Drawing: N/A Series AA/BA/CA (Fore-Aft Stance):
page 7-27 Remove top cover first.
Series DA/EA/FA (Side Stance):
Remove top display cover first.
Cover, Right Drawing: N/A Series AA/BA/CA (Fore-Aft Stance):
Front page 7-27 Remove top cover and primary control
handle cover first.
Series DA/EA/FA (Side Stance):
Remove top elbow cover first.
Cover, Right Drawing: N/A All series:
Side Series Gives access to:
AA/BA/CA • Vehicle Manager
(Fore-Aft • Contactors
Stance):
• Power Fuses
page 7-28
• Traction Power Amplifier
• Traction Power Amplifier Fan
• Inertial Dampener
• Steerable Idler Adjustment
Series Series DA/EA/FA (Side Stance):
DA/EA/FA Also gives access to:
(Side Stance): • Relay/Control Fuse Panel
page 7-31
Cover, Steering Drawing: N/A Series AA/BA/CA (Fore-Aft Stance):
Series Gives access to:
AA/BA/CA • Steer Encoder
(Fore-Aft Remove top cover, steering wheel cover, and
Stance): steering wheel first.
page 7-29
Series DA/EA/FA (Side Stance):
Series Gives access to:
DA/EA/FA • Steering orbitrol
(Side Stance):
Remove top cover-display first.
page 7-32
1026304B, 15 July 2007 7-25
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Covers Component Procedures Summary Covers and Finish
Table 7-2. Covers Component Procedures Summary
Procedure Thread-Locking
Component /Photo or Compound/ Helpful Hints
Drawing Torque Values
Cover, Top Drawing: N/A Series AA/BA/CA (Fore-Aft Stance):
Series Gives access to:
AA/BA/CA • Relay/Control Fuse Panel
(Fore-Aft • Operator Display
Stance):
• Key Switch
page 7-30
• Lift Motor
• Lift Power Amplifier
• Main Hydraulic Manifold, Solenoids,
Pressure Switches and Transducer
• Hydraulic Reservoir
Open drive motor compartment door first.
Series Series DA/EA/FA (Side Stance):
DA/EA/FA Top Cover, Display
(Side Stance): Gives access to:
Top Cover, • Operator Display
Display: • Key Switch
page 7-32
• Lift Motor
• Lift Power Amplifier
• Main Hydraulic Manifold, Solenoids,
Pressure Switches and Transducer
• Hydraulic Reservoir
Remove control handle first.
Top Cover,
Top Cover, Elbow
Elbow:
Gives access to:
page 7-31
• Operator Display
• Lift Motor and Pump
• Steer Power Amplifier
Remove right side cover first, slide glass
mast guard up for more room.
Decals Drawings:
N/A
page 7-33
7-26 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Covers and Finish Cover Drawings, All Series
Cover Drawings, All Right Front Cover
Series
Left Front Cover
Fastener
location
Fastener 7R1008452_C2A.CGM
location Figure 7-18. Right Front Cover fastener
7R1011308_C1A.CGM
Figure 7-16. Left Front Cover
7R1011307_D1A.CGM
Figure 7-19. Right Front Cover
Fastener
location
7R1008452_C2B.CGM
Figure 7-17. Left Front Cover fastener
1026304B, 15 July 2007 7-27
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Cover Drawings, Series AA/BA/CA (Fore-Aft Stance) Covers and Finish
Cover Drawings, Secondary Control Handle Filler
Series AA/BA/CA
(Fore-Aft Stance)
Primary Control Handle Cover
Fastener
location
7R1011300_B1A.CGM
Figure 7-22. Secondary Control Handle Filler Cover
Removal,
Series AA/BA/CA (Fore-Aft Stance)
Fastener
location
Right Side Cover
7R1008452_C3G.CGM
Figure 7-20. Primary Control Handle Cover,
Series AA/BA/CA (Fore-Aft Stance)
Secondary Control Handle
Cover
Fastener
location
Fastener
locations
7R1011298_C1A.CGM
Figure 7-21. Secondary Control Handle Cover,
Series AA/BA/CA (Fore-Aft Stance)
Fastener
locations
7R1011299_C1A.CGM
Figure 7-23. Right Side Cover,
Series AA/BA/CA (Fore-Aft Stance)
7-28 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Covers and Finish Cover Drawings, Series AA/BA/CA (Fore-Aft Stance)
Steering Cover
Fastener
location
7R1008452_C3A.CGM
Figure 7-24. Steering Cover,
Series AA/BA/CA (Fore-Aft Stance)
7R1011302_B1A.CGM
Figure 7-25. Steering Cover,
Series AA/BA/CA (Fore-Aft Stance)
1026304B, 15 July 2007 7-29
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Cover Drawings, Series AA/BA/CA (Fore-Aft Stance) Covers and Finish
Top Cover
Fastener location
- see Figure 7-27
Fastener
location Figure 7-28. Top Cover,
7R1011825.CGM
7R1008452_C2C.CGM
Series AA/BA/CA (Fore-Aft Stance)
Figure 7-26. Top Cover,
Series AA/BA/CA (Fore-Aft Stance)
Underside fastener
location in motor
compartment
7R1008452_C3B.CGM
Figure 7-27. Top Cover fastener,
Series AA/BA/CA (Fore-Aft Stance)
7-30 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Covers and Finish Cover Drawings, Series DA/EA/FA (Side Stance)
Cover Drawings, Top Cover, Elbow
Series DA/EA/FA (Side
Stance)
Right Side Cover
Fastener
location
Fastener location
- underside
7R1014215_A.CGM
Figure 7-30. Top Cover, Elbow,
Series DA/EA/FA (Side Stance)
Fastener
location
7R1014218
Figure 7-29. Right Side Cover,
Series DA/EA/FA (Side Stance)
1026304B, 15 July 2007 7-31
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Cover Drawings, Series DA/EA/FA (Side Stance) Covers and Finish
Steering Cover
Top Cover, Display
Fastener
location
Underside
fastener location
Access underside fasteners
from motor compartment
7R1014221_B1a.CGM
7R1014221_B1b.CGM
Figure 7-32. Cover, Steering,
Series DA/EA/FA (Side Stance)
7R1014211_B2.CGM
7R1014211_B1.CGM
Figure 7-31. Top Cover, Display,
Series DA/EA/FA (Side Stance)
7-32 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Covers and Finish Decals and Plates
Decals and Plates
Table 7-3. Decal and Plate Location Chart
Decal and Specification Plate Locations
Identifier Description Location
1 Raymond Tractor frame, aft of battery compartment
(both sides)
2 AC Tractor frame, with respect to battery
compartment opening, aligned with front edge
and bottom of decal 5.8 inches above opening
(both sides)
3 EE Compliance (optional) Tractor frame, centered 5 inches above battery
opening (both sides), above battery warning
decal
4 Battery Warning Decal Tractor frame, centered 0.25 inch above
battery compartment opening (both sides)
5 Battery Connector Polarity Right side of tractor frame above battery
connector
6 Key Switch Key Switch
7 EPO Function EPO Knob
8 Primary Control Handle Functions Next to Primary Control Handle
9 Optional Secondary Control Handle Next to Secondary Control Handle
Functions
10 General Safety Decal Mast guard, bottom edge of decal 1.5 inches
above bottom of guard, left edge of decal
11.5 inches inside widest tractor dimension.
11 Specification Plate Front of operator compartment
12 Cold Storage Front of operator compartment, below spec
plate
13 Type E Specification Plate Front of operator compartment, below cold
storage decal
14 Torque Specs (motor, power amplifier, Front of operator compartment, under top
contactors) cover, centered on sloping deck
15 Patent Decal Inside of drive motor compartment door, above
and centered with ventilation slots
16 Lubrication Decal Inside of drive motor compartment door,
centered with ventilation slots, above patent
decal
17 Traction Motor Warning Decal Inside of drive motor compartment door,
centered with ventilation slots, above
lubrication decal
1026304B, 15 July 2007 7-33
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Decals and Plates Covers and Finish
Table 7-3. Decal and Plate Location Chart
Decal and Specification Plate Locations
Identifier Description Location
18 Hydraulic Filter Locator On reservoir, forward of filler cap
19 Mast Specification Plate Right side of mast, 2 inches above top of
baseleg
20 ISO 9001 Decal Centered on mast main frame (both sides),
61.7 inches above floor
21 Operating Instructions Centered on left mast upright under ISO9001
decal
22 Manual Replacement Centered at top of operator manual pocket
23 No Riding Centered on load backrest
24 Overhead Guard ASME conformance Inside left side of overhead guard
NOTE: Items in italics are safety decals.
7-34 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Covers and Finish Decals and Plates
Series AA/BA/CA (Fore-Aft Stance) Series DA/EA/FA (Side Stance)
7 8
7 6
9
2
2
3
3
4
4
1
1
10 10
14 14
17
17
16 11
16 11
15
15
12
12
13
13
7R1017410_A1.CGM
7R1010652_A1.CGM
7R1017410_A2.CGM
7R1010652_A2.CGM
Figure 7-33. Decal and Specification Plate Locations, Tractor
1026304B, 15 July 2007 7-35
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Decals and Plates Covers and Finish
24 (inside surface) 23
5 20
21
22
19
7R1017504_A1.CGM
Figure 7-34. Decal and Specification Plate Locations, Mast
7-36 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Covers and Finish Decals and Plates
10
17
23
71024303.eps R1017269.eps R1017233.eps R1017232.eps R1017362.eps R411_587.eps
Figure 7-35. Warning/Safety Decals
1026304B, 15 July 2007 7-37
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Decals and Plates Covers and Finish
7-38 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls
Steering and Controls
Section 7. Component Procedures
1026304B, 15 July 2007 7-39
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Steering and Controls Component Procedures Summary Steering and Controls
Steering and Controls
Component Procedures
Summary
Table 7-4. Steering and Controls Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Caster Assembly Procedure: See procedure.
page 7-45
Control Handle, Procedure: N/A
Fore-Aft Stance, page 7-49
Primary
Control Handle, Procedure: N/A
Fore-Aft Stance, page 7-70
Secondary
Control Handle, Procedure: N/A
Side Stance page 7-59
EPO Switch No P/N 990-536/6 ft. lb. Separate switch button from body by
(8.6 Nm) pushing in and twisting button.
Operator Drawing: N/A
Display Figure 3-2 on
page 3-6
Use correct electrostatic
discharge precautions. See
“Static Precautions” on page 2-9.
When changing Display Manager software,
make sure a matched VM/DM set of
software is installed. See “Matching Software
Versions” on page 7-272.
Scribe a witness mark around bracket to
locate it in the elongated holes.
Hydraulic Locator Spur Gear: Pressure fittings: 60 ft. lb. (81 Nm)
Steering Motor Photo: P/N 990-536/ Drain connection: 21 ft. lb. (28 Nm)
Series Figure 7-11 6.25 ft. lb. (8.5 Nm)
AA/BA/DA/EA on page 7-17 Motor Mounting bolts:
(DC lift) P/N 990-536/
55 ft. lb. (72 Nm)
Flange Mounting Bolts:
P/N 990-536/
75 ft. lb. (102 Nm)
7-40 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Steering and Controls Component Procedures Summary
Table 7-4. Steering and Controls Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Steer Contactor Locator
Photos:
Series CA/FA
(AC lift):
Figure 7-5 on
page 7-11
Series N/A
AA/BA/DA/
EA (DC lift):
Figure 7-12
on page 7-18
Drawings:
page 7-121
Steer Limit Adjustment Switch Bracket to Adjust the vertical gap between sensor and
Switch S11 Procedure: Drive Unit: sensing rail to 0.05 to 0.10 inch (1.3 to
Series CA/FA page 7-44 P/N 990-536/ 2.5 mm).
(AC lift) 9 ft. lb. (12 Nm)
Steer Motor, Locator Pinion gear set screw: Apply anti-seize compound (P/N 990-638) to
Electric Photo: P/N 1013829/ pinion gear. Orient pinion gear with teeth
Series CA/FA Figure 7-4 on 6 ft. lb. (8.6 Nm). toward gear box and shoulder toward the
(AC lift) page 7-10 Pinion gear mounting mounting bolt (see photo).
bolt: P/N 1013829/ Orient steer motor with encoder harness
21 ft. lb. (29 Nm). towards the operator compartment.
Motor mounting bolts:
P/N 1013829/ Pinion
Gear Gear Teeth
30 ft. lb. (42 Nm).
Flange mounting bolts: Mounting
P/N 990-536/ Bolt
95 ft. lb. (129 Nm).
Set Screw
Shoulder
7RCH07R009BW.JPG
Steer Power No N/A
Amplifier
Series CA/FA
(AC lift) Use correct electrostatic
discharge precautions. See
“Static Precautions” on page 2-9.
1026304B, 15 July 2007 7-41
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Steering and Controls Component Procedures Summary Steering and Controls
Table 7-4. Steering and Controls Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Steering Procedure: N/A
Encoder Series page 7-43
CA/FA (AC lift)
Use correct electrostatic
discharge precautions. See
“Static Precautions” on page 2-9.
Adjust snubber so steering wheel requires 5
to 7 in. lb. (0.5 to 0.7 Nm) force to turn.
Steering Linkage Setup and
adjustment
procedure
See procedure.
“Steerable
Caster” on
page 7-45
Steering Orbitrol Locator Mounting bolts: N/A
Series Photo: P/N 990-536/
AA/BA/DA/EA Figure 7-10 15 ft. lb. (21 Nm).
(DC lift) on page 7-16
Steering Wheel No Series CA/FA (AC lift): Series CA/FA (AC lift)
Mounting bolts: Series AA/BA/DA/EA (DC lift)
P/N 990-536/ Apply anti-seize compound (P/N 990-452) to
21 ft. lb. (29 Nm). shoulder bolt through knob.
Steering Knob Bolt:
P/N 990-536/
35 ft. lb. (47 Nm)
Series AA/BA/DA/EA
(DC lift): Mounting
bolts: P/N 990-536/
15 ft. lb. (21 Nm).
Steering Knob Bolt:
P/N 990-536/
35 ft. lb. (47 Nm)
7-42 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Steering Encoder
Steering Encoder 8. Remove three bolts holding the steering
encoder to the bracket.
NOTE: Series CA/FA (AC lift)
Fore-Aft Stance
Removal
1. Turn the key switch OFF and disconnect
the battery connector.
Snubber
Adjustment Nut
Use correct electrostatic discharge
precautions. See “Static Precautions” on
page 2-9.
76353_108G.JPG
Figure 7-36. Steer Encoder and Snubber
2. Remove the top cover and steering cover.
Reference “Top Cover” on page 7-30 and Installation
“Steering Cover” on page 7-29. (You must
remove the knob, steering wheel cover, 1. Route wiring harness of new encoder
and steering wheel before removing the through the hole in the bracket. Install
steering cover.) encoder to bracket with three bolts.
3. Remove the steering wheel cover. 2. Route encoder harness and install cable
a. Remove the plastic plug in the steering ties where previously removed. Connect
knob. Remove the shoulder bolt and harness connectors JPE1 and JPE2.
knob. 3. Assemble the snubber and tighten the jam
nut on the eyebolt so that the force
b. Remove the 2 bolts holding the steering
required to turn the steering wheel is 5 to
wheel cover to the steering wheel.
7 in. lb. (0.5 to 0.7 Nm).
4. Remove the 2 cap screws holding the
4. Apply thread-locking compound
steering wheel to the steering encoder.
(P/N 990-536) to the steering wheel
Remove the wheel.
cap screws.
5. Remove three screws holding the steering
5. Position the steering wheel over the
cover to the steering bracket. Remove the
steering encoder. Install cap screws.
cover.
6. Install the steering wheel cover.
6. Remove the snubber adjustment nut and
swing the halves of the snubber out of the a. Attach the steering wheel cover to the
way. See Figure 7-36. steering wheel with two bolts.
7. Disconnect encoder harness connectors b. Apply anti-seize compound
JPE1 and JPE2. Cut cable ties as needed. (P/N 990-452) to the shoulder bolt.
Install the steering knob.
7. Install the top cover.
1026304B, 15 July 2007 7-43
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Steer Limit Switch (S11) Steering and Controls
Steer Limit Switch (S11)
NOTE: Series CA/FA (AC lift)
Steer Limit Steer Motor
Switch
Sensing Rail
View is toward
motor compartment
door, drive motor
removed for clarity
7R1016524_A.CGM
Figure 7-37. Steer Limit Switch
Adjustment
1. Turn the key switch OFF and disconnect
the battery connector.
2. Open the drive motor compartment door.
3. Loosen the nuts securing the switch to the
bracket.
4. Adjust the vertical gap between the switch
and the sensing rail to 0.05 to 0.10 inch
(1.3 to 2.5 mm). Tighten the nuts.
7-44 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Steerable Caster
Steerable Caster device, remove the battery and battery
rollers from the lift truck to provide access
to adjustment bolts underneath.
Correct caster adjustment is critical for proper
3. Loosen the center steering link locking
performance. A misadjusted caster can cause
bolts. See Figure 7-39.
excessive braking distances, poor stability, or
damage to inertial dampener components.
Drive
C Caster
Initial Adjustment Wheel Wheel
B
1. The drive and caster wheels should be
parallel.
a. Place a straightedge along the tractor
frame. Measure the distance from the B
straightedge to the front edge of the C
drive tire and to the back edge. Adjust
steering until the measurements are
equal. The drive wheel is now parallel to
the tractor frame. See Figure 7-38. A
Steering Steering
Straightedge Drive Tire Link Link
Locking Adjusting
Bolts (4) Bolts (2)
E E
C 7R86758A.EPS
Figure 7-39. Steering Adjustments
4. Loosen jam nuts on center steering link
adjusting bolts and adjust the bolts to get
both wheels parallel to the tractor frame.
5. Apply thread-locking compound
(P/N 990-536) to steering link adjusting
C bolts and locking bolts.
6. Tighten the jam nuts on the adjusting
bolts.
7. Tighten locking bolts and torque to
70 ft. lb. (95 Nm).
A 7R86758A.EPS
8. Re-install the battery rollers. Using a
Figure 7-38. Setting Drive Wheel Parallel
suitable battery removing device, re-install
b. Place a straightedge along the opposite the lift truck battery. Re-install battery
side tractor frame. Measure the gates.
distance from the straightedge to the
front edge of the caster wheel and to the Caster height adjustment varies, depending
back edge. If the dimensions are not upon the type of mast. See “Caster Height
equal, adjust as follows. Adjustment” on page 7-46.
2. Turn the key switch OFF and disconnect
the battery connector. Remove battery
gates. Using a suitable battery removing
1026304B, 15 July 2007 7-45
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Steerable Caster Steering and Controls
Caster Height Adjustment
NOTE: Make sure a correctly rated battery is
installed in the lift truck prior to making
Use extreme caution whenever the lift
this adjustment.
truck is jacked up. Never block the lift
1. Remove the inertial dampener cover plate. truck between the telescopic and the
See Figure 7-40. floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
beneath vehicle while jacking the lift
truck. After the lift truck is jacked up,
place solid blocks or jack stands under it
for support. DO NOT rely on the jack
alone to support the lift truck. See
“Jacking Safety” on page 2-11.
Cover Plate
Initially Initially
1 in. 6 in.
(25 (152
77074_004.TIF
mm) mm)
Figure 7-40. Inertial Dampener Cover Plate
2. Check the A-frame down-travel
adjustment bolt in Figure 7-41. Make sure
it is installed correctly. If the bolt is
missing, the A-frame could drop and allow
the springs to escape when the truck is
jacked up. 7R86758B.EPS
Figure 7-42. A-frame Spring Adjustments
A-frame Spring Nuts 3. Jack the lift truck until the caster is clear
of the floor.
4. Turn the A-frame down-travel adjustment
bolt to obtain an initial gap of 1.0 inch
(25 mm) between the arm and frame.
Adjust the A-frame spring nuts to obtain
an initial spring length of 6.0 inches
(152 mm). See Figure 7-41 and
Figure 7-42.
A-frame
5. Lower the lift truck back onto the floor.
Down-Travel
Adjustment Bolt Make sure the lift truck is sitting on a flat
floor surface.
713Y7S001.TIF
6. Adjust the A-frame spring nuts to obtain
Figure 7-41. A-frame Down-Travel Adjustment Bolt the spring length in the table that follows.
The dimension is measured from the top of
the spring to the top of the caster, not the
frame.
7-46 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Steerable Caster
Elevated Height Spring Length Elevated
Gap
Height
Below 330 in. 5.75 in.
(8328 mm) (146 mm) Below 330 in. 0.38 in. (9.65 mm)
(8328 mm)
Above 331 in. 5.50 in.
(8407 mm) (140 mm) Above 331 in. 0.25 in. (6.35 mm)
(8407 mm)
7. Apply thread-locking compound
(P/N 990-536) and turn the A-frame 10. Apply thread-locking compound
down-travel adjustment bolt to set the (P/N 990-536) to the A-frame up-travel
correct gap between the bottom of the bolt stop bolt. Tighten the jam nut.
head and the top of the flat washer. See 11. Test the lift truck for correct braking
Figure 7-42 and the table below. action.
12. Reinstall the inertial dampener cover
Elevated Height Gap plate.
0.12 in.
All
(3.05 mm)
NOTE: Do not overtighten the bolt. The
bolt head should apply slight
pressure on the flat washer.
8. Loosen the jam nut on the A-frame
up-travel stop bolt. See Figure 7-43.
A-frame
Up-Travel
Stop Bolt
713Y7S001.TIF
Figure 7-43. A-frame Up-Travel Stop Adjustment
9. Turn the A-frame up-travel stop bolt to
adjust the gap between the bolt head and
the top of the A-frame as follows
(See Figure 7-43):
1026304B, 15 July 2007 7-47
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Steering Linkage Steering and Controls
Steering Linkage
Use Figure 7-44 as a reference when components. After replacing any components,
removing/replacing steering linkage make sure the steering is adjusted correctly.
Section BB
and
Section CC
D
C
B
B
C D
A A
Detail of
Section AA
E E
Section EE
Section AA
7R86758A.EPS R86758C.EPS R86758D.EPS R86758E.EPS R86758F.EPS
Figure 7-44. Steering Linkage
7-48 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Control Handle component are identified by “X’s” in the column
for that component.
Series AA/BA/CA (Fore-Aft Legend:
LP = Lift Pot
Stance) Primary Control Handle
LPS = Lift Pot Spring
If a ThermaKit component has failed in the TP = Travel Pot
primary control handle, replace both handle TPS = Travel Pot Spring
shells. In this case, it is more cost effective to
replace the entire handle than to rebuild it. FC = Flex Circuit (including pot heaters,
buttons, and tilt/sideshift card)
For all other components, Table 7-5 lists the
steps for a complete tear down and rebuild
procedure. Steps required for a specific single
Table 7-5. Control Handle Repair, Series AA/BA/CA, Primary Control Handle
Step
Procedure Step LP LPS TP TPS FC
No.
1 X X X X X
Control handles contain ESD-sensitive [arts. Use
correct electrostatic discharge precautions. See
“Static Precautions” on page 2-9.
2 Remove the lift knob’s nylon set screw. The nylon set screw X X X X X
has a slotted head, but the old style with the hex socket will
also fit this knob.
3 Loosen the steel set screw two turns. X X X X X
4 Slide the lift knob off the lift pot shaft. NOTE: The outer spring X X X X X
paddle might fall off when the lift knob is removed.
5 Remove five M5x10mm socket head cap screws (SHCS) from X X X X X
the handle shell.
6 Slide out the cable clamp. X X X X X
7 Remove one M5x40mm SHCS from the handle shell. X X X X X
8 Remove two machine screws holding the harness connector. X X X X X
1026304B, 15 July 2007 7-49
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Table 7-5. Control Handle Repair, Series AA/BA/CA, Primary Control Handle
Step
Procedure Step LP LPS TP TPS FC
No.
9 Carefully pull the flex circuit down the cable clamp slot. X X X X X
Flex Circuit
7HNDL_FA1.jpg
Figure 7-45. Flex Circuit in Cable Clamp Slot
10 Lift off the upper handle shell. If ThermaKit equipped, the X X X X X
upper shell can be removed but wiring will connect the two
halves.
11 Carefully peel the flex heater from the travel pot. It is attached X X X
to the pot with double-sided tape.
Travel Pot Heater Lift Pot
Travel Pot Connector
ThermaKit Connector Lift Pot Connector
7HNDL_FA2.jpg
Figure 7-46. Control Handle, Series AA/BA/CA
12 Press the latch on the travel pot connector and disconnect the X X X
travel pot from the flex circuit. See Figure 7-46.
Travel Pot
13 Slide the travel pot out of the travel shaft assembly. Note: Be X X
careful not to lose the D-shaped metal spring clip seated inside
the travel shaft. See Figure 7-47.
7-50 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Table 7-5. Control Handle Repair, Series AA/BA/CA, Primary Control Handle
Step
Procedure Step LP LPS TP TPS FC
No.
Travel Pot Spring
14 Remove the external snap ring. X
“D” Ring
Spring
Snap Ring
Pin
Paddle Paddle
7HNDL_FA3.jpg
Figure 7-47. Travel Pot Shaft Assembly
15 Note the orientation of travel spring, paddles, and travel shaft. X
Remove the travel pot spring and paddles from the travel shaft.
See Figure 7-47.
16 Apply a thin coat of lubricant P/N 990-635 to the inside X
surface of the spring. In your hand, assemble a new travel
spring between the spring paddles.
7HNDL_FA4.jpg
Figure 7-48. Travel Pot Spring, assembling
17 Slide the spring and paddles part way down the travel shaft to X
engage the lower spring tang.
18 Using the upper paddle, press the upper spring tang over the X
pin on the travel shaft. With one paddle and one spring tang on
each side of the pin, slide all parts down to expose the snap
ring groove. See Figure 7-48.
19 Install the external snap ring. See Figure 7-47. X
20 Confirm that the D-shaped metal clip is inside the travel shaft. X X
21 Slide a new travel pot into the travel shaft assembly. Skip the X
next step.
22 Slide the travel pot into the travel shaft assembly. X
1026304B, 15 July 2007 7-51
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Table 7-5. Control Handle Repair, Series AA/BA/CA, Primary Control Handle
Step
Procedure Step LP LPS TP TPS FC
No.
Lift Pot/Spring
23 Note orientation of lift pot spring, paddles, and dowel pin. Slide X
the outer spring paddle and lift pot spring off the lift pot
bracket.
Lift Pot Paddle (flush
with bracket
stem)
Lift Pot Shaft
Lift Pot
Connector Paddle Spring Dowel Pin
7HNDL_FA5.jpg
Figure 7-49. Lift Pot and Spring Assembly
24 If you are replacing the inner spring paddle, slide the old inner X
spring paddle off the lift pot bracket.
25 Slide the new inner spring paddle onto the lift pot bracket. X
26 Apply a thin coat of lubricant P/N 990-635 to the inside X
surface of the new lift spring. Install the spring with one tang
resting on the inner spring paddle (not the dowel pin).
27 Slide the outer spring paddle part way onto the lift pot bracket X
to engage the outer spring tang.
28 Using the outer paddle, press the outer spring tang over the X
dowel. Slide parts together until the outer paddle is flush with
the lift pot bracket. See Figure 7-49.
Lift Pot
29 Press the latch on the lift pot connector and disconnect the lift X X X
pot from the flex circuit. See Figure 7-49.
30 Carefully peel the flex heater from the lift pot. It is attached to X X
the pot with double-sided tape.
31 Pull the lift pot/bracket assembly out of the lower handle shell. X X
32 Slide the old lift pot out of the lift pot bracket. X
7-52 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Table 7-5. Control Handle Repair, Series AA/BA/CA, Primary Control Handle
Step
Procedure Step LP LPS TP TPS FC
No.
33 Slide the new lift pot into the lift pot bracket. The lift pot tang X
must slide into the slot on the lift pot bracket.
Pot Tang Slot in
Bracket
7HNDL_FA6.jpg
Figure 7-50. Lift Pot and Bracket
Flex Circuit Assembly (including pot heaters, reach/retract
and horn buttons, and tilt/sideshift card)
34 Press the latch on the ThermaKit connector and disconnect the X
ThermaKit (if so equipped) from the flex circuit.
ThermaKit Horn Reach/Retract
Connector Buttons Buttons
ThermaKit Tilt/Sideshift
Heaters Card
7HNDL_FA7.jpg
Figure 7-51. ThermaKit heaters and connector
35 Hold the tilt/sideshift button and card between thumb and X
forefinger. Tip the card back and remove from the lower handle
shell. The gasket on the tilt/sideshift button sometimes falls
off as you remove the tilt/sideshift card from the lower handle
shell.
36 Gently remove the lift pot connector from the slot in the lower X
handle shell.
1026304B, 15 July 2007 7-53
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Table 7-5. Control Handle Repair, Series AA/BA/CA, Primary Control Handle
Step
Procedure Step LP LPS TP TPS FC
No.
37 Remove the reach/retract buttons from the handle shell. X
38 Lift the horn button off the positioning pin. X
39 Gently remove the ThermaKit and travel pot connectors from X
the slots in the lower handle shell. See Figure 7-46.
40 Lift the flex circuit out of the lower handle shell. X
41 Remove the tilt/sideshift button and spring from the flex X
circuit by removing one screw from the back of the
tilt/sideshift card.
Orientation Letter ”A”
Tilt/Sideshift Circuit Card
Button
7HNDL_FA8.jpg
Figure 7-52. Tilt/Sideshift Card and Button
42 To install the tilt/sideshift button and spring on the X
tilt/sideshift card, place the spring over the post on the back of
the tilt/sideshift button. Align the “A” on the back of the
button with the “A” on the card. See Figure 7-52. Press the
button against the card so the post protrudes through the
back of the card. Thread the screw into the post until it just
bottoms, then tighten 1/8 turn additional. Do not overtighten.
43 Hold the new flex circuit over the lower handle shell and hang X
the reach/retract switches over their mounting ribs. The
switches do not have to been in their final position. The
switches are being used to position the flex circuit temporarily.
44 Slide the horn button over the positioning pin. X
45 Allow the tilt/sideshift knob/card, lift pot connector, and lift X
pot heater to hang outside the handle shell.
46 Press the ThermaKit and travel pot connectors into the slots in X
the lower handle shell. See Figure 7-46.
7-54 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Table 7-5. Control Handle Repair, Series AA/BA/CA, Primary Control Handle
Step
Procedure Step LP LPS TP TPS FC
No.
47 Place the gasket over the tilt/sideshift button. Using thumb X
and forefinger, gently position the tilt/sideshift card in the
handle shell. The bottom of the card sits forward of a ridge in
the handle; the card edge nearest the lift knob sits behind a
ridge in the handle. Confirm that the gasket is in place on the
tilt/sideshift button. See Figure 7-53.
Card Sits
Forward
of Ridge
Card Sits
Behind
Ridge
7HNDL_FA10.jpg
Figure 7-53. Tilt/Sideshift Card position
48 Move the reach/retract buttons into their final position on the X
ribs.
49 Route the harness connector end of the flex circuit through the X
locating slots.
Install Lift Pot
50 Make sure the tilt/sideshift card is correctly positioned. Slide X X
the lift pot/bracket assembly into the lower handle shell.
Slot in Shell
Tab on Pot
Bracket
7HNDL_FA11.jpg
Figure 7-54. Lift Pot Bracket position
51 Re-tape the lift pot flex heater to the pot body. Replace the X X
double-sided tape if necessary. Use a screwdriver blade to
press the heater against the pot body.
1026304B, 15 July 2007 7-55
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Table 7-5. Control Handle Repair, Series AA/BA/CA, Primary Control Handle
Step
Procedure Step LP LPS TP TPS FC
No.
52 Re-seat the lift pot flex connector in the handle shell. X X
Re-connect the lift pot to the flex circuit.
53 Re-connect the ThermaKit (if so equipped) to the flex circuit. X
54 Align the tang on the travel pot with the 2nd rib on the flex X
circuit side of the lower handle shell.
Tang
Rib
7HNDL_FA12.jpg
Figure 7-55. Travel Pot alignment in shell
Install Travel Pot
55 Re-tape the travel pot flex heater to the pot body. Replace the X X X
double-sided tape if necessary. See Figure 7-46.
56 Re-seat the travel pot flex connector in the handle shell. X X X
Re-connect the travel pot to the flex circuit. See Figure 7-46.
7-56 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Table 7-5. Control Handle Repair, Series AA/BA/CA, Primary Control Handle
Step
Procedure Step LP LPS TP TPS FC
No.
Assemble Handle
57 Confirm that the flex circuit is routed correctly through the X X X X X
locating slots.
58 Position the upper handle shell over the lower shell and ease it X X X X X
into position. See Figure 7-56. Make sure:
A: Travel pot tang is entering the slot in the shell.
B: Plastic alignment post on upper shell is entering the
alignment hole on the lower shell.
C: Travel shaft pin on upper shell is passing between the
paddles of the travel shaft assembly.
D: The reach/retract buttons are entering the holes in the
handle shell.
E: The backing ribs that hold the horn button in place are not
pinching the flex circuit.
F: The harness connector end of the flex circuit is entering the
cable clamp slot without pinching.
If the lift knob was not removed, rotate the knob slightly to
allow the upper handle shell to clear it. The upper handle shell
should mate with the lower shell with very little force.
F D D
A
A
C B
7HNDL_FA13.jpg
Figure 7-56. Control Handle assembly, Series AA/BA/CA
59 Squeeze the handle halves together. X X X X X
1026304B, 15 July 2007 7-57
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Table 7-5. Control Handle Repair, Series AA/BA/CA, Primary Control Handle
Step
Procedure Step LP LPS TP TPS FC
No.
60 Place the tip of a screwdriver into the travel shaft set screw X X X X X
hole. Gently rotate the shaft in both directions to confirm that
the pin in the upper handle shell is between the paddles. Do
not over-rotate the shaft, as this can cause plastic parts to
break. You should feel spring tension immediately and there
should be no free play in the travel shaft. If you do not feel
spring tension, lift off the upper handle shell, and repeat step
58.
61 Fasten the harness connector to the upper handle shell with X X X X X
two machine screws. Tighten each screw until it bottoms, then
1/16 turn additional. Do not overtighten.
62 Install four M5x10mm SHCS and one M5x40mm SHCS. X X X X X
Tighten each screw until it bottoms, then 1/4 turn additional
(8 to 12 in. lb.). Do not overtighten.
63 Slide the cable clamp into the cable clamp slot. Install one X X X X X
M5x10mm SHCS to fasten the cable clamp.
64 Confirm that the two spring paddles and spring are in place. X X X X X
The outer paddle must be flush with the end of the lift pot
bracket. See Figure 7-49.
65 Set the flat on the lift pot shaft 90 degrees to the top spring X X X X X
paddle.
Dowel Pin Paddles
7HNDL_FA14.jpg
Figure 7-57. Lift Pot shaft alignment
66 Slide the lift knob on, with the dowel pin in the knob is passing X X X X X
between the paddles.
67 Tighten the steel set screw until it bottoms, then 1/4 turn X X X X X
additional (4 to 6 in. lb.).
68 Install the nylon set screw. Run the nylon set screw down flush X X X X X
or below the surface of the knob.
7-58 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Series DA/EA/FA (Side Stance) Legend:
LP = Lift Pot
Control Handle
LPS = Lift Pot Spring
If a ThermaKit component has failed in the TP = Travel Pot
control handle, replace both handle shells. In
TPS = Travel Pot Spring
this case, it is more cost effective to replace the
entire handle than to rebuild it. FC = Flex Circuit (including pot heaters,
buttons, and tilt/sideshift card)
For all other components, Table 7-6 lists the
steps for a complete tear down and rebuild
procedure. Steps required for a specific single
component are identified by “X’s” in the column
for that component.
Table 7-6. Control Handle Repair, Series DA/EA/FA
Step
Procedure Step LP LPS TP TPS FC
No.
1 X X X X X
Control handles contain ESD-sensitive [arts. Use
correct electrostatic discharge precautions. See
“Static Precautions” on page 2-9.
2 Remove the lift knob’s nylon set screw. The nylon set screw X X X X X
has a slotted head, but the old style with the hex socket will
also fit this knob.
3 Loosen the steel set screw two turns. X X X X X
4 Slide the lift knob off the lift pot shaft. NOTE: The outer spring X X X X X
paddle might fall off when the lift knob is removed.
5 Remove six M5x10mm socket head cap screws (SHCS) from X X X X X
handle shell.
6 Lift off the upper handle shell. If ThermaKit equipped, the X X X X X
upper shell can be removed but wiring will connect the two
halves.
1026304B, 15 July 2007 7-59
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Table 7-6. Control Handle Repair, Series DA/EA/FA
Step
Procedure Step LP LPS TP TPS FC
No.
7 Remove harness connector and travel pot heater from lower X X X
shell.
Travel Pot Travel Pot Travel Pot
Spring Connector
Harness Travel Pot Travel Pot
Connector Heater Shaft
7HNDL_SS1.JPG
Figure 7-58. Travel Pot Shaft Components
8 Press the latch on the travel pot connector and disconnect the X X X
travel pot from the flex circuit. See Figure 7-58.
Travel Pot
9 Lift the travel pot shaft out of the lower handle shell. X X
10 Slide the travel pot out of the travel shaft assembly. Note: Be X X
careful not to lose the D-shaped metal spring clip seated inside
the travel shaft.
Travel Pot Spring
7-60 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Table 7-6. Control Handle Repair, Series DA/EA/FA
Step
Procedure Step LP LPS TP TPS FC
No.
11 Remove the external snap ring. X
Snap Ring
7HNDL_SS2.JPG
Figure 7-59. Travel Pot Spring, Paddles, and Snap Ring
12 Note the orientation of travel spring, paddles, and travel shaft. X
Remove the travel pot spring and paddles from the travel shaft.
See Figure 7-59.
13 Apply a thin coat of lubricant P/N 990-635 to the inside X
surface of the spring. In your hand, assemble a new travel
spring between the spring paddles.
14 Slide the spring and paddles part way down the travel shaft to X
engage the lower spring tang.
15 Using the upper paddle, press the upper spring tang over the X
pin on the travel shaft. With one paddle and one spring tang on
each side of the pin, slide all parts down to expose the snap
ring groove.
7HNDL_SS3.JPG
Figure 7-60. Installing Travel Pot Spring
16 Install the external snap ring. See Figure 7-59. X
17 Confirm that the D-shaped metal clip is inside the travel shaft. X X
18 Slide a new travel pot into the travel shaft assembly. Skip the X
next step.
19 Slide the travel pot into the travel shaft assembly. X
1026304B, 15 July 2007 7-61
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Table 7-6. Control Handle Repair, Series DA/EA/FA
Step
Procedure Step LP LPS TP TPS FC
No.
20 Insert the travel shaft assembly into the lower handle shell. X X
Make sure the tang on the travel pot enters the center slot in
the shell. See Figure 7-61.
Tang
Slot
7HNDL_SS4.JPG
Figure 7-61. Travel Pot Tang alignment
Lift Pot
21 Press the latch on the lift pot connector and disconnect the lift X X X
pot from the flex circuit. Lift the wires past the reach/retract
buttons.
Flex Reach/Retract Horn Button Lift Pot
Circuit Buttons
Lift Pot ThermaKit Lift Pot Tilt/Sideshift
Connector Connector Heater Button
7HNDL_SS5.JPG
Figure 7-62. Upper Handle (Lift Pot, Buttons)
7-62 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Table 7-6. Control Handle Repair, Series DA/EA/FA
Step
Procedure Step LP LPS TP TPS FC
No.
22 Carefully peel the flex heater from the lift pot. It is attached to X X
the pot with double-sided tape.
23 Pull the lift pot/bracket assembly out of the lower handle shell. X X
7HNDL_SS6.JPG
Figure 7-63. Lift Pot/Bracket Assembly
24 Slide the old lift pot out of the lift pot bracket. X
25 Slide the new lift pot into the lift pot bracket. The lift pot tang X
must slide into the slot on the lift pot bracket.
Tang and Slot
7HNDL_SS8.JPG
Figure 7-64. Lift Pot Tang and Bracket Slot
Lift Pot/Spring
26 Note orientation of lift pot spring, paddles, and dowel pin. Slide X
the outer spring paddle and lift pot spring off the lift pot
bracket. See Figure 7-64.
27 If you are replacing the inner spring paddle, slide the old inner X
spring paddle off the lift pot bracket.
28 Slide the new inner spring paddle onto the lift pot bracket. X
1026304B, 15 July 2007 7-63
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Table 7-6. Control Handle Repair, Series DA/EA/FA
Step
Procedure Step LP LPS TP TPS FC
No.
29 Apply a thin coat of lubricant P/N 990-635 to the inside X
surface of the new lift spring. Install the spring with one tang
resting on the inner spring paddle (not the dowel pin).
30 Slide the outer spring paddle part way onto the lift pot bracket X
to engage the outer spring tang.
31 Using the outer paddle, press the outer spring tang over the X
dowel. Slide parts together until the outer paddle is flush with
the lift pot bracket. See Figure 7-64.
Flex Circuit Assembly (including pot heaters, reach/retract
and horn buttons, and tilt/sideshift card)
32 Press the latch on the ThermaKit connector and disconnect the X
ThermaKit (if so equipped) from the flex circuit. See
Figure 7-62.
33 Hold the tilt/sideshift button and card between thumb and X
forefinger. Tip the card back and remove from the lower handle
shell. The gasket on the tilt/sideshift button sometimes falls
off when you remove the tilt/sideshift card from the lower
handle shell.
34 Lift the horn button off the positioning pin. X
35 Remove the reach/retract buttons from the handle shell. X
36 Gently remove the lift pot connector from the slot in the lower X
handle shell.
37 Gently remove the ThermaKit and travel pot connectors from X
the slots in the lower handle shell. See Figure 7-58 and
Figure 7-62.
38 Lift the flex circuit out of the lower handle shell. X
7-64 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Table 7-6. Control Handle Repair, Series DA/EA/FA
Step
Procedure Step LP LPS TP TPS FC
No.
39 Remove the tilt/sideshift button and spring from the flex X
circuit by removing one screw from the back of the
tilt/sideshift card.
Orientation Letter “A”
Tilt/Sideshift
Button Circuit Card
7HNDL_SS9.JPG
Figure 7-65. Tilt/Sideshift Button, Spring, and Circuit Card
40 To install the tilt/sideshift button and spring on the X
tilt/sideshift card, place the spring over the post on the back of
the tilt/sideshift button. Align the “A” on the back of the
button with the “A” on the card. See Figure 7-65. Press the
button against the card so the post protrudes through the
back of the card. Thread the screw into the post until it just
bottoms, then tighten 1/8 turn additional. Do not overtighten.
41 Hold the new flex circuit over the lower handle shell and hang X
the reach/retract switches over their mounting ribs. The
switches do not have to been in their final position. The
switches are being used to position the flex circuit temporarily.
42 Slide the horn button over the positioning pin. X
43 Allow the tilt/sideshift knob/card and lift pot heater to hang X
outside the handle shell.
44 Press the ThermaKit, lift pot, and travel pot connectors into the X
slots in the lower handle shell. See Figure 7-58 and
Figure 7-62.
1026304B, 15 July 2007 7-65
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Table 7-6. Control Handle Repair, Series DA/EA/FA
Step
Procedure Step LP LPS TP TPS FC
No.
45 Place the gasket over the tilt/sideshift button. Using thumb X
and forefinger, gently position the tilt/sideshift card in the
handle shell. The bottom of the card sits forward of a ridge in
the handle; the card edge nearest the lift knob sits behind a
ridge in the handle. Confirm that the gasket is in place on the
tilt/sideshift button.
Horn Button Hole Card Sits
Forward of
Ridge
Card Sits
Behind
Ridge
7HNDL_SS10.JPG
Figure 7-66. Tilt/Sideshift Card Insertion
Install Lift Pot
46 Make sure the tilt/sideshift card is correctly positioned. Slide X X
the lift pot/bracket assembly into the lower handle shell.
Bracket Sits Notch Fits in
on Card Slot
7HNDL_SS06.JPG HNDL_SS7.JPG
Figure 7-67. Lift Pot/Bracket Assembly Insertion
47 Re-tape the lift pot heater to the pot body. Replace the X X
double-sided tape if necessary. Use a screwdriver blade to
press the heater against the pot body.
48 Route lift pot wires under the reach/retract buttons. X X
Re-connect the lift pot to the flex circuit at the connector.
7-66 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Table 7-6. Control Handle Repair, Series DA/EA/FA
Step
Procedure Step LP LPS TP TPS FC
No.
49 Move the reach/retract buttons into their final position on the X
ribs.
50 Re-connect the ThermaKit (if so equipped) to the flex circuit. X
Install Travel Pot
51 Position the travel pot heater against the pot body. X X X
Double-sided tape is not necessary. See Figure 7-58.
52 Re-connect the travel pot to the flex circuit at the connector. X X X
53 Route the harness connector end of the flex circuit through the X
locating slots.
Assemble Handle
54 Confirm that the flex circuit is routed correctly through the X X X X X
locating slots.
1026304B, 15 July 2007 7-67
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Table 7-6. Control Handle Repair, Series DA/EA/FA
Step
Procedure Step LP LPS TP TPS FC
No.
55 Position the upper handle shell over the lower shell and ease it X X X X X
into position.
B B
7HNDL_SS11.JPG
Figure 7-68. Sidestance Handle Assembly
Make sure:
A: Travel pot tang is entering the slot in the lower shell.
B: Travel shaft rib on upper shell is passing between the
paddles of the travel shaft assembly.
If the lift knob was not removed, rotate the knob slightly to
allow the upper handle shell to clear it. The upper handle shell
should mate with the lower shell with very little force.
56 Squeeze the handle halves together X X X X X
57 Place the tip of a screwdriver into the travel shaft set screw X X X X X
hole. Gently rotate the shaft in both directions to confirm that
the pin in the upper handle shell is between the paddles. Do
not over-rotate the shaft, as this can cause plastic parts to
break. You should feel spring tension immediately and there
should be no free play in the travel shaft. If you do not feel
spring tension, lift off the upper handle shell, and repeat step
55.
58 Install six M5x10mm SHCS. Tighten each screw until it X X X X X
bottoms, then 1/4 turn additional (8 to 12 in. lb.). Do not
overtighten.
59 Confirm that the two spring paddles and spring are in place. X X X X X
The outer paddle must be flush with the end of the lift pot
bracket.
7-68 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Table 7-6. Control Handle Repair, Series DA/EA/FA
Step
Procedure Step LP LPS TP TPS FC
No.
60 Set the flat on the lift pot shaft parallel to the top spring X X X X X
paddle.
7HNDL_SS12.JPG
Figure 7-69. Lift Pot shaft alignment
61 Slide the lift knob on, with the dowel pin in the knob is passing X X X X X
between the paddles.
62 Tighten the steel set screw until it bottoms, then 1/4 turn X X X X X
additional (4 to 6 in. lb.).
63 Install nylon set screw. Run nylon set screw down flush or X X X X X
below the surface of the knob.
1026304B, 15 July 2007 7-69
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Series AA/BA/CA (Fore-Aft
Stance) Secondary Control
Handle
For all other components, Table 7-7 lists the
If a ThermaKit component has failed in the steps for a complete tear down and rebuild
control handle, replace the handle shell. In this procedure. Steps required for a specific single
case, it is more cost effective to replace the component are identified by “X’s” in the column
entire handle than to rebuild it. for that component.
Table 7-7. Control Handle Repair, Series AA/BA/CA Secondary Handle
Travel
Step Travel Horn
Procedure Step Pot
No. Pot Button
Spring
Travel Pot
Control handles contain ESD-sensitive [arts. Use
correct electrostatic discharge precautions. See
“Static Precautions” on page 2-9.
2 Pull the travel pot out of the handle shell. Note: Be careful not to X
lose the D-shaped metal spring clip seated inside the travel shaft.
3 Attach the foam pad to the back of the new travel pot body. X
4 Turn the travel pot shaft so the flat on the shaft aligns with the tang X
on the pot body.
D-Clip Slot in Shell
Tang
Snap Ring Flat on Shaft
7HNDL_SEC1.JPG
Figure 7-70. Secondary Handle Travel Pot
5 Insert travel pot into the handle shell, aligning the flat on the shaft X
with the D-clip, and the tang on the pot body with the slot in the
shell. See Figure 7-70.
7-70 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Table 7-7. Control Handle Repair, Series AA/BA/CA Secondary Handle
Travel
Step Travel Horn
Procedure Step Pot
No. Pot Button
Spring
Other Components
6 Remove the M4x12 mm button-head socket screw and cavity plug X X
from the end of the handle. See Figure 7-71.
7 Remove two M4x8 mm button-head socket screws from the end of X X
the handle.
M4x8 mm
M4x12 mm
7HNDL_SEC2.JPG
Figure 7-71. Secondary Handle End Cap
8 Remove the handle grip from the handle shell. X X
Travel Pot Spring
9 Pull the travel pot out of the handle shell. Note: Be careful not to X
lose the D-shaped metal spring clip seated inside the travel shaft.
10 Remove the snap ring in the handle shell. See Figure 7-70. X
11 Remove travel shaft assembly from handle shell. X
1026304B, 15 July 2007 7-71
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Table 7-7. Control Handle Repair, Series AA/BA/CA Secondary Handle
Travel
Step Travel Horn
Procedure Step Pot
No. Pot Button
Spring
12 Note the orientation of parts on the travel shaft. Remove two X
washers, C-clip, washer (if used), paddle, washer (if used), spring,
washer (if used), and paddle.
7HNDL_SEC3.JPG
Figure 7-72. Secondary Handle Travel Shaft parts
13 Apply a thin coat of lubricant P/N 990-635 to the inside surface of X
the spring. Assemble parts in the correct order on the shaft.
14 Slide the spring and paddles part way down the travel shaft to X
engage the lower spring tang.
15 Using the upper paddle, press the upper spring tang over the tab on X
the travel shaft. With one paddle and one spring tang on each side
of the pin, slide all parts down to expose the snap ring groove.
Paddle/Tang Spring
Tab on Shaft
Paddle/Tang
Tab on Shell Shell
7HNDL_SEC4.JPG
Figure 7-73. Secondary Handle, Travel Shaft alignment
16 Install the external snap ring. Install two nylon washers. X
17 Confirm that the D-shaped metal clip is inside the travel shaft. X
18 Insert the travel shaft assembly into the handle shell. Make sure X
the tab on the shell slides between the paddles on the shaft
assembly. See Figure 7-73.
7-72 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Steering and Controls Control Handle
Table 7-7. Control Handle Repair, Series AA/BA/CA Secondary Handle
Travel
Step Travel Horn
Procedure Step Pot
No. Pot Button
Spring
19 Insert travel pot into the handle shell, aligning the flat on the shaft X
with the D-clip, and the tang on the pot body with the slot in the
shell. See Figure 7-70.
Horn Button
20 Remove the three wires from the PH3 connector, noting their colors X
and locations for later re-connection.
Insulation
7HNDL_SEC5.JPG
Figure 7-74. Secondary Handle, PH3 Connector
21 Remove the two-inch length of insulator tubing from the wires. See X
Figure 7-74.
22 Remove the snap ring from the back of the horn button. X
Snap Ring
7HNDL_SEC6.JPG
Figure 7-75. Secondary Handle, Horn Button Snap Ring
23 Pull wiring out through the channel in the handle grip. X
24 Thread new wires down the channel in the handle grip. X
25 Install the horn button in the grip and secure it with the snap ring. X
26 Install a 2-inch length of insulator shrink tubing loosely over the X
wire ends.
1026304B, 15 July 2007 7-73
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Control Handle Steering and Controls
Table 7-7. Control Handle Repair, Series AA/BA/CA Secondary Handle
Travel
Step Travel Horn
Procedure Step Pot
No. Pot Button
Spring
27 Re-connect connector PH3 to the horn button wires: red to pin 1, X
black to pin 2, white to pin 3. Make sure there is a connector seal
on the connector.
28 Shrink the insulator tubing at the connector end of the wires. See X
Figure 7-74.
Handle Reassembly
29 Slide the handle grip over the handle shaft and shell assembly. X X
Orient the notch in the handle flange with the harness channel in
the grip.
7HNDL_SEC7.JPG
Figure 7-76. Secondary Handle Assembly
30 Install two M4x8 mm button-head socket screws in the end of the X X
handle.
31 Install the M4x12 mm button-head socket screw and cavity plug in X X
the end of the handle.
7-74 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake
Drive and Brake
Section 7. Component Procedures
1026304B, 15 July 2007 7-75
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Drive and Brake Component Procedures Summary Drive and Brake
Drive and Brake
Component Procedures
Summary
Table 7-8. Drive and Brake Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Brake Procedure: Total air gap locking Lower air gap: 0.012 inch (0.305 mm)
Adjustment page 7-96 screws: Total air gap: 0.030 inch (0.762 mm)
17 ft. lb. (23 Nm)
Brake Assembly Procedure:
See procedure.
page 7-98
Brake Pads Procedure: See procedure.
page 7-98
Deadman Pedal Photo: Assembly to Frame: Pedal travel:
Assembly page 7-102 15 ft. lb. (21 Nm) Series AA/BA/CA (Fore-Aft Stance):
3.50 in. (90 mm)
Series DA/EA/FA (Side Stance):
3.58 in. (99 mm)
Deadman Photo:
N/A
Sensor VR4 page 7-102
Deadman Procedure: See procedure.
Switch S2 page 7-102
7-76 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Drive and Brake Component Procedures Summary
Table 7-8. Drive and Brake Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Drive Motor Locator Pinion gear: Remove electric steering motor, steer limit
Photos: P/N 990-536/ switch and rail, brake.
Series CA/FA 85 ft. lb. (115 Nm) Motor weighs approx. 125 lb. (57 kg).
(AC lift): Drive Motor mounting
Figure 7-3 on bolts: P/N 990-536/ Note end bell and cabling differences:
page 7-9 and 18 ft. lb. (24.4 Nm) P/N 1020728/601 ..... P/N 1029753/600
Figure 7-4 on Power cables:
page 7-10. 18 ft. lb. (24.4 Nm)
Steer limit sensing rail:
Series P/N 990-536/
AA/BA/DA/ 9 ft. lb. (12 Nm)
EA (DC lift):
Figure 7-9 on
page 7-15
and
Figure 7-10
on page 7-16.
On trucks below serial number 05921, to
replace drive motor P/N 1020728/601 with
P/N 1029753/600, order kit
P/N 1020728/6K1 (fore-aft) or
P/N 1020728/6K2 (side stance). Kits
contain new brackets and cable harness
required. Discard existing washers between
end bell and end bell bracket.
Drive Unit Locator
Photos:
Series CA/FA
(AC lift):
Figure 7-3 on
page 7-9 and
Figure 7-4 on
page 7-10.
Series
See procedure.
AA/BA/DA/
EA (DC lift):
Figure 7-9 on
page 7-15
and
Figure 7-10
on page 7-16.
Procedure:
page 7-79
1026304B, 15 July 2007 7-77
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Drive and Brake Component Procedures Summary Drive and Brake
Table 7-8. Drive and Brake Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Drive Unit Procedure:
Radial Rings Removal
page 7-84 See procedure.
Installation
page 7-93
Drive Wheel and No Wheel mounting bolts: N/A
Tire 170 ft. lb. (230 Nm)
Inertial Procedure: See procedure. Adjust dampener spring length to 1 9/16 in.
Dampener page 7-103. (40 mm). Adjust idler after installing
dampener. See Page 7-45.
7-78 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Drive Unit
Drive Unit
Drive Unit Set-Up
22 23 21 20 19 25 26
24
4
27
3
2
18
6
12 16
13
5
9
7
28 8 10 11 7 14 15 32
7R1008858_C.CGM
Figure 7-77. Drive Unit Exploded View
1026304B, 15 July 2007 7-79
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Drive Unit Drive and Brake
Standard Tools
Table 7-9. Legend for Figure 7-77
Before performing any maintenance on the
Item Description
drive unit, note the tools required. Also, make
1 Housing, Drive Unit sure that any maintenance performed does not
void warranty.
2 Gear, Pinion, Drive Unit
3 Gear, Helical, Drive Unit Standard Hand Tools Required
4 Nut, Clamp
Table 7-10. Standard Hand Tools for Servicing Drive Unit
5 Bearing Set, Drive Unit
Bearing puller
6 Bearing Set, Drive Unit
Bearing press
7 Gear and Pinion Set, Drive Unit
Micrometer
8 Bearing Set, Drive Unit
Hammer or mallet
9 Shaft, Flanged Output, Drive
Brass punch
10 Shim, Drive Unit Output Bearing
Pinion gauge
11 Ring, Retaining
Bearing heater
12 Plug, Pipe
Screwdriver
13 Screw
Magnetic dial indicator
14 Bearing Set, Drive Unit
Pry bars
15 Seal, Lip
Tube 12 in. diam. x 6 in. long
16 Cover
Tube 8 in. diam. x 6 in. long
18 Ring, Pivot
Torque wrench, 150 ft. lb.
19 Pin, Spiral (210 Nm) capacity
20 Plug, Bearing Filler
21 Fitting, Grease
22 Screw
23 Washer, Flat
24 Kit, Ring Set
25 Bearing, Ball
26 Gear, Spur, Drive Unit
27 Fitting, Grease
28 Cover, Shim
32 Cover, Shim
7-80 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Drive Unit
Troubleshooting
Table 7-11. Troubleshooting Drive Unit Symptoms
Symptom Probable Cause Required Action Available Kits
Oil leaks Damaged lip seal Replace lip seal, main cover and Seal Kit
bearing shims, and output shaft P/N 410-029/50
bearings
Worn or damaged output Replace lip seal, main cover and Axle Shaft Kit
shaft bearing shims, output shaft P/N 410-029/51
bearings, and output shaft
Housing/main cover joint Reseal N/A
Worn or damaged housing Replace drive unit N/A
Drive wheel Worn or damaged output Replace lip seal, main cover and Seal Kit
wobbles shaft bearings bearing shims, and output shaft P/N 410-029/50
bearings
Worn or damaged output Replace lip seal, main cover and Axle Shaft Kit
shaft bearing shims, output shaft P/N 410-029/51
bearings, and output shaft
Loose wheel mounting Inspect housing and main cover for N/A
hardware damage, retorque mounting
hardware
Noise Worn or damaged output Replace lip seal, main cover and Seal Kit
shaft bearings bearing shims, and output shaft P/N 410-029/50
bearings
Worn or damaged pinion Replace pinion bearings and clamp N/A
bearings nut
Worn or damaged gear set - Replace lip seal, main cover and Seal Kit
Output shaft is in good bearing shims, output shaft P/N 410-029/50
condition bearings, pinion bearings, gear set, Drive Gear Kit
and clamp nut P/N 410-029/52
Worn or damaged gear set - Replace lip seal, main cover and Axle Shaft Kit
Output shaft is worn or bearing shims, output shaft P/N 410-029/51
damaged bearings, pinion bearings, gear set, Drive Gear Kit
clamp nut, and output shaft P/N 410-029/52
Worn or damaged helical Replace helical gear and pinion N/A
gear and pinion
Steering Inadequate bearing Grease pivot bearing and spherical N/A
binds lubrication bearing
Worn or damaged pivot Replace radial ring set, steel balls, Steer Kit
bearing bearing filler plug, and spherical P/N 410-029/53
bearing
1026304B, 15 July 2007 7-81
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Drive Unit Drive and Brake
Table 7-11. Troubleshooting Drive Unit Symptoms
Symptom Probable Cause Required Action Available Kits
Steering Worn or damaged spur Replace spur gear and spherical N/A
binds gear bearing
Worn or damaged spherical Replace spherical bearing and N/A
bearing grease fittings
Worn or damaged pivot Replace pivot ring, radial ring set, Steer Kit
ring steel balls, bearing filler plug, and P/N 410-029/53
spherical bearing
Top View Edge View
35°
Typical
“Eye” welded
to plate
Four 0.342 to 0.350 in. (8.7 to 5/16-18 UNC-2B equally
8.9 mm) holes spaced as spaced on a 10.5 in.
shown on a 10.5 in. 5/16 in. (8 mm) steel
(266.7 mm) bolt circle (used to
(266.7 mm) bolt circle plate 11.25 in.
separate tool from drive unit)
(286 mm) in diameter
73323_002.EPS
Figure 7-78. Drive Unit Removal/Installation Tool
Removal 3. Loosen the drive tire lug nuts.
4. Remove the horn assembly.
1. Turn the key switch OFF and disconnect
the battery connector. 5. Disconnect the power cables from the
drive motor, labeling the cables if
2. Drain the oil from the drive unit.
necessary for later installation. Use two
7-82 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Drive Unit
wrenches to avoid twisting the motor
studs.
6. Disconnect remainder of wires and brake Drive unit weighs approximately 175 lb.
hose. (80 kg.)
7. Remove mounting bolts for cable bracket.
16. Loosen, then remove the four mounting
8. Remove drive motor mounting bolts. Lift
screws holding the drive unit to the tractor
brake assembly and motor off drive unit.
frame. The steering stop will also become
9. Remove the steering shaft. unattached at this stage.
10. To facilitate the removal of the drive unit, 17. Lower the drive unit to the floor. Tip the
construct the tool shown in Figure 7-78. drive unit over on its side and remove the
Attach the tool to the top of the drive unit hoist.
using the screws which held the drive
18. If you have trouble separating the tool
motor.
from the drive unit, thread mounting
11. Remove the dust shield between the ring screws in the threaded holes in the tool to
gear and the tractor frame. push the tool off the drive unit.
Disassembly
Use extreme care whenever the lift truck All item numbers refer to exploded view,
is jacked up. Never block the lift truck Figure 7-77 on page 7-79.
between the telescopic and the floor. Clean the outside of the drive unit thoroughly
Use a suitable hoist to stabilize the mast. and drain any remaining oil from the drive unit
Keep hands and feet clear from vehicle by removing the drain plug (Item 12).
while jacking the lift truck. After the lift
truck is jacked, place solid blocks or jack Visually inspect the outside of the housing
stands beneath it to support it. Do not (Item 1) for damage, wear or cracks.
rely on the jack alone to support the lift
truck. See “Jacking Safety” on
Pivot Ring Disassembly
page 2-11.
1. On the pivot ring (Item 18), remove the
12. Secure the lift truck with a suitable grease fitting (Item 21) and the bearing
capacity hoist attached to the overhead filler plug (Item 20). Inspect the bearing
guard. Jack the rear of tractor so that the filler plug hole for uneven wear.
bottom edge of the bumper is approx.
6.5 in. (16.5 cm) off the floor.
Filler Plug
13. Remove the drive wheel.
14. Disconnect the steer linkage from the drive
unit; swing the linkage clear (if the lift
truck has a steered idler).
15. Place a temporary support under the drive
unit or attach a hoist to the tool installed
in Step 10.
Pivot Ring
71018_003.tif
Figure 7-79. Remove Grease Fitting and Filler Plug
1026304B, 15 July 2007 7-83
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Drive Unit Drive and Brake
2. Turn the pivot ring (Item 18) to remove the
steel balls (Item 25) through the bearing
filler plug hole.
Due to normal wear, the edges of the
NOTE: If the pivot ring will not spin or even radial rings could be very sharp.
turn, it is an indication of damaged
radial rings and/or excessive wear to the 5. Clean the grease from the radial ring
channel in housing. If this is the case, channel in the housing. Inspect the
replace the entire drive unit. No further channel for uneven wear. Also clean and
disassembly is necessary. inspect the inside of the pivot ring.
Radial Rings
71018_002.tif
71018_001.tif
Figure 7-80. Remove Steel Ball Bearings
Figure 7-82. Remove Radial Rings
3. After removing all the steel balls, remove
the pivot ring (Item 18) by working it off Main Cover and Output Shaft
toward drive end of the housing. Disassembly
1. Visually inspect the housing around the
main cover (Item 16) for wear outside the
cover bolts (Item 13). Refer to Figure 7-83.
NOTE: Excessive housing wear outside the
Pivot Ring cover bolts can make them difficult to
remove. If this occurs, replace the entire
drive unit. No further disassembly is
necessary.
2. Remove the main cover bolts (Item 13).
3. Using a mallet, knock the flanged output
shaft (Item 9) to break the seal on the
71018_004.tif main cover (Item 16).
Figure 7-81. Remove Pivot Ring 4. Remove the main cover and output shaft
assembly.
4. Remove the radial rings (Item 24) from the
channel in the housing and inside the 5. You need a press and 8 in. x 6 in. tube to
pivot ring. remove the bearing cup (Item 14) on the
end of the output shaft.
7-84 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Drive Unit
8. Place the main cover assembly, gear side
up, on 12 in. x 6 in. tube so the bearing
puller clamp is resting on the tube. Press
Always watch for pinch points when
the flanged output shaft (Item 9) and the
using a press or pressing tools.
output bearing spacer (Item 10) out.
9. Remove the exterior retaining ring
(Item 11).
Main Cover
71018_005.tif
Figure 7-83. Remove Cover and Output Shaft
71018_011.tif
Figure 7-85. Press Out Output Shaft
10. To remove the bevel gear (Item 7), support
Safety glasses are required after this
the main cover assembly on 8 in. x 6 in.
point in disassembly.
tube under press. Press the output shaft
(Item 9) down through the bevel gear. The
6. Place the main cover assembly, gear side
bearing cone (Item 14) will be removed at
down, on the tube under press. Press the
the same time.
output shaft (Item 9) down slightly to
create a space between the bevel gear
(Item 7) and the output bearing spacer
(Item 10).
Output Shaft
Output Shaft
71018_012.tif
Figure 7-86. Remove Bevel Gear
Bevel Gear
11. Remove the bearing cup (Item 8) from the
71018_010.tif
main cover with a race driver and pry bars.
Figure 7-84. Press Down Output Shaft
7. Tighten a bearing puller clamp under the
lip of the output bearing spacer, being
careful not to catch the exterior retaining
ring (Item 11).
1026304B, 15 July 2007 7-85
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Drive Unit Drive and Brake
12. Remove the lip seal (Item 15) from the Spiral Pinion Disassembly
main cover.
NOTE: The spiral pinion and bevel gear are a
matched set. Their alignment is critical. Do not
replace them separately.
Lip Seal 1. Loosen the set screw on the clamp nut
(Item 4) on the spiral pinion (Item 7).
Remove the clamp nut.
71018_013.tif
Figure 7-87. Remove Bearing Cup and Lip Seal
13. Remove the output shaft bearing cone
(Item 8) in the base of the housing using Clamp Nut
two pry bars. Insert the pry bars under
bottom edge of the cone on opposite sides. 71018_006.tif
Apply even pressure on both tools to lift Figure 7-89. Remove Clamp Nut
the cone out.
2. Using a brass punch and hammer, drive
the spiral pinion (Item 7) out of the
housing.
Output Shaft
Bearing Cone NOTE: You may need to remove the spiral
pinion with a press or pressing device
equivalent.
Helical Gear
71018_009.tif
Figure 7-88. Remove Output Shaft Bearing Cone
14. Remove the shims (Item 28) from the
housing bore. Save shims for reference
only, as they are usually damaged when
removing the bearing cone. New shims are
provided with Kits #1 and #2. 71018_007.tif
Figure 7-90. Remove Spiral Pinion
15. Remove the cover shims (Item 32). Save
the shims for reference only. Replacement 3. Remove the helical gear (Item 3) and the
shims are provided with Kits #1 and #2. bearing cone (Item 5) from the housing.
4. Drive out the bearing cup (Item 6). Inspect
the bearing cup and housing bores for
wear.
7-86 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Drive Unit
NOTE: The bearing cups and cones are usually 2. Install the second bearing cup (Item 6) into
damaged during removal. Replace them the housing bore on the opposite side.
as sets; they are included with Kits #1
and #2.
Bearing Cup
71018_014.tif
Bearing Cup
Figure 7-92. Drive In Bearing Cup
71018_008.tif
Figure 7-91. Remove Bearing Cup
Thoroughly wash the housing and visually Always watch for pinch points when
inspect entire housing again for excessive using a press or pressing tools.
damage, wear, or cracks.
3. Press the bearing cone (Item 5) onto the
Assembly spiral pinion (Item 7) until it is seated.
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
1. Using a press or mallet, install the bearing
71018_015.tif
cup into the housing bore.
Figure 7-93. Press Bearing onto Spiral Pinion
1026304B, 15 July 2007 7-87
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Drive Unit Drive and Brake
Main Cover and Output Shaft that dial indicator tips come into contact
Assembly with flange surface.
1. Prior to installing the output shaft lip seal
(Item 15), apply a thin layer of sealing
adhesive around the seal surface of the
main housing, to prevent leaking. Install
the lip seal, spring side down, in the
housing.
2. Press the lip seal (Item 15) into the
housing until it is just below flush with
housing surface.
71826_127.tif
Figure 7-96. Bearing Cone to Flange Measurement
6. The reading on the two dial indicators
should be the same. If they are different,
repeat steps 4 and 5 until the readings are
identical. Record final reading as
Measurement D on flange surface. This is
required during final assembly.
Lip Seal
7. Remove the bearing cone (Item 17) in
71018_016.tif preparation for installing the flanged
Figure 7-94. Press Lip Seal output bearing shaft (Item 10).
8. Use a light oil on the surface of the lip seal
3. Press the output bearing cup (Item 14)
(Item 15) and inside the bearing cup
into main cover until it is seated. Place the
(Item 14).
bearing cone into the bearing cup.
9. Place the main cover down over the output
4. Push down on the bearing and turn to seat shaft, flange side up. Place the bearing
bearing into the bearing cup.
cone (Item 14) down over the output shaft
(Item 9).
Output
Bearing Cup
Bearing Cone
71018_017.tif Output Shaft
Figure 7-95. Press Output Bearing Cup
71018_021.tif
Figure 7-97. Install Main Cover and Bearing Cone
5. Take a measurement from the edge of the
bearing cone (Item 14) to the flange
surface of main cover (Item 16). Make sure
7-88 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Drive Unit
10. Press the bearing cone onto the output 14. Press the bearing cone (Item 8) down until
shaft. it is fully seated against the spacer and
snap ring.
Bearing Cone
Output
Bearing
71018_020.tif
Spacer
Figure 7-98. Press on Bearing Cone 71018_023.tif
Figure 7-100. Press Down Bearing Cone
11. Place the bevel gear (Item 7) down over the
output shaft, teeth side up. Press the bevel 15. Place the main cover assembly, flange side
gear down, which seats the bearing cone up. Press the bearing cone (Item 8) into
(Item 14) into the bearing cup. place. At the same time, pull the gear
sideways to eliminate any backlash in the
spline area.
Bevel Gear
Bearing Cup
Bearing Cone
71018_022.tif
Figure 7-99. Press on Bevel Gear
71018_024.tif
12. Install the external retaining ring (Item 13) Figure 7-101. Eliminate Backlash
on the output shaft (Item 10). Pull up on
the bevel gear (Item 7) to make sure the 16. Place bearing cup (Item 8) onto bearing
external retaining ring is installed and rotate cup while applying downward
securely. pressure to seat bearing.
13. Place the output bearing spacer (Item 10), 17. Position dial indicator onto the main cover
with the recessed area down, over the so that the tips rest on the bearing cup.
output shaft. Place the bearing cone The readings on the two dial indicators
(Item 8) on top of the output shaft. should be the same. If they are different,
1026304B, 15 July 2007 7-89
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Drive Unit Drive and Brake
repeat Steps 15 and 16 until the readings NOTE: Complete steps 2 through 4 before the
are identical. bearing cools.
Clamp Nut
Helical Gear
71826_130.tif
Figure 7-102. Bearing Cup to Flange Measurement 71018_027.tif
Figure 7-103. Install Helical Gear and Pinion
18. Record final readings as Measurement E.
This is required during final assembly. 5. While the bearing cone (Item 6) is cooling,
calculate the formula for determining the
required shim (Item 28) thickness.
Helical Gear Assembly
NOTE: The pinion shaft and bevel gear are a Calculate Shim Formulas
matched set. Their alignment is critical.
Do not replace them separately. • A = Dimension A stamped on housing
(2.102/2.108)
• B = Dimension B stamped on housing
(3.409/3.412)
Bearing can become extremely hot. Use • C = Number etched on back of gear
gloves to protect hands from burns. (nominal 1.812)
• D = Distance from bearing cone to flange
1. Preheat the bearing cone with a bearing surface (see Figure 7-104 on page 7-91)
heater. Install the heated bearing cone in • E = Distance from bearing cup to flange
the bearing cup (Item 6) in the housing. surface (see Figure 7-105)
2. Place the helical gear (Item 3) into the
housing. S1 = (B - A - E + D + C)
3. Install the spiral pinion (Item 7) up S1 = Shim amount behind bearing cup in
through the helical gear (Item 3). main housing to position gear for proper
backlash (S1).
4. Put the clamp nut (Item 4) on the end of
the spiral pinion (Item 7) and hand tighten S2 = E + S1 - B - 0.006 preload
until the bearing cools.
7-90 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Drive Unit
S2 = Shim amount between cover plate
face to set preload of bearings for output
shaft (S2).
71018_028.tif
Figure 7-106. Remove End Play
2. Preload the helical gear (Item 3) for 0.000
71826_127.tif
to 0.002.
Figure 7-104. Bearing Cone to Flange Measurement
3. Remove any oil from the clamp nut
(Item 4). Apply thread-locking compound
(P/N 990-544) to the threads in the clamp
nut. Tighten the set screw in the clamp
nut to 140 in. lb. (15.8 Nm).
4. Spin the helical gear (Item 3) to ensure
that the bearings are not too tight.
5. One tooth on the spiral gear (Item 7) is
etched or marked with an X. With a
marker, mark that tooth surface for the
purpose of lining up the spiral and bevel
gears (Item 7) to check backlash. One
tooth on the matching bevel gear is also
marked. Mark that tooth surface also.
71826_130.tif
Figure 7-105. Bearing Cup to Flange Measurement
Spiral Gear
Installing and Testing Shims
1. Remove any end play in the bearings
between the helical gear (Item 3) and the
spiral gear (Item 7) using lock nut wrench.
Wedge the helical gear, and tighten the
clamp nut (Item 4) until there is no end
play between the gears.
71018_029.tif
Figure 7-107. Mark Spiral and Bevel Gears
6. Place the predetermined shims (Item 28)
into the housing bore for the bearing cup
(Item 8). Install the bearing cup into the
housing bore over the shims.
1026304B, 15 July 2007 7-91
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Drive Unit Drive and Brake
7. Install the cover shims (Item 32).
Cover Shim
71826_131.tif
71018_030.tif
Figure 7-110. Backlash Measurement
Figure 7-108. Install Cover Shims
2. Calculate any necessary adjustments to
8. Place the main cover assembly over the the shims. Remove the main cover
shims, being sure to line up the marked assembly and the bearing cup, and adjust
teeth on both the spiral and bevel gears the shims. Repeat Steps 6 through 9 “Installing
(Item 7). and Testing Shims” until backlash is between
0.004 and 0.006.
9. Put in four housing cover bolts (Item 13),
evenly spaced, and tighten to 40 ft. lb. 3. When backlash is within acceptable range,
(54 Nm). remove the main cover assembly and the
cover shims.
Main Cover Installation
Spiral gear
1. Clean the cover mating surface on the
housing, then apply thread-locking
compound (P/N 990-411) sparingly.
2. Install the cover shims (Item 32) and the
main cover assembly. Install the main
cover bolts (Item 13), and torque to
40 ft. lb. (54 Nm).
Bevel Gear
Pivot Ring Assembly
71018_031.tif
Figure 7-109. Line Up Spiral and Bevel Gears
Measuring Backlash Safety glasses are required.
NOTE: Backlash tolerance is critical to the
performance of the drive unit. Improperly 1. On the inside of the pivot ring (Item 18),
adjusted units will experience premature make sure the roll pins (Item 19) are
failure. installed and in good condition on either
1. Wedge the helical gear (Item 3), then side of the bearing filler plug hole. If they
slightly turn the output shaft to determine are missing or damaged, install new roll
backlash. Backlash reading on the dial pins.
indicator should be between 0.004 and 0.006.
7-92 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Drive Unit
5. Install the outer radial rings (Item 24) on
Pivot Ring
the housing. Refer to Figure 7-113.
Outer
Radial Ring
Roll Pin
71018_035.tif
Figure 7-111. Install Roll Pins
71018_037.tif
2. Install the grease fitting (Item 27) on the
Figure 7-113. Install Outer Radial Rings
outside of the pivot ring.
3. Screw the grease fitting (Item 21) in the 6. Lift the drive end of the housing and slide
bearing filler plug. the pivot ring over the housing. Be careful
4. Install radial rings (Item 24). Install the not to jar the radial rings out of place.
flat radial ring on the inside flat surface of Slide the pivot ring into place just behind
the pivot ring. Place the ends of the the spur gear (Item 26).
chamfered radial rings against the roll 7. Make sure the pivot ring bearing filler plug
pins (Item 19) to install them in the pivot hole is on top, in preparation for installing
ring. the steel balls (Item 25).
8. Put one ball at a time into the pivot ring
filler hole. Use a screwdriver to direct the
Radial Rings
steel balls first to one side then the other.
Continue until all 70 balls are installed.
Fit the bearing filler plug (Item 20) with the
grease fitting pointing toward the spur
gear (Item 26).
\
Steel Ball
Roll Pins
71018_036.tif
Figure 7-112. Install Radial Rings
71018_038.tif
Figure 7-114. Install Ball Bearings
1026304B, 15 July 2007 7-93
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Drive Unit Drive and Brake
7. Install mounting bolts for drive motor and
drive unit and toque to 13 ft. lb. (17.6 Nm).
Excessive thread-locking compound will 8. Connect cables, wires, and brake line.
damage the ball bearings and pivot Torque motor cables to 18 ft. lb. (24.4 Nm).
ring. Use thread-locking compound 9. Install the drive unit dust shield.
sparingly.
10. Install the drive wheel. Torque the drive
tire lug bolts to 170 ft. lb. (230 Nm).
9. Apply thread-locking compound
(P/N 990-536) sparingly to the filler plug 11. Install the horn assembly.
bolts (Item 22). Install the bolts and 12. Check the drive unit fluid level.
washers (Item 23) on either side of the
13. Test the brake for correct operation.
bearing filler plug (20) and tighten to
20 ft. lb. (27 Nm).
10. Grease and then test the pivot ring,
checking to see that it spins freely.
Filler Plug Filler Plug
Bolt
Washer
71018_040.tif
Figure 7-115. Install Bearing Filler Plug
Installation
1. Place the new drive unit in position.
2. Apply thread-locking compound
(P/N 990-544) to the drive unit mounting
bolts. Install and torque the drive unit
mounting bolts to 130 ft. lb. (176 Nm).
3. Apply thread-locking compound
(P/N 990-536) to the steer linkage bolt
threads. Reconnect the steering linkage.
Torque bolts to 150 ft. lb. (204 Nm).
4. Reinstall the steering shaft and hydraulic
motor.
5. Refill the drive unit with the correct type
fluid. Add fluid until level reaches the
bottom of the helical gear.
6. Install the drive motor and brake. Use a
fiber gasket between drive motor and drive
unit.
7-94 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Brake, Electric
Brake, Electric
Coil Locking
Body Brake Armature 0.007 in. Bolt
Pad Plate Shim
Shoulder Total
Bolt Air Gap
Rotor 0.030
Adjuster in.
Lock Nut
Total
Lower Air Gap
Air Gap Adjuster
0.012 in.
Base Brake
Plate Pad
Lower
Air Gap Encoder
Adjuster Bearing
7Brake Engaged-7400-Gold.jpg
Figure 7-116. Brake cross-section
0.007 in.
Gap
0.011 in.
+ Gap
0.012 in.
+ Gap
0.030 in.
Total
Air Gap
7Brake Engaged-7400-Gold.jpg
Figure 7-117. Brake gaps
1026304B, 15 July 2007 7-95
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Brake, Electric Drive and Brake
Brake Pads
Baseplate
Brake Pads (3)
Spacer
Lower Air Gap
Adjusters Springs
Coil Body
Rotor
Air Gap Adjusters Armature
Plate
Locking Bolts
7R1010694_B.CGM
Figure 7-118. Brake Assembly
Brake Adjustment 2. Turn the steering wheel all the way left or
right.
3. Turn the key switch OFF and disconnect
the battery connector.
Use extreme caution whenever the lift 4. Open drive motor compartment door.
truck is jacked up. Never block the lift Remove cable ties holding the cable
truck between the telescopic and the bundle to the brake assembly.
floor. Use a suitable hoist to stabilize the NOTE: Adjustment photos show drive motor
mast. Keep hands and feet clear from P/N 1020728/600. Drive motor P/N
vehicle while jacking the lift truck. After 1029753/600 and 1029754/600 are
the lift truck is jacked, place solid blocks similar.
or jack stands beneath it to support it.
DO NOT rely on the jack alone to NOTE: Make sure to adjust both the total air gap and
support the lift truck. See “Jacking lower air gap. See Figure 7-116 and
Safety” on page 2-11. Figure 7-117 on page 7-95.
5. Adjust the total air gap at each of the three
NOTE: If black lower air gap adjuster nuts total air gap adjusters:
crack, replace with zinc-plated nuts. See
a. Loosen the locking bolt.
Parts Catalog for part number.
b. Turn the total air gap adjuster until
1. Jack up the lift truck so the drive wheel is there is a 0.030 inch (0.762 mm) gap
off the ground. between the armature plate and the coil
7-96 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Brake, Electric
body, close to the adjuster and at the a. Loosen the locking nut on top of the
outer perimeter of the brake base plate.
(Figure 7-120).
7D20000054_2BW.JPG
Figure 7-121. Loosening brake base plate locking nut
7D20000054_5BW.JPG
Figure 7-119. Loosening brake locking bolt b. Turn the hex head adjuster under the
base plate (Figure 7-123) until there is
a 0.012 inch (0.305 mm) gap between
the adjuster and the top surface of the
drive motor (Figure 7-122).
c. Tighten the locking nut while holding
the adjuster with another wrench.
7D20000054_6BW.JPG
Figure 7-120. Adjusting total air gap
c. Tighten the locking bolt before
measuring the gap.
6. Adjust the air gap at each of the three
lower air gap adjusters: 7D20000054_3BW.JPG
Figure 7-122. Measuring brake lower air gap
1026304B, 15 July 2007 7-97
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Brake, Electric Drive and Brake
Brake Pad Inspection
Replace brake pads if they are:
• contaminated by oil or other chemicals
(contamination cannot be removed by
cleaning with solvents)
• worn to within 0.020 inch (0.5 mm) of the
rivet heads
Brake Assembly
Removal and Disassembly
Figure 7-123. Adjusting brake lower air gap
7D20000054_4BW.JPG
NOTE: You can remove the entire brake
assembly without disassembling it and
7. Reconnect the battery connector and turn the without using the brake release bolts.
key switch ON. 1. Turn the key switch OFF and disconnect
8. Turn the steering wheel carefully until the the battery connector.
next set of adjusters is accessible. Make 2. Chock the drive tire to prevent movement.
sure the loose cables do not catch on
adjacent parts. 3. Remove the top cover and open the motor
compartment door.
9. Turn the key switch OFF and disconnect
the battery connector. 4. Note the location of cable ties securing the
cable bundle to the cable bracket. Cut
10. Repeat steps 6 through 9 until you have cable ties to free the cables from the
adjusted all air gap adjuster sets. bracket. Remove the cable bracket.
11. Torque total air gap locking screws to 5. Scribe a witness mark down the side of the
17 ft. lb. (23 Nm). brake to help orientation during
12. Measure all gaps again. Readjust as reassembly.
needed. 6. If you are replacing only the brake coil or
13. Install cable ties removed previously. upper brake pad, skip to step 12.
14. Close the motor compartment door. 7. If you have an air wrench available, skip to
Remove blocks and lower the lift truck to step 8. Otherwise, loosen one of the
the floor. locking bolts enough to insert a penny or
15. Reconnect the battery connector and turn the similar spacer between the armature plate
key switch ON. and coil body. Do not turn the total air gap
adjuster. See Figure 7-124. Tighten the
16. Test the brake for correct operation. locking bolt to lock the armature plate to
the coil body. This prevents rotation of the
7-98 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Brake, Electric
brake rotor as the retaining nut is 13. Remove the three bolts holding the coil
removed. and armature plate to the base plate.
Remove coil and armature plate (with
upper brake pad). If you performed steps 7
through 11, the rotor and base plate (with
Coil Body Locking Bolt
lower brake pad) are now free.
“Brake3.doc” photo 8
14. Remove the three total air gap adjusters
from the brake coil body.
15. The brake release bolts are under tension
from springs inside the coil body. Carefully
loosen and remove the brake release bolts.
Spacer
Separate the coil from the armature plate.
Reassembly and Installation
Upper Pressure Plate
1. With the new coil inverted, make sure all
Figure 7-124. Locking Brake Rotor
7IMAGE037.JPG
springs are inserted into the holes in the
coil body.
2. Place the thin washer shaped spacer on
8. Remove the retaining nut from the drive
the springs. See Figure 7-118 on
motor shaft.
page 7-96.
9. If you used an air wrench to remove the
3. Place the inverted armature plate on the
but, skip to step 10. Otherwise, loosen the
coil directly on the spacer.
locking nut. Remove the spacer.
4. Thread the three total air gap adjusters
10. Remove the three shoulder bolts that hold
into the brake coil body.
the brake base plate to the motor end bell.
5. Thread the brake release bolts through the
11. Using a brake puller threaded for M6,
coil and armature plate and draw tight.
remove the brake assembly from the lift
truck. See Figure 7-125. 6. Assemble base plate, rotor, and armature
plate/coil. Witness mark on parts not
replaced may aid in orientation. Install
three locking bolts through coil, armature,
and base plate.
7. Torque the three locking bolts to 16 ft. lb.
(21.7 Nm).
8. If you did not previously remove the entire
brake assembly (rotor and base plate),
skip to step 17.
9. Drive Motor P/N 1029753/600 or
1029754/600 only: Make sure the sleeve
spacer on the drive motor shaft is seated
all the way down onto the encoder bearing.
See Figure 7-127 on page 7-101.
10. Drive Motor P/N 1029753/600 or
7DSCF2954C.JPG
Figure 7-125. Pulling brake assembly 1029754/600 only: Make sure the
improved lower cable bracket P/N
12. Install and tighten brake release bolts in
brake release holes. See Figure 7-116 on
page 7-95.
1026304B, 15 July 2007 7-99
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Brake, Electric Drive and Brake
1047867 is installed on the drive motor 20. Make sure brake operates correctly and
end bell. See Figure 7-126. drive motor rotates without interference to
motor cables.
NOTE: When the truck is stationary, depressing
Sleeve Spacer
and releasing the deadman pedal should
cause the brake to release and engage.
When the truck is traveling, the brake
should remain released (coil energized)
until the truck speed reaches zero.
Motor
Harness
Lower
Bracket
7BRKT_SHIELD2.JPG
Figure 7-126. Lower Cable Bracket
11. Install the brake assembly over the drive
motor shaft, aligning holes with the drive
motor end bell.
12. Thread three shoulders bolts through the
base plate into the motor end bell. Torque
to 16 ft. lb. (21.7 Nm).
13. Remove brake release bolts and install in
their storage locations.
14. Loosen one of the locking bolts enough to
insert a penny or similar spacer between
the armature plate and coil body. Do not
turn the total air gap adjuster. See
Figure 7-124 on page 7-99. Tighten the
locking bolt to lock the armature plate to
the coil body. This prevents rotation of the
brake rotor as the retaining nut is
removed.
15. Install the rotor retaining nut and washer
and torque to 150 ft. lb. (203 Nm).
16. Loosen the locking bolt. Remove the
spacer.
17. Adjust the brake gap. See “Brake
Adjustment” on page 7-96.
18. Attach the motor cable bracket to the
brake. Apply thread-locking compound
(P/N 990-536) to the bolts and torque to
6 ft. lb. (8 Nm).
19. Attach the cable bundle to the cable
bracket with cable ties installed where
previously removed.
7-100 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Brake, Electric
Incorrectly Seated Correctly Seated
Motor Shaft
Sleeve Spacer
End Bell
Encoder Bearing
Motor Shaft Motor Shaft
Sleeve Spacer Sleeve Spacer
End Bell
End Bell
Shoulder
Shoulder
Encoder Encoder
Bearing Bearing
7sleeve spacer
Figure 7-127. Drive Motor Shaft Sleeve Spacer Orientation (Motors P/N 1029753/600 and 1029754/600)
1026304B, 15 July 2007 7-101
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Deadman Switch (S2) Drive and Brake
Deadman Switch (S2)
Connector
Sensor VR4
Jam Nuts
Switch S2
7R1011291 _D1.CGM
7R1011291_D2.CGM
Figure 7-128. Deadman Sensor and Switch
Adjustment continuity across switch terminals with a
DVM.
1. Adjust deadman pedal height by adjusting
3. With the deadman pedal adjusted and in
the two jam nuts on the pedal pushrod
the fully up position, set the gap between
until the dimension between top of pedal
deadman switch roller and the cam
tip and top surface of bracket bottom is:
surface on the pedal casting.
a. Series AA/BA/CA (Fore-Aft Stance):
Loosen switch mounting screws and slide
3.50 in. (89 mm)
the switch to establish a gap of 0.001 to
b. Series DA/EA/FA (Side Stance): 0.005 in. (0.025 to 0.127 mm). Retighten
3.58 in. (91 mm) screws.
Tighten the jam nuts against each other. 4. Repeat steps 2 and 3 until both pedal
2. Adjust the deadman switch S2 by travel and switch gap dimensions are
loosening the two switch mounting screws correct.
and sliding the switch along the curved
slots. Retighten mounting screws.
Switch should activate when pedal is
depressed 0.50 to 0.75 in. (13 to 19 mm)
from the top. Verify switch activation
either by hearing the click or by measuring
7-102 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Inertial Dampener
Inertial Dampener
Mounting
Bracket
Slide Plate
Friction
Plate
Friction
Plate
Dampener
Spring
Spring
Retainer
Locknut
7R1014725_B.CGM
Figure 7-129. Inertial Dampener Assembly
NOTE: The A-frame up-travel stop bolt 4. Loosen and remove the inertial dampener
adjustment is critical. Incorrect lock nuts, spring retainer, two springs,
adjustment will result in damage to the and friction plate. See Figure 7-130.
inertial dampener. See “Steerable
Caster” on page 7-45. If extra A-frame
Dampener
Dampener Spring
Spring
travel is required such that stop bolt
(1 (1
9/16
9/16
in.in.
oror
4040
mm)
adjustment cannot be maintained,
remove the inertial dampener.
Spring
Retainer Friction
Removal
Plate
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the right side cover.
3. Remove the inertial dampener cover plate.
Locknut
713Y7S001.TIF
Figure 7-130. Inertial Dampener (unrelated parts removed
for clarity)
1026304B, 15 July 2007 7-103
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Inertial Dampener Drive and Brake
5. If necessary, turn the A-frame down-travel 10. Remove the bolt holding the friction plate
adjustment bolt clockwise until there is to the A-frame yoke. See Figure 7-132 and
clearance between the dampener bolts and Figure 7-133.
the bottom of the slot in the slide plate.
See Figure 7-131 and Figure 7-135 on
page 7-105. Friction Plate
6. Remove the cap screws holding the slide
plate mounting bracket to the frame.
Remove the bracket. See Figure 7-131.
Cap Screws
Bolt
A-frame
Spring Slide
Plate
713Y7S004.TIF
Figure 7-132. Inertial Dampener (A-frame springs, slide
plate removed)
A-frame Down-Travel
A-frame Friction Plate
Adjustment Bolt
Down-Travel
713Y7S002.TIF Adjustment
Figure 7-131. Inertial Dampener (nuts, retainer, springs,
Bolt Hole
friction plate removed)
7. Loosen the A-frame down-travel
adjustment bolt and remove the bolt and
washers.
Bolt Thread-Locking
Use extreme care whenever the lift truck Compound
is jacked up. Never block the lift truck 713Y7S005.TIF
between the telescopic and the floor. Figure 7-133. Inertial Dampener (jacked up for shoulder
Use a suitable hoist to stabilize the mast. bolt removal)
Keep hands and feet clear from vehicle
while jacking the lift truck. After the lift Installation and Adjustment
truck is jacked, place solid blocks or jack
1. Attach the friction plate to the A-frame
stands beneath it to support it. DO NOT
yoke with the bolt and nylon lock nut.
rely on the jack alone to support the lift
truck. See “Jacking Safety” on 2. Install the A-frame springs. Lower the lift
page 2-11. truck slightly on the jack to seat the
springs in their retainer holes.
8. Jack the tractor up approximately 2 in. 3. Install the A-frame down-travel
(5 cm) at the tractor frame and block. See adjustment bolt with the plastic washer
Figure 7-133. between the metal washer and the frame.
9. Remove the A-frame springs. See Tighten until the distance between the top
Figure 7-131 and Figure 7-132 this page. of the A-frame and the bottom of the
7-104 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Drive and Brake Inertial Dampener
A-frame spring upper weldment is 7 in. (40 mm) at both bolts. See Figure 7-130 on
(17.7 cm). page 7-103.
7. Adjust the idler. See “Steerable Caster” on
Dampener page 7-45.
Slide Plate
Spring 8. Install the inertial dampener cover plate.
Spring 9. Reattach the right side cover.
Retainer
Locknuts
Friction Plates
76906_001.JPG
Figure 7-134. Inertial Dampener parts
4. Attach the slide plate over the dampener
bolts. Apply thread-locking compound
(P/N 1013829) to the threads in the frame.
Attach the slide plate mounting bracket to
the frame with the two cap screws. Pivot
joint on mounting bracket should be free
to flex. Torque the slide plate mounting
cap screws to 18 ft. lb. (24.4 Nm).
Pivot Joint Slide Plate
Clearance Here Friction Plate
76906_002.JPG
Figure 7-135. Inertial Dampener adjustment
5. Unblock and lower the lift truck to the
floor.
6. Attach the friction plate, two springs,
spring retainer, and two lock nuts.
Reference Figure 7-134 for orientation of
parts. Tighten the lock nuts until the
distance between the top of the spring
retainer and the friction plate is 1 9/16 in.
1026304B, 15 July 2007 7-105
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Inertial Dampener Drive and Brake
7-106 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Electrical Components
Electrical Components
Section 7. Component Procedures
1026304B, 15 July 2007 7-107
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Electrical Component Procedures Summary Electrical Components
Electrical Component
Procedures Summary
Table 7-12. Electrical Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Auxiliary Motor Locator Motor Mounting bolts: Remove hydraulic steer motor, steer bracket,
Series Photo: P/N 990-536/ aux motor with pump attached.
AA/BA/DA/EA Figure 7-11 15 ft. lb. (21 Nm)
(DC lift) on page 7-17
Battery Cables Procedure:
See procedure.
and Connector page 7-113
Battery Exterior Procedure:
See procedure.
Cleaning page 7-114
Battery Gate No N/A Less than 0.5 in. (13 mm) “free play”
Inspection movement
Battery Rollers, No N/A Clean off electrolyte using a solution of 1 lb.
Inspection (0.45 kg) of baking soda added to 0.5 gal.
(1.9 liters) of hot water.
Battery Procedure:
For explanation of BSOC, see page 5-11.
State-of-Charge page 5-11
Cold Storage Procedure:
See procedure.
Conditioning page 7-127
Connectors, Procedure:
See procedure.
AMP page 7-118
Connectors, Procedure:
See procedure.
Molex page 7-117
Contactors Locator
Photo:
Series CA/FA
(AC lift):
Figure 7-5 on
page 7-11;
Series
AA/BA/DA/ N/A
EA (DC lift):
Figure 7-11
on page 7-17;
Drawings:
Figure 7-149
on
page 7-121.
7-108 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Electrical Components Electrical Component Procedures Summary
Table 7-12. Electrical Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Fan, Tractor No P/N 990-536 on fan N/A
Compartment bracket mounting
Cooling bolts.
(FAN-FW)
Fan, Lift Motor No N/A Series CA/FA (AC lift): Attach guards and
(FAN-LM) fan to bracket, bracket to frame.
Series AA/BA/DA/EA (DC lift): Attach
shroud to lift motor, guard and fan to
shroud.
Fan, Drive Motor No P/N 990-536/ N/A
(FAN-DU) 6 ft. lb. (9 Nm)
Fan, Traction No P/N 990-536 on fan N/A
Power Amplifier bracket mounting
(FAN-2) bolts.
Fuses Table 5-1,
“Fuse Chart,” N/A
on page 5-7
Horn No Bracket to Frame: N/A
P/N 990-536/
15 ft. lb. (21 Nm)
HTI Belt An encoder and belt guard is available for
Procedure: freezer curtain applications. Contact Parts
page 7-214 Distribution Center.
Lift Motor Locator Series CA/FA (AC lift) Series CA/FA (AC lift):
Photos: Series AA/BA/DA/EA Motor weighs 125 lb. (57 kg).
Series CA/FA (DC lift):
(AC lift): Lift pump mounting Series CA/FA (AC lift)
Figure 7-7 on bolts: P/N 990-536/ Series AA/BA/DA/EA (DC lift):
page 7-13; 55 ft. lb. (72 Nm) Remove pump from motor, leaving hoses
Series Motor mounting bolts attached.
AA/BA/DA/ to bracket: Apply anti-seize compound (P/N 990-638) to
EA (DC lift): P/N 990-536/15 ft. lb. pump spline and mating surfaces.
Figure 7-13 (21 Nm)
on page 7-19 Bracket mounting bolts
to deck: P/N 990-536
Lift motor power
cables: 18 ft. lb.
(24.4 Nm)
Motor Tests Procedure:
AC Motors page 5-10 See procedure.
DC Motors page 5-8
Over-the-Mast Procedure:
See procedure.
Cable page 7-220
1026304B, 15 July 2007 7-109
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Electrical Component Procedures Summary Electrical Components
Table 7-12. Electrical Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Power Amplifier, Locator Amplifier bolts to
Lift Photo: bracket:
Series CA/FA Figure 7-8 on 6 ft. lb. (8.6 Nm)
(AC lift) page 7-14 Bracket mounting bolts Use correct electrostatic
to deck: discharge precautions. See
15 ft. lb. (21 Nm) “Static Precautions” on page 2-9.
Power cables:
11 ft. lb. (15 Nm) To discharge internal capacitor:
Note: Make sure cable 1. Turn the key switch OFF and
is perpendicular to disconnect the battery connector.
controller housing ±20 2. Measure voltage between (+) and (B–)
degrees, with terminal amplifier cable lugs.
barrel facing up or
away from housing. 3. If voltage is present, jump the terminals
with an insulated jumper attached to a
2-watt 20 ohm or larger resistor.
4. Do not jump terminals with tools or
jumper without resistor, as damage or
injury could result.
Power Amplifier, Locator Amplifier bolts to
Traction Photos: bracket:
Series CA/FA 6 ft. lb. (8.6 Nm)
(AC lift): Bracket mounting nuts Use correct electrostatic
Figure 7-5 on to deck: discharge precautions. See
page 7-11; 15 ft. lb. (21 Nm) “Static Precautions” on page 2-9.
Series Power cables:
AA/BA/DA/ 11 ft. lb. (15 Nm) To discharge internal capacitor:
EA (DC lift): Note: Make sure cable 1. Turn the key switch OFF and
Figure 7-12 is perpendicular to disconnect the battery connector.
on page 7-18 controller housing ±20 2. Measure voltage between (+) and (B–)
degrees, with terminal amplifier cable lugs.
barrel facing up or
away from housing. 3. If voltage is present, jump the terminals
with an insulated jumper attached to a
2-watt 20 ohm or larger resistor.
4. Do not jump terminals with tools or
jumper without resistor, as damage or
injury could result.
Motors, Power No Table 7-13, “Power N/A
Cable Terminals Cable Terminal
Torques,” on
page 7-122.
7-110 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Electrical Components Electrical Component Procedures Summary
Table 7-12. Electrical Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Relays, Drawing
Relay/Control Figure 6-3 on
Fuse Panel page 6-117;
Locator
Photo:
Series CA/FA
(AC lift):
N/A
Figure 7-6 on
page 7-12;
Series
AA/BA/DA/
EA (DC lift):
Figure 7-12
on page 7-18
Speed Sensor, Procedure:
See procedure.
AC Motor page 7-124
Static Strap No N/A Resistance must measure more than 10K
and less than 1.2 megohms. “EE” rated lift
trucks must use phosphor bronze cables
rather than steel.
Steer Limit Adjustment Switch Bracket to Adjust the vertical gap between sensor and
Switch S11 Procedure: Drive Unit: sensing rail to 0.05 to 0.10 inch (1.3 to
Series CA/FA page 7-44 P/N 990-536/ 2.5 mm).
(AC lift) 9 ft. lb. (12 Nm)
Steer Manager Procedure:
Series CA/FA page 7-126 See procedure.
(AC lift)
Switch S18 (HTI Drawings: Torque:
pressure) Series CA/FA 12 ft. lb. (16 Nm)
(AC lift):
Figure 7-170
on
page 7-142;
Series
AA/BA/DA/
EA (DC lift):
Figure 7-174
on
page 7-146
1026304B, 15 July 2007 7-111
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Electrical Component Procedures Summary Electrical Components
Table 7-12. Electrical Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Switch S19 Drawings: 12 ft. lb. (16 Nm) N/A
(Clogged Filter) Series CA/FA
(AC lift):
Figure 7-170
on
page 7-142;
Series
AA/BA/DA/
EA (DC lift):
Figure 7-174
on
page 7-146
Temperature Locator
Sensor, Ambient photo: N/A
(T) page 7-20
Temperature Procedure:
Sensor, AC page 7-123
See procedure.
Motor (LMT or
TMT)
Temperature No N/A Apply heatsink compound (P/N 990-508) to
Sensor, DC Lift sensor threads. Be sure sensor does not
Motor touch field poles when retaining nut is
tightened.
Travel Light No P/N 990-536/ N/A
23 ft. lb. (31 Nm)
Vehicle Manager Locator N/A After installation, run config mode, set
Photo: defaults, then set parameters to customer
Series CA/FA settings.
(AC lift):
Figure 7-5 on When changing VM software, make sure a
page 7-11; matched VM/DM set of software is installed.
Series See “Matching Software Versions” on
AA/BA/DA/ page 7-272.
EA (DC lift):
Figure 7-12
on page 7-18
Wiring, General Procedure: See procedure.
page 7-116
7-112 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Electrical Components Battery Procedures
Battery Procedures 5. Look inside the connector. Check all
internal contacts for damage, dirt, or
corrosion. Do not use a metal object to
clean the connector.
Before working on the battery, review
Battery Safety, beginning on page 2-6.
Batteries for this lift truck weigh Some degreasers and parts cleaners will
between 2000 and 2900 lb. (908 to cause the connector shell to disintegrate.
1316 kg). Use extreme care during Avoid contacting battery connectors with
replacement. Use a suitable battery solvents.
moving device or hoist for lifting. Do not
extend a battery more than 1/3 of its Removal, Replacement, and
length outside the battery compartment Installation
without being attached to a
battery-moving device. The cables to either half of the connector have a
lip on their forward end. This lip snaps over a
Battery Connector/Cables spring-loaded retainer that is part of the
connector.
Location
The battery connector is located at the
front-right of the tractor, above the battery.
Battery
Connector
7BATTCON2.TIF
Figure 7-137. Battery Cable and Connector
76353_118G.JPG
Figure 7-136. Battery Connector location
When replacing battery cable ends,
remove only one end at a time from the
Inspection connector, to avoid the cable ends
1. Turn the key switch OFF and disconnect touching and causing a short circuit. Do
the battery connector. not allow the metal cable end to touch
the battery. Use insulated tools and
2. Check the battery connector for damaged avoid contact with battery case or cable
cables. ends.
3. Check to see if battery cables are pulling
out of the connector. 1. To remove a cable from the connector,
4. Check the cables at the battery terminals. push the retainer down while pulling the
Connections should be tight, with no battery cable towards the rear and out of
corrosion.
1026304B, 15 July 2007 7-113
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Battery Procedures Electrical Components
the connector. See Figure 7-138 and battery and battery charger
Figure 7-137. manufacturer’s manuals.
725L6S014.EPS
2. Wear personal protective equipment. See
7BATTCON1.TIF “Battery Safety” on page 2-6.
Figure 7-138. Battery Cable Removal from Connector
3. Turn the key switch OFF and disconnect
2. Do not attempt to repair battery cables by the battery connector. Remove the battery
crimping new terminals. Replace the from the lift truck. See “Battery - Removal”
cable. above.
4. Inspect the battery cables to make sure
Disconnect blocks they are not frayed or loose. Inspect the
battery connector to make sure there is no
Model 7400/7420/7440 lift trucks use an foreign material inside the connector.
electrical EPO system, so battery connectors do Make sure the filler plugs are tight and the
not need to have battery disconnect blocks vent holes in the filler plugs are open.
installed.
Battery Cable
Beginning with serial number 05498, battery
connectors with disconnect blocks attached can
experience interference with the side plate of
the tractor.
In such cases, remove the disconnect block
from the connector. If this is not practical due
to mixed EASi/7000 fleet, replace the battery
connector mounting bracket (P/N 1009263)
with a new style (P/N 1063890).
Filler Plug
Vent Hole
Battery Exterior Cleaning
709G6S047.TIF
1. Read, understand, and follow procedures, Figure 7-139. Battery Cable and Filler Plug
recommendations and specifications in the
5. Keep the top of the battery clean and dry.
Corrosion, dust, and moisture provide a
conducting path to short-circuit cells or
create shorts to ground.
7-114 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Electrical Components Battery Procedures
Do not clean the top of the battery with Never plug the battery charger into the
the soda solution while it is installed in lift truck. This will severely damage the
the lift truck. Water can seep into the lift truck’s electrical system. Plug the
electrical components and cause serious charger only into the connector from the
damage. battery.
6. Wash dirty batteries (or any that have had
electrolyte spilled on them) with a solution
of 1 lb. (0.45 kg) of baking soda added to
0.5 gal. (1.9 liters) of hot water.
7. Use a brush with flexible bristles to clean
the entire top of the battery with the soda
solution. Wait until all foaming stops,
indicating that the battery exterior is
neutralized.
8. Rinse the battery with clean water.
9. Dry the battery completely before
reinstalling it. 76173_012.EPS
10. Reinstall the battery in the lift truck, using
a suitable battery moving device. Battery State-of-Charge
Reconnect the battery connector.
Battery State-of-Charge (BSOC) is a feature that
monitors and remembers the charge level of the
Testing, Charging, and battery connected to the lift truck and prevents
Maintenance excessive discharging of that battery. Operating
a lift truck using a discharged battery can
For information on testing, charging, and damage both the battery and the electrical
maintaining your lift truck battery, consult the components of the lift truck. See page 5-11 for a
battery manufacturer’s specifications and detailed description of how BSOC works. See
instruction manual. page 5-12 for the procedure for setting BSOC
Cutout.
1026304B, 15 July 2007 7-115
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Wiring and Harness Connectors Electrical Components
Wiring and Harness When replacing wires, follow these guidelines:
• Use the appropriate tools to remove and
Connectors insert terminations at each connector.
• Remove damaged terminations and
discard. Never reuse a termination from a
General Repair Procedures wire.
• Do not cut away a terminal lug and reuse
Inspection
the wire strands that were crimped into
the original lug.
See “Electrical Troubleshooting Guidelines” on
page 5-3. • When stripping wire, use new wire strands
for new terminations. Make sure to use a
Whenever working on the lift truck, use care new wire with extra length to allow for
around wiring harnesses. cutting and stripping of the ends to install
new terminations.
• Carefully connect and disconnect all
connections. • Use a new wire that is the same gauge
(typically gauge 18 AWG), size, type, and
• Do not pry connectors apart with
color as the wire it is replacing.
unspecified tools.
• Use a hand stripper capable of stripping
There should be a wire marker at each by wire gage number. Use care not to nick
termination. If the marker is missing or or cut any of the wire strands. Discard and
unreadable, remark the wire to allow easier replace a wire with damaged strands.
identification. Insert the wire strands the proper length
into termination before crimping.
NOTE: It is normal to find unused connectors
for uninstalled options that have had
heat shrink applied over them and have Soldering Procedures
been strapped to the harness.
To prevent damage from excessive heat when
soldering small components in assemblies,
Repair follow these guidelines:
• Make sure the soldering tip is clean. A
dirty tip does not transfer heat well and
Use correct electrostatic discharge encourages long dwell time and greater
precautions. See “Static Precautions” on pressure. Apply light pressure on the
page 2-9. terminal.
• Flux: rosin base
When pulling a wire out through a bundle, cut • Solder: 60/40 rosin core or equivalent
off the pin or socket so it will not snag. When
replacing wires, in some cases you will be able • Solder Iron: 15-25 watt “pencil-type”
to tape or solder one end of a new wire to one maximum
end of the failed wire. Then you can pull the old • Tip Size: 3 mm (0.118 in.) diameter x
wire out of the bundle and pull the new wire 30 mm (1.182 in.) long screwdriver tip.
into the bundle, all at the same time. Make sure Make sure the tip is clean.
to disconnect the old wire from the new wire. • After soldering, clean the terminals with a
brush dampened with an alcohol-based
In other cases, it will be easier to secure a new cleaner (P/N 990-600/FOF). Do not allow
wire to the outside of the existing wire bundle any cleaner to seep into the switches or
with straps of an appropriate size. You can potentiometers, or contact contamination
leave the failed wire in the bundle, or pull it by may occur.
one end to remove it from the bundle.
7-116 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Electrical Components Wiring and Harness Connectors
Molex Connectors from a Molex connector, depress these locking
ears far enough to clear the ridge in the
connector.
Socket Pin Extraction
To remove a pin from a Molex connector, use
Pin pin extraction tool P/N 950-026.
1. Insert the extraction tool over the pin and
push all the way into the connector. This
releases the locking ears on the pin.
2. Pull the wire and pin from the connector.
Locking
Ears Pin Insertion
7MOLEX.EPS
Figure 7-140. Molex Connector, end view
To insert a pin into a Molex connector, insert
the pin into the back side of the connector and
For pin orientation of Molex connectors, see
push the wire all the way in until it clicks. The
Figure 6-1 on page 6-115. Molex connectors
locking ears have now engaged the connector.
have pins with locking ears that engage ridges
in the plastic connector body. To remove a pin
Top view of
connector Tool inserted over
pin
Extraction
Locking Tool
ears
Side view of
connector
7MOLEX1.EPS
Figure 7-141. Pin Extraction
1026304B, 15 July 2007 7-117
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Wiring and Harness Connectors Electrical Components
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.
Wire Seal
Interface
Seal
Contact
Cavity
Wire Seal Jack
Housing
Pin Contact
Pin Housing
Sealing Plug
74570_001.TIF
Figure 7-142. AMP Water-Resistant Connector
To maintain the integrity of water-resistant
seals, use the following procedures when Extraction Tool
working with AMP connectors.
Pin Extraction
To aid in separating AMP connectors, use
unlatching tool Raymond P/N 950-042. To
remove a pin from an AMP connector, use pin
extraction tool Raymond P/N 950-009.
1. While holding the wire seal, push the
selected wire forward, then insert the
Locking
extraction tool into the contact socket. See
Lance
Figure 7-143. 74570_009.TIF
Figure 7-143. AMP Pin Extraction
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
7-118 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Electrical Components Wiring and Harness Connectors
prevents damage to the seal. See make sure the contact is locked in place.
Figure 7-144. See Figure 7-146.
Rotate and Pull
Pin Contact
74570_008.TIF 74570_004.TIF
Figure 7-144. Removing Wire Figure 7-146. Wire Insertion
Pin Insertion Seals
1. Be sure the connector has a wire seal 1. Use a wire seal at the back (wire end) of
attached to the connector back. See each connector half. See Figure 7-145.
Figure 7-145. 2. Plug unused pin positions with sealing
plugs. See Figure 7-147.
Wire Seal a. 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.
b. Remove sealing plugs by pulling with
needle-nose pliers while grasping the
Pin Housing wire seal and connector.
74570_002.TIF
Figure 7-145. Wire Seal Sealing Plug
2. If re-inserting a wire previously removed,
check the pin contact locking lances to
ensure 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
74570_005.TIF
Figure 7-147. Sealing Plug
3. Use an interface seal between pin and jack
halves of the connector. To prevent
damage to the seal, use the matching
1026304B, 15 July 2007 7-119
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Wiring and Harness Connectors Electrical Components
connector cap to slide the interface seal
over the contact silos on the pin housing.
See Figure 7-148.
Interface
Seal
Pin Housing
74570_003.TIF
Figure 7-148. Interface Seal
4. When mating connectors, make sure
polarized silos are properly oriented. Push
pin and jack halves of the connector
together until locking latches engage. See
Figure 7-149.
Locking
Latches
74570_006.TIF
Figure 7-149. Latching AMP Connector
7-120 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Electrical Components Contactor Panel
Contactor Panel
Series CA/FA (AC lift)
7R1020143_A.CGM
Figure 7-150. Contactor Panel layout, Series CA/FA (AC lift)
Series AA/BA/DA/EA (DC lift)
7R1013882_A.CGM
Figure 7-151. Contactor Panel layout, Series AA/BA/DA/EA (DC lift)
1026304B, 15 July 2007 7-121
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Motors Electrical Components
Motors
Terminal Nuts
Table 7-13. Power Cable Terminal Torques
Stud Size/Type Torque
Motors
M8 top nut 18 ft. lb. (24.4 Nm)
Power Amplifiers and Contactors
Aluminum 132 in. lb. (15 Nm)
M6 steel 50 in. lb. (5.6 Nm)
M8 steel 180 in. lb. (20.3 Nm)
M8 brass/copper 70 in. lb. (7.8 Nm)
DC Motor Troubleshooting
See “DC Motor Troubleshooting” on page 5-8.
AC Motor Troubleshooting
See “AC Motor Troubleshooting” on page 5-10.
7-122 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Electrical Components Temperature .Sensor, AC Motor, LMT/TMT (Danaher Motor)
Temperature .Sensor, AC 6. Reinstall cover/door previously
removed/opened.
Motor, LMT/TMT 7. Reconnect the battery connector and turn
the key switch ON.
(Danaher Motor)
Temperature sensors in the AC drive and lift
motors are integral to the motor. When a motor
temperature sensor fails, replace it with an
externally mounted sensor, using the procedure
below.
Temperature
Sensor
Power
Cables
74612_019.TIF
Figure 7-152: Drive Motor External Temperature Sensor
Installation (External)
1. Turn the key switch OFF and disconnect
the battery connector.
2. Drive Motor (TMT): Open drive motor
compartment door.
Lift Motor (LMT): Remove top cover.
Use correct electrostatic discharge
precautions. See “Static Precautions” on
page 2-9.
3. Disconnect the temperature sensor
connector JPT3 (drive motor) or JPL3 (lift
motor). Cut the wires from JT3 or JL3
close to the motor body and discard the
cut off connector.
4. Mount the external sensor in a recess
groove in the motor housing and fasten
with adhesive provided with the sensor kit.
5. Reconnect JPT3 or JPL3.
1026304B, 15 July 2007 7-123
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Speed Sensor, AC Motor (Danaher Motor) Electrical Components
Speed Sensor, AC Motor
Bearing Sensor
(Danaher Motor) Retainer Bearing
Removal
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the top and right side covers.
3. Remove the motor from the lift truck. Place
the motor on a bench.
4. Remove the six end bell rod nuts securing Snap Ring
the end bells to the motor. A vise grip 74472_016.TIF
pliers is useful in gripping the rods. Figure 7-154. Speed Sensor Removed
5. Remove the three machine screws
securing the encoder assembly to the Installation
upper end bell.
1. Make sure you install the bearing retainer
6. Remove the motor end bell. over the motor shaft with the recess
7. Remove the snap ring securing the speed towards the end bell.
sensor bearing. 2. Place the sensor bearing over the motor
8. Using a wheel puller behind the bearing shaft with the wiring harness in line with
retainer, remove the bearing from the the motor power cables. Place a deep
motor shaft. See Figure 7-153. socket or pipe nipple with a 1.25 inch
(30 mm) inside diameter over the motor
shaft and onto the bearing inner race. Seat
Wheel Puller the bearing firmly with a hammer by
striking the socket or pipe nipple.
See Figure 7-155.
Bearing Retainer
Sensor Bearing
Snap Ring
74472_015.TIF
Figure 7-153. Speed Sensor Removal
74472_017.TIF
Figure 7-155. Seating the Bearing
3. Install the snap ring above the bearing. On
P/N 570-610/603 only, use a feeler gauge
to measure the gap between the support
7-124 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Electrical Components Speed Sensor, AC Motor (Danaher Motor)
ring and snap ring. See Figure 7-156. 6. Install and tighten the machine screws
Install shims as needed to fill the gap. securing the bearing and retainer to the
end bell.
7. Install and tighten the nuts securing the
Encoder Bearing end bell to the end bell rods. Torque to
55 in. lb. (6.2 Nm).
Support Ring 8. Re-install the lift motor in the lift truck.
9. Re-install top and right side covers.
Shim Here
Snap Ring
7P1010738r.JPG
Figure 7-156. Shimming the Motor Shaft
4. Place the bearing retainer over the
bearing, feeding the cable harness through
the slot in the retainer. Align the bearing
so the cable harness is in line with the
motor power cables.
5. Use one of the end bell rods to align the
end bell temporarily with the bearing
retainer. See Figure 7-157.
74472_018.TIF
Figure 7-157. Aligning End Bell with Bearing Retainer
1026304B, 15 July 2007 7-125
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Steer Manager Electrical Components
Steer Manager 5. Disconnect wire STR-1 from the contactor,
removing cable ties as necessary.
NOTE: Series CA/FA (AC lift)
Removal
1. Turn the key switch OFF and disconnect
the battery connector.
2. Series CA (Fore-Aft Stance): Remove the
top cover, right side cover, primary control
handle cover, and right front cover.
Reference “Top Cover” on page 7-30,
“Cover Drawings, Series AA/BA/CA
(Fore-Aft Stance)” on page 7-28, “Primary
Control Handle Cover” on page 7-28, and
“Right Front Cover” on page 7-27.
7R1020143_A.CGM
Figure 7-159. Contactor/Fuse Panel
6. Open the drive motor compartment.
Use correct electrostatic discharge
7. Disconnect the steer motor primary power
precautions. See “Static Precautions” on
wires at A1 and A2 on the motor. Cut cable
page 2-9.
ties as needed.
3. Disconnect wire from TP4. 8. Remove bolts holding steer manager to
frame.
Installation
1. Install steer manager to frame with bolts.
2. Route steer motor wires to steering electric
motor and connect. Install cable ties where
previously removed.
3. Route wire STR-1 to the contactor panel
and connect to STR-2 on the steer
contactor. Install cable ties where
previously removed. Make sure cable is
not pinched behind traction power
amplifier.
4. Connect the remaining wire to TP4.
5. Install the contactor cover, right front
Steer cover, primary control handle cover, right
TP4 side cover, and front cover. Close the drive
Manager
motor compartment door.
76353_116G.JPG
Figure 7-158. Steer Manager Removal
4. Remove the contactor/fuse panel cover.
7-126 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Electrical Components Cold Storage Conditioning
Cold Storage sealing compound (P/N 990-445). Connect
wires and connectors. Coat the outside and
Conditioning where connectors attach to the circuit board.
Coat terminals and terminal strips.
NOTE: Conversion of Model 7400/7420/7440 NOTE: Self-sealing AMP connectors (reference
lift trucks for cold storage operation page 7-118) do not need sealing
requires prior Raymond approval via treatment.
Form S207.
Treat the following parts to prevent moisture
New Model 7400/7420/7440 lift trucks to be from entering:
operated in a cold storage environment require
• EPO button
the following:
• Key switch terminals
Components • Light and fan switch terminals, if not
sealed
Required • Deadman switch terminals
• Proportional valve (SOL2) terminals
• All-weather hydraulic fluid (P/N 1017238)
• DC Lift motor temperature sensor JPZ
• Ambient temperature sensor
• Operator display interface card: coat both
• Special cold storage control handle sides completely
assemblies with heaters
• All control wire (18 GA) terminals and
• Wire mesh mast guard terminal strip posts (TS1, TS2)
• Suggested (Series AA, BA, CA): • Any unsealed connectors not located in a
Condensation drip guard (P/N 1036240) heated compartment.
• Optional heated floor pad
• Optional heated glass guard Corrosion Inhibitor Coating
Not Permitted Coat or spray bare metal surfaces listed below
with Corrosion Inhibitor Coating (P/N 990-644):
• Unheated glass or Plexiglas mast guard
• Reach cylinder cotter pins
• U.L. E or EE label
• Main and free lift chain pulleys and shafts
• Main and free lift chain anchors and
Lubricants threaded pins
See the “Lubrication Specification Chart” on • Drive unit dipstick
page A-2 for special hydraulic fluid and drive
unit lubricants for cold storage operation. Condensation Drip Guard
Coat battery roller shafts with all-weather To add the control handle condensation drip
grease (P/N 1012992). guard (P/N 1036240) to the overhead guard of
fore-aft stance lift trucks (Series AA, BA, CA), do
Grease carriage fittings with all-weather grease the following:
(P/N 1012992).
1. Remove from the overhead guard the
right-hand lower hex head cap screw,
Sealing Treatment located almost directly above the control
handle.
Fill sockets and the front and back of both 2. Install an M16 flat washer onto the cap
halves of unsealed connectors with cold storage screw.
1026304B, 15 July 2007 7-127
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Cold Storage Conditioning Electrical Components
3. Reinstall the cap screw with flat washer
and drip guard. See Figure 7-160.
7RCH_05_002.JPG
Figure 7-160. Condensation Drip Guard
Control Handle Modification
Control handles of early fore-aft stance lift
trucks (Series AA, BA, and CA) lacked a drain
hole.
To better drain these control handles, do the
following:
1. Remove the control handle.
2. Drill a 0.15 inch (5/32 inch) hold in the
center of the recessed area below the
handle shaft. See Figure 7-161.
3. Reinstall the control handle.
Drill hole here
7RCH_04_010.tif
Figure 7-161. Drain Hole Location
7-128 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components
Hydraulic Components
Section 7. Component Procedures
1026304B, 15 July 2007 7-129
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic Component Procedures Summary Hydraulic Components
Hydraulic Component
Procedures Summary
Table 7-14. Hydraulic Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Auxiliary Procedure: See procedure. Set pressure at port G5 to 2000 psi
Pressure page 7-140 (13790 kPa).
Adjustment
Auxiliary Pump Locator Pressure fitting torque: Clamp and cap hydraulic hoses. Remove
Series Photo: 45 ft. lb. (61 Nm) hydraulic steer motor, steer bracket, aux
AA/BA/DA/EA Figure 7-11 Mounting bolts: motor with pump.
(DC lift) on page 7-17 P/N 990-536/ Apply anti-seize compound (P/N 990-638) to
11 ft. lb. (15 Nm) spline, mating surfaces.
Counterbalance See manifold See Table 7-18 on If carriage drifts, replace CB-1 P/N
Valve CB-1 and drawing: page 7-154. 1020951/001 with 1020951/004, and
CB-2 page 7-149 REL-3 P/N 1007104/001 with
Deep-Reach 1009281/013.
Valve CE1 Series See manifold See Table 7-17 on N/A
AA/BA/DA/EA drawings: page 7-153
(DC lift) page 7-145
Clogged Filter See manifold See Table 7-16 on N/A
Switch CFS-1 drawings: page 7-152.
page 7-141 See Table 7-17 on
and page 7-153.
page 7-145
Check Valve See manifold See Table 7-16 on N/A
CV-1 drawings page 7-152.
page 7-141, See Table 7-17 on
page 7-145. page 7-153.
Check Valve See manifold See Table 7-17 on N/A
CV-2 Series drawings: page 7-153.
AA/BA/DA/EA page 7-145
(DC lift)
Check Valve See manifold See Table 7-18 on N/A
CV-3 drawings: page 7-154.
Deep-Reach page 7-149
Flow Limiters Procedure: See Table 7-18 on N/A
page 7-184 page 7-154.
and
page 7-185
Hydraulic Filter Procedure:
See procedure.
page 7-135
7-130 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components Hydraulic Component Procedures Summary
Table 7-14. Hydraulic Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Hydraulic Fluid No N/A Volume: 7400: 5.5 gallons (20.8 liters)
7420/7440: 7.5 gallons (28.4 liters)
Sight glass in reservoir.
Hydraulic Procedure:
See procedure.
System Bleeding page 7-134
Lift Pressure Procedure: N/A
Adjustment Page 7-137
Lift Pump Locator Fittings:
Photos: Series CA/FA (AC lift):
Series CA/FA P1: 85 ft. lb. (115 Nm)
(AC lift): Input: 120 ft. lb.
Figure 7-7 on (163 Nm)
page 7-13; Series AA/BA/DA/EA
Series (DC lift):
Apply anti-seize compound (P/N 990-638) to
AA/BA/DA/ P1: 85 ft. lb. (115 Nm)
spline, mating surfaces.
EA (DC lift): P2: 60 ft. lb. (81 Nm)
Figure 7-11 Lift pump mounting
on page 7-17 bolts: Series
AA/BA/DA/EA (DC
lift):
P/N 990-536/
55 ft. lb. (72 Nm)
Load Shuttle See manifold See Table 7-16 on N/A
LS-1 drawings: page 7-152.
page 7-141 See Table 7-17 on
and page 7-153.
page 7-145
Lowering, Procedure:
Manual Page 7-138
See procedure.
Lowering of
Carriage
Manifold, Drawing Mounting bolts:
Auxiliary Page 7-147 P/N 990-536/
Reach/Tilt/ Procedure: 21 ft. lb. (29 Nm)
Sideshift page 7-148 Solenoids:
Series CA/FA (AC lift): Label wires as needed before removing.
Table 7-16 on Cap ports and plug hoses.
page 7-152.
Series AA/BA/DA/EA
(DC lift): Table 7-17 on
page 7-153.
1026304B, 15 July 2007 7-131
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic Component Procedures Summary Hydraulic Components
Table 7-14. Hydraulic Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Manifold, Main Drawings: Mounting bolts:
page 7-141 P/N 990-536/
and 21 ft. lb. (29 Nm)
page 7-145 Solenoids:
Series CA/FA (AC lift): Label wires as needed before removing.
Table 7-16 on Cap ports and plug hoses.
page 7-152.
Series AA/BA/DA/EA
(DC lift): Table 7-17 on
page 7-153.
Manifold, Reach Drawing: Solenoids: N/A
(DR only) page 7-149 See Table 7-18 on
Procedure: page 7-154.
page 7-150
Manifold, Drawing and Solenoids: N/A
Tilt/Sideshift procedure: See Table 7-18 on
(DR only) page 7-151 page 7-154.
Priority-on- See manifold See Table 7-16 on N/A
Demand Valve drawing page 7-152.
POD-1 page 7-141
Pressure Switch, See manifold See Table 7-16 on N/A
HTI drawings page 7-152.
page 7-141, See Table 7-17 on
page 7-145 page 7-153.
Pressure See manifold See Table 7-16 on Install with new O-ring.
Transducer drawings page 7-152.
CYL-P page 7-141, See Table 7-17 on
page 7-145 page 7-153.
Proportional Procedure: Torque: 95 ft. lb. N/A
Valve page 7-139 (129 Nm)
Adjustment
Relief Valve See manifold See Table 7-17 on N/A
REL-1 drawings: page 7-153.
Series page 7-145
AA/BA/DA/EA
(DC lift)
Relief Valve See manifold See Table 7-16 on N/A
REL-2 drawings page 7-152.
Series CA/FA page 7-141
(AC lift)
Relief Valve See manifold See Table 7-18 on If carriage drifts, replace CB-1 P/N
REL-3 drawings: page 7-154. 1020951/001 with 1020951/004, and
Deep-Reach only page 7-149 REL-3 P/N 1007104/001 with
1009281/013.
7-132 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components Hydraulic Component Procedures Summary
Table 7-14. Hydraulic Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Solenoids No See charts beginning N/A
on page 7-152 for valve
body and coil torques.
1026304B, 15 July 2007 7-133
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Bleeding Hydraulic Components
Hydraulic System 6. Repeat steps 4 and 5 for the other main lift
cylinder.
Bleeding 7. Repeat steps 4 and 5 for each of the two
free lift cylinders.
You must bleed the hydraulic system to remove
any trapped air whenever you:
• Change a hydraulic hose
• Disconnect a hydraulic fitting
• Remove a hydraulic cylinder
Bleed Screw
• Remove the hydraulic pump
• Remove the hydraulic reservoir
• Notice that the load is bouncing
Procedure
1. Elevate the fork carriage past free lift and
lower it to the floor. Repeat several times.
This will tend to encourage any trapped air
bubbles to migrate to the top of the
cylinders.
7bleederfree.jpg
2. With no load on the forks, elevate the forks Figure 7-163. Bleed Screw, Free Lift Cylinder
2 to 3 inches (5 to 7.5 cm) off the floor.
3. Turn the key switch OFF and disconnect 8. Reconnect the battery connector and turn
the battery connector. the key switch ON.
4. Loosen (but do not remove) the bleed screw 9. Lower the forks all the way down to the
at the top of the main lift cylinder. Hold a floor.
rag close to and beneath the bleed screw to 10. Fully extend and retract the reach
keep hydraulic fluid from spraying out. mechanism several times.
11. If the truck is equipped with tilt, tilt the
carriage all the way forward and backward
several times.
12. If the truck is equipped with sideshift,
shift the carriage all the way to the left and
right several times.
13. Series AA/BA/DA/EA (DC lift): Step on the
deadman pedal and turn the steering
wheel from stop to stop for approx. 2
Bleed Screw
minutes.
14. Thoroughly clean up any spilled hydraulic
fluid.
15. Check the hydraulic reservoir level and
7bleedermain.jpg
refill as necessary. Do not overfill the reservoir.
Figure 7-162. Bleed Screw, Main Lift Cylinder
5. When hydraulic fluid starts flowing from
the bleed screw hole, securely tighten the
bleed screw.
7-134 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components Hydraulic Filter
Hydraulic Filter 6. Using the extraction bolt installed in the
manifold, remove the filter.
One of two types of hydraulic filters is installed
in the main manifold, herein referred to as
Type 1 and Type 2.
Filter Type 1
Removal
1. Remove the top cover.
2. If you are not draining the reservoir,
elevate the mast to lower the hydraulic oil
level in the reservoir to minimize oil
leakage.
3. Turn the key switch OFF and disconnect
7R1022231_A.CGM
the battery connector. Figure 7-165. Filter Extraction
4. Remove the plug retaining the oil filter
using a 3/4 in. socket. Installation
1. Check the cavity for contamination and
clean as required.
Extraction Bolt
2. Install the new filter, making sure it seats
into the cavity correctly.
3. Install the spring on top of the filter.
4. Install and torque the hex plug to 30 ft. lb.
(40 Nm).
5. Reinstall the extraction bolt into the
manifold.
6. Reconnect the battery connector and turn
the key switch ON.
Plug 7. Lower the mast and check for leaks.
8. Install the top cover.
7R1022231_A.CGM
Figure 7-164. Filter Plug
5. Remove the spring on top of the filter.
Filter Type 2
NOTE: For Model 7400 Series BA and EA lift
trucks (DC High Performance Lift), use a
filter cartridge with a shield,
P/N 1012615/103 or later).
Models 7420/7440 use two filter
cartridges in the main manifold.
1. Remove the top cover.
2. If you have not drained the reservoir,
elevate the mast to lower the hydraulic
1026304B, 15 July 2007 7-135
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic Filter Hydraulic Components
fluid level to minimize hydraulic fluid Installation
leakage.
1. Install the cartridge core into the manifold
3. Turn the key switch OFF and disconnect
making sure the core seats correctly into
the battery connector.
the nose of the cavity.
4. Remove the plug retaining the hydraulic
fluid filter, using a 3/4 in. socket.
7R1022231_A.CGM
Figure 7-167. Cartridge Core
7R1022231_A.CGM
Figure 7-166. Filter Plug 2. Install the new filter cartridge onto the
cartridge core.
5. Remove the filter cartridge.
6. If contamination is evident, remove the
cartridge core and clean as required.
7. Inspect the O-ring on the core and replace
if necessary.
7R1022231_A.CGM
Figure 7-168. Filter Cartridge (without shield)
3. Install and torque the hex plug to 30 ft. lb.
(40 Nm).
4. Reconnect the battery connector and turn
the key switch ON.
5. Lower the mast and check for leaks.
6. Install the top cover.
7-136 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components Lift Pressure Adjustment
Lift Pressure Adjustment 10. Loosen the lock nut on the main lift
pressure relief valve (REL1) on the main
manifold. See “Manifold, Main, DC Lift,
Series CA/FA (AC lift) Model 7400” on page 7-145.
11. Elevate the carriage until the upper limit is
Lift pressure is set by software in Series CA/FA reached.
(AC lift). 12. Continue trying to elevate and turn the
relief valve adjusting screw to obtain a
See Table 7-15 for maximum permissible lift pressure reading 200 psi (1379 kPa)
pressure. greater than that required to lift the
maximum rated load (the value recorded
in step 8). Turn the adjusting screw
clockwise to increase pressure,
Table 7-15. Maximum Permissible LIft Pressures
counterclockwise to decrease pressure.
Maximum
Model/Mast Permissible Lift For maximum permissible lift pressure,
Pressure see Table 7-15.
Model 7400 3300 psi (22,753 kPa) 13. Tighten the lock nut on the lift pressure
R45TT mast relief valve.
14. Check the pressure again. If the value has
Model 7400 3600 psi (24,821 kPa)
DR32TT mast changed, repeat this procedure until the
correct pressure reading is obtained.
Model 7420/7440 2950 psi (20,339 kPa)
15. Turn the key switch OFF and disconnect
R45TT mast
the battery connector.
Model 7420/7440 2600 psi (17,926 kPa) 16. Remove the pressure gauge from the lift
DR32TT mast pressure test port and replace the cap.
17. Reinstall the top cover. Reconnect the
Series AA/BA/DA/EA (DC lift) battery connector and turn the key switch
ON.
1. Lower the carriage completely.
2. Turn the key switch OFF and disconnect
the battery connector.
3. Remove the top cover.
4. Remove the cap from the G1 lift pressure
test port on the main manifold. See
“Manifold, Main, DC Lift, Model 7400” on
page 7-145.
5. Connect a pressure gauge capable of
reading at least 5000 psi (34,470 kPa).
6. Reconnect the battery connector and turn
the key switch ON.
7. Place the maximum rated load on the
forks.
8. Elevate the carriage past free lift, that is,
until the telescopics begin to lift. Record
the pressure required to lift the load.
9. Lower the carriage and remove the load.
1026304B, 15 July 2007 7-137
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Manual Lowering of Fork Carriage Hydraulic Components
Manual Lowering of Series AA/BA/DA/EA (DC lift)
Fork Carriage 1. Turn the key switch OFF and disconnect
the battery connector.
2. Loosen and remove the lock nut on the
If the fork carriage is hung up and unable to be
main relief valve REL1. See “Manifold,
lowered normally, use the following procedure
Main, DC Lift, Model 7400” on page 7-145.
to lower the carriage.
Note the number of threads exposed on
the lift pressure relief valve.
3. Turn the lift pressure adjusting screw
Make sure the forks and carriage are slowly counterclockwise until the fork
free from racks and other obstructions carriage begins to lower.
before lowering.
4. When you have resolved the cause of the
hung carriage, you must reset the lift
Series CA/FA (AC lift) pressure.
1. Manually open the load holding valve 5. Turn the lift pressure adjusting screw
SOL1. See “Manifold, Main, AC Lift, Model clockwise until the same number of
7400” on page 7-141. On the top of SOL1 threads are exposed as you noted in
is a small knurled knob. Depress the knob step 2.
and turn counterclockwise until the knob 6. Install but do not tighten the lock nut on
pops up. the relief valve.
2. If there is power on the lift truck, try to 7. Perform the procedure to adjust lift
lower by using the lift/lower knob. pressure. See “Lift Pressure Adjustment”
a. If this is successful, go to step 4. on page 7-137.
b. If this is unsuccessful, continue to the
next step.
3. Manually adjust the proportional lift/lower
valve SOL2 to cause the carriage to lower.
a. Loosen the lock nut on top of SOL2.
b. Using a hex-key wrench, adjust the
brass adjustment screw clockwise until
the carriage begins to move.
c. Turning the screw clockwise increases
lowering speed. Turning the screw
counterclockwise slows the lowering
speed.
4. After making necessary repairs to the lift
truck, return SOL1 and SOL2 to their
original positions.
a. Depress the knob on top of SOL1 and
turn the knob clockwise until it locks in
the depressed position.
b. Adjust the proportional lift/lower valve
as described under “Proportional Valve
Adjustment” on page 7-139.
7-138 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components Proportional Valve Adjustment
Proportional Valve
Adjustment
Series CA/FA (AC lift) and
Series AA/BA/DA/EA (DC lift)
If the carriage hesitates when being lowered, or
cannot be feathered, adjust the proportional
valve as follows:
1. Raise the fork carriage to eye level.
2. Turn the key switch OFF and disconnect
the battery connector.
3. Remove the top cover.
4. Remove one of the coil wires from SOL2.
See “Manifold, Main, AC Lift, Model 7400”
on page 7-141 or “Manifold, Main, DC Lift,
Model 7400” on page 7-145. Loosen the
jam nut and lock nut holding the
adjusting screw on the proportional valve.
5. Reconnect the battery connector and turn
the key switch ON.
6. Energize the load holding solenoid by
requesting “lower” with the lift/lower
potentiometer.
7. Slowly rotate the adjusting screw
clockwise until the carriage just starts to
creep downward. Turn the screw
counterclockwise until the carriage stops.
Repeat several times in order to refine the
adjustment point. When adjustment is
complete, tighten the lock nut and jam
nut.
8. Turn the key switch OFF and disconnect
the battery connector.
9. Reconnect the coil wire previously
removed.
10. Reconnect the battery connector and turn
the key switch ON.
11. Check for correct lowering operation
empty and loaded, using Test A23 in active
Service Mode. Carriage movement should
start at approximately 9 to 10% request.
12. Reinstall the top cover.
1026304B, 15 July 2007 7-139
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Auxiliary Pressure Adjustment Hydraulic Components
Auxiliary Pressure
Adjustment
Series CA/FA (AC lift)
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the top cover.
3. Loosen the lock nut on the aux pressure
relief valve (REL2) on the main manifold.
See “Manifold, Main, AC Lift, Model 7400”
on page 7-141.
4. Remove the cap from the G2 auxiliary test
port on the main manifold. Connect a
pressure gauge capable of measuring
5000 psi (34,470 kPa).
5. Reconnect the battery connector and turn
the key switch ON.
6. Tilt the carriage all the way back against
the stops.
7. While continuing to try tilting the carriage
backward, use a hex key to turn the
auxiliary pressure adjusting screw to
obtain a pressure of 2000 psi
(13,790 kPa).
8. Turn the key switch OFF and disconnect
the battery connector.
9. Tighten the locknut on the aux pressure
relief valve. Remove the pressure gauge
from the auxiliary pressure test port and
replace the cap.
10. Reinstall the top cover.
Series AA/BA/DA/EA (DC lift)
Auxiliary pressure is fixed at 1800 psi
(12,410 kPa) on the Series AA/BA/DA/EA (DC
lift). There is no pressure adjustment.
7-140 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components Manifold, Main, AC Lift, Model 7400
Manifold, Main, AC Lift,
Model 7400
Model 7400 Series CA/FA (AC lift)
Hydraulic G2 port CYL-P SOL 1 POD-1 A1 A2
Filter Valve
S-RET
SOL 3
SOL 5
SOL 2 Clogged HTI G1 port P1 or CYL-1 CV-1 REL-2 LS-1
Filter PMP-1
Switch
7R1015351_B1A.CGM
7R1015351_B1B.CGM
Figure 7-169. Main Manifold, Model 7400 Series CA/FA (AC lift)
1026304B, 15 July 2007 7-141
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Manifold, Main, AC Lift, Model 7400 Hydraulic Components
Model 7400 Series CA/FA (AC lift)
Hydraulic POD-1
G2 port A1
Filter Valve
CYL-P SOL 1 SOL 5 A2
SOL 2 SOL 3
CYL-1
CV-1
CFS G1 port HTI P1 or REL-2
TANK SOL 3 SOL 2
PMP-1
LS-1
7R1015351_B2.CGM
Figure 7-170. Main Manifold, Model 7400 Series CA/FA (AC lift)
7-142 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components Manifold, Main, AC Lift, Model 7420/7440
Manifold, Main, AC Lift,
Model 7420/7440
Model 7420/7440 Series CA/FA (AC lift)
Hydraulic G2 port POD-1 CYL-P SOL 1 POD-1 A1 A2
Filter Valve Valve
Hydraulic
Filter
S-RET
TANK
SOL 5
SOL 2 Clogged SOL 3 HTI G1 port P1 or CYL-1 CV-1 REL-2 LS-1
Filter PMP-1
Switch
71044947_B1.CGM
71044947_B2.CGM
Figure 7-171. Main Manifold, Model 7420/7440 Series CA/FA (AC lift)
1026304B, 15 July 2007 7-143
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Manifold, Main, AC Lift, Model 7420/7440 Hydraulic Components
Model 7420/7440 Series CA/FA (AC lift)
Hydraulic POD-1
Filter Valve A1
G2 port
CYL-P SOL 1 SOL 5 A2
S-RET SOL 2 SOL 3
CYL-1
CV-1
CFS G1 port HTI P1 or REL-2
TANK SOL 2 SOL 3
PMP-1
LS-1
71044947_B3.CGM
71044947_B4.CGM
71044947_B6.CGM
71044947_B5.CGM
Figure 7-172. Main Manifold, Model 7420/7440 Series CA/FA (AC lift)
7-144 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components Manifold, Main, DC Lift, Model 7400
Manifold, Main, DC Lift,
Model 7400
Model 7400 Series AA/BA/DA/EA (DC lift)
A2 A1 Hydraulic
CV-2 P2 Fore-Aft
Filter
P2 Side Stance
CYL-1
SOL 5
SOL 4
SOL 2
CV-1
CYL-P
SOL 1
LS-1 REL-1
G2 port
S-RET P2
PWR BYND
TANK
CE-1
HTI CASE DRAIN SOL 8 LS-1 SOL 5
7R1020354_A1.CGM
7R1020354_A2.CGM
Figure 7-173. Main Manifold, Model 7400 Series AA/BA/DA/EA (DC lift)
1026304B, 15 July 2007 7-145
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Manifold, Main, DC Lift, Model 7400 Hydraulic Components
Model 7400 Series AA/BA/DA/EA (DC lift)
CYL-P
CYL-1
G1 Port
SOL 4
CFS
P2 SOL 1
SOL 2
SOL 2
CYL-P
SOL 4
CV-2 REL-1
CV-1
SOL 5 PP
Hydraulic
Filter
LS1
A2
A1
SOL 8
SOL 5
G2 Port
CE-1
PWR HTI
BYND
S-RET TANK
7R1020534_A3.CGM
7R1020534_A4.CGM
7R1020534_A5.CGM
7R1020534_A6.CGM
Figure 7-174. Main Manifold, Series AA/BA/DA/EA (DC lift)
7-146 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components Manifold, Auxiliary (Single Reach)
Manifold, Auxiliary
(Single Reach)
Sideshift
Solenoid
Tilt
Solenoid
Reach
Solenoid
Tilt
Sideshift Solenoid
Solenoid
A1
A2
SSL TR
7R1015154_A1.CGM
7R1015154_A2.CGM
Figure 7-175. Manifold, Aux (Single Reach), with Reach, Tilt, Sideshift
1026304B, 15 July 2007 7-147
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Manifold, Auxiliary (Single Reach) Hydraulic Components
Removal 5. Connect reach cylinder to inner scissor.
Apply thread-locking compound
1. Reach (extend) the fork carriage fully. (P/N 1013829) to threads of cylinder pin
2. Block the scissor assembly so that the screws.
scissors will not retract. 6. Install mast guard.
3. Turn the key switch OFF and disconnect 7. Reconnect the battery connector and turn
the battery connector. the key switch ON. Remove the carriage
4. Remove auxiliary carriage cover. blocking.
Disconnect solenoid wires. Label as 8. Lower the carriage completely.
needed for correct re-connection.
9. Turn the key switch OFF and disconnect
5. Reconnect the battery connector and turn the battery connector.
the key switch ON.
10. Connect the solenoid coil wires and attach
6. Elevate the carriage approximately 2.5 feet the manifold cover to the carriage.
(0.75 m).
11. Reconnect the battery connector and turn
7. Block the carriage so it cannot lower. the key switch ON.
8. Tilt forks completely down. 12. Bleed the hydraulic system as necessary.
9. Turn the key switch OFF and disconnect See “Hydraulic System Bleeding” on
the battery connector. page 7-134.
10. Remove mast guard. 13. Test auxiliary functions for correct
operation. Check the manifold connections
11. Disconnect the reach cylinder at the inner
for leaks.
scissor to permit removal of the manifold.
12. Remove auxiliary manifold mounting
screws.
13. Disconnect and cap the auxiliary hoses
from the manifold. Label as needed for
correct re-connection.
14. Place manifold in a vice and remove the
solenoid coils and valves from the
manifold. Note the position of all the
fittings and remove them.
Installation
NOTE: For torque values, see Table 7-18 on
page 7-154.
1. Install all fittings in the new manifold in
the same orientation as they were in the
manifold removed.
2. Install and torque all valves and solenoid
coils.
3. Position the manifold and connect all
auxiliary hoses.
4. Mount auxiliary manifold to carriage.
Apply thread-locking compound
(P/N 990-536) to mounting bolt threads
and torque to 21 ft. lb. (29 Nm).
7-148 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components Manifold, Reach (Deep-Reach ®)
Manifold, Reach
(Deep-Reach ®)
Reach CB-1 CB-2 REL-3
Solenoid
RR
RC
CV-3
REL-3
Reach
Solenoid
RR
RC
CV-3
7R1020906_B1.CGM
7R1020906_B2.CGM
7R1020906_B3.CGM
Figure 7-176. Manifold, Reach (Deep-Reach Carriage)
1026304B, 15 July 2007 7-149
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Manifold, Reach (Deep-Reach ®) Hydraulic Components
Removal 3. Clean the surface of the reach manifold to
avoid contamination.
1. Reach the carriage out and lower to the
4. Remove relief valve REL-3.
floor. Block the reach mechanism so that
the scissors can not retract. 5. Remove counterbalance valve CB-1.
2. Turn the key switch OFF and disconnect 6. Removed the reach solenoid coil.
the battery connector. 7. Remove counterbalance valve CB-2, using
3. Remove the two manifold mounting bolts an offset 15/16 in. open-end wrench.
to gain access to all hydraulic fittings. 8. Install the new relief valve REL-3.
4. Label as required all the solenoid wires 9. Reinstall counterbalance valve CB-2.
and remove.
10. Install the new counterbalance valve CB-1.
5. Disconnect and cap all hydraulic hoses.
11. Reinstall the reach solenoid coil.
Note the location of each of the hoses.
12. Remove the blocking from the scissor
6. Remove the manifold from the truck.
mechanism.
Installation 13. Reconnect the battery connector and turn
the key switch ON.
NOTE: For torque values, see Table 7-18 on 14. Bleed the auxiliary system by fully
page 7-154. extending the reach mechanism several
1. Install all fittings in the new manifold in times. Hold over the relief until the system
the same orientation that they were in the times out if air remains present.
manifold removed. 15. Test reach and retract functions for
2. Install and torque all valves and solenoid correct operation.
coils.
3. Position the manifold and connect all the
hydraulic hoses.
4. Reconnect the solenoid wires.
5. Mount the manifold to the scissors.
6. Reconnect the battery connector and turn
the key switch ON.
7. Remove the blocking.
8. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on
page 7-134.
9. Test the auxiliary functions for correct
operation and check connections for leaks.
Reducing Carriage Drift
If carriage drifts, replace CB-1 P/N
1020951/001 with 1020951/004, and REL-3
P/N 1007104/001 with 1009281/013.
1. Fully extend and block the scissor
mechanism.
2. Turn the key switch OFF and disconnect
the battery connector.
7-150 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components Manifold, Tilt/Sideshift (Deep-Reach ®)
Manifold, Tilt/Sideshift
(Deep-Reach ®)
Sideshift Tilt
Solenoid Solenoid
71014583_A1.CGM
Figure 7-177. Manifold, Tilt/Sideshift (Deep-Reach Carriage)
Removal 3. Mount the manifold to the carriage.
4. Connect the hydraulic hoses.
1. Reach the fork carriage out and fully lower
to the floor. 5. Connect the wiring to the solenoids.
2. Tilt the forks fully down. 6. Reconnect the battery connector and turn
the key switch ON.
3. Turn the key switch OFF and disconnect
the battery connector. 7. Bleed the hydraulic system.
4. Disconnect the wiring for the solenoids. 8. Test the auxiliary functions for correct
operation and the connections for leaks.
5. Disconnect and cap the hydraulic hoses.
Note the location of the hoses.
6. Remove the manifold from the truck.
7. Remove the solenoid valves from the
manifold.
8. Note the position of all fittings and remove
them from the manifold.
Installation
NOTE: For torque values, see Table 7-18 on
page 7-154.
1. Install all fittings in the new manifold in
the same orientation that they were in the
manifold removed.
2. Install and torque all valves and solenoid
coils.
1026304B, 15 July 2007 7-151
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Manifold Solenoids, Fittings, and Attachments Hydraulic Components
Manifold Solenoids,
Fittings, and
Attachments
Table 7-16. Series CA/FA (AC lift) Main Manifold Attachment Torques
Valve/ Valve/
Coil Nut Coil Nut
Solenoid/ Fitting Fitting Locking tab
Torque Torque
Attachment/Fitting Torque Torque or bracket
(ft. lb.) (Nm)
(ft. lb.) (Nm)
SOL1 Load Holding 50 68 Yes 5 6.8
SOL2 Lift/Lower 95 129 No 0.5 0.7
SOL3 Proportional Main 25 34 No 5 6.8
Relief/Dump
SOL5B/5T Aux 20 27 No 5 6.8
A1 21 28 No n/a n/a
A2 21 28 No n/a n/a
CFS-1 Clogged Filter 12 16 No n/a n/a
Switch
CV-1 Check Valve 30 41 n/a n/a n/a
CYL-1 55 75 No n/a n/a
CYL-P Pressure 12 16 No n/a n/a
Transducer
Filter Plug 30 41 n/a n/a n/a
G1 21 28 No n/a n/a
G2 21 28 No n/a n/a
HTI Pressure Switch 12 16 No n/a n/a
LS-1 Load Shuttle 20 27 n/a n/a n/a
P1 55 75 No n/a n/a
POD-1 Priority on 35 47 No n/a n/a
Demand
REL-2 Aux Relief 25 34 n/a n/a n/a
Return (Suction) to Pump 55 75 No n/a n/a
S-RET 21 28 n/a n/a n/a
TANK 55 75 No n/a n/a
7-152 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components Manifold Solenoids, Fittings, and Attachments
Table 7-17. Series AA/BA/DA/EA (DC lift) Main Manifold Attachment Torques
Valve/ Valve/
Solenoid/ Coil Nut Coil Nut
Fitting Fitting Locking tab
Attachment/Fitting Torque Torque
Torque Torque or bracket
(ft. lb.) (Nm)
(ft. lb.) (Nm)
SOL1 Load Holding 35 47 No 5 6.8
SOL2 Lift/Lower 95 129 No 0.5 0.7
SOL4 2d Pump 20 28 No 5 6.8
SOL5B/5T Aux 25 34 No 5 6.8
SOL8 Aux Dump 20 27 No 5 6.8
A1 21 28 n/a n/a n/a
A2 21 28 n/a n/a n/a
Case Drain 12 16 n/a n/a n/a
CE1 Compensating 25 34 n/a n/a n/a
Element
CFS-1 Clogged Filter 12 16 No n/a n/a
Switch
CV-1 Check Valve 35 47 n/a n/a n/a
CV-2 Check Valve 20 27 n/a n/a n/a
CYL-P Pressure 12 16 n/a n/a n/a
Transducer
CYL-1 55 75 n/a n/a n/a
Filter Plug 30 41 n/a n/a n/a
G1 21 28 n/a n/a n/a
G2 21 28 n/a n/a n/a
HTI Pressure Switch 12 16 No n/a n/a
LS-1 Load Shuttle 20 27 n/a n/a n/a
P2 21 28 n/a n/a n/a
PWR BYND 21 28 n/a n/a n/a
REL-1 Main Relief 25 34 No n/a n/a
Return to Pump P1 55 75 n/a n/a n/a
Return to Pump P3 55 75 n/a n/a n/a
S-RET 21 28 n/a n/a n/a
TANK 55 75 n/a n/a n/a
1026304B, 15 July 2007 7-153
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Manifold Solenoids, Fittings, and Attachments Hydraulic Components
Table 7-18. Series CA/FA (AC lift) and Series AA/BA/DA/EA (DC lift) Aux Manifold and Cylinder Attachment Torques
Valve/ Valve/
Coil Nut Coil Nut
Solenoid/ Fitting Fitting Locking tab
Torque Torque
Attachment/Fitting Torque Torque or bracket
(ft. lb.) (Nm)
(ft. lb.) (Nm)
A1 (Standard Reach) 15 20 n/a n/a n/a
A2 (Standard Reach) 15 20 n/a n/a n/a
Reach Valve 20 (standard) 27 (standard) no 5 6.8
25 (deep) 34 (deep)
RC 15 20 n/a n/a n/a
RR 15 20 n/a n/a n/a
Tilt Valve 20 27 no 5 6.8
TC 15 20 n/a n/a n/a
TR 15 20 n/a n/a n/a
Sideshift Valve 20 27 no 5 6.8
SSR 15 20 n/a n/a n/a
SSL 15 20 n/a n/a n/a
Flow Limiter (7420/7440 85 115 n/a n/a n/a
Free Lift Cylinder)
Pump 15 20 n/a n/a n/a
Tank 15 20 n/a n/a n/a
A1 (Deep-Reach) 15 20 n/a n/a n/a
A2 (Deep-Reach) 15 20 n/a n/a n/a
A1 (Deep-Reach Tilt or 15 20 n/a n/a n/a
Tilt/Sideshift)
A2 (Deep-Reach Tilt or 15 20 n/a n/a n/a
Tilt/Sideshift)
REL-3 Deep-Reach Relief n/a n/a n/a n/a n/a
CV-3 Deep-Reach Check 25 34 n/a n/a n/a
valve
CB-1 Deep-Reach 35 47 n/a n/a n/a
Counterbalance
CB-2 Deep-Reach 35 47 n/a n/a n/a
Counterbalance
7-154 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder
Hydraulic Components, Cylinder
Section 7. Component Procedures
1026304B, 15 July 2007 7-155
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic Component (Cylinder) Procedures Summary Hydraulic Components, Cylinder
Hydraulic Component
(Cylinder) Procedures
Summary
Table 7-19. Hydraulic Component (Cylinder) Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Free Lift Cylinder, Procedure:
See procedure.
remove/install page 7-157
Cylinder, Free Lift, Seal Procedure:
See procedure.
Repacking page 7-164
Cylinder, Free Lift, Lowering Procedure:
See procedure.
Cushion and Dampener page 7-176
Cylinder, Main Lift Procedure: Model 7400: Use cylinder brackets with sleeves (kit
page 7-167 P/N 1042989). Bracket bolts: P/N 1013829/55 ft. lb.
(75 Nm)
Cylinder, Main Lift, Seal Procedure:
See procedure.
Repacking page 7-174
Cylinder, Main Lift, Lowering Procedure:
See procedure.
Cushion page 7-176
Cylinder, Reach (Single) Procedure:
See procedure.
page 7-179
Cylinder, Reach (Single), Procedure:
See procedure.
Seal Repacking page 7-179
Cylinder, Deep-Reach ® Procedure:
See procedure.
page 7-179
Cylinder, Deep-Reach ®, Seal Procedure:
See procedure.
Repacking page 7-179
Cylinder, Tilt Procedure:
See procedure.
page 7-182
Cylinder, Tilt, Seal Procedure:
See procedure.
Repacking page 7-182
Cylinder, Sideshift No Not serviceable.
Flow Limiter, Free Lift Procedure:
See procedure.
page 7-185
Flow Limiter, Main Lift Procedure:
See procedure.
page 7-184
7-156 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Remove/Install
Lift Cylinder, Free Lift, 12. Disconnect the hydraulic line at the
bottom of the cylinder. Plug and cap the
Remove/Install fittings to prevent contamination from
entering the system.
NOTE: Place a pan below the mainframe to
Model 7400 catch any hydraulic fluid when the line
is disconnected.
Left Side Free Lift Cylinder
13. Remove the eyelet retainer pin at the top of
the cylinder housing.
Removal
14. Position the carriage at an appropriate
1. Remove mast guard.
height to allow removal of the cylinder.
2. Elevate telescopics to access the
15. Using a suitable lifting device, remove the
over-the-mast (OTM) hoses/cable clamp at
cylinder.
the bottom of the free lift cylinder.
3. Remove the clamp and the free lift cylinder Installation
set screw at the bottom of the cylinder
mounting bracket. Remove any cable ties NOTE: The left side free lift cylinder contains a
securing the hoses/cable to the cylinder. flow limiter located in the manifold block
at the bottom of the cylinder. See “Flow
4. Fully lower the telescopics carefully so as Limiter, Free Lift” on page 7-185.
not to damage the hoses and cable.
1. Install the flow control, fitting, and feed
5. Using a suitable lifting device, lift the
hose at the bottom of the cylinder.
carriage to relieve the tension on the lift
chains and hoses. 2. Position the cylinder into the truck.
6. Turn the key switch OFF and disconnect 3. Install the upper eyelet retainer pin and
the battery connector. the set screw at the bottom of the cylinder.
7. Remove the master link from the free lift 4. Connect the hydraulic line at the bottom of
chain at the free lift cylinder anchor bolt. the cylinder.
8. Drape the chain over the carriage 5. Lift the carriage assembly to provide slack
assembly. in the lift chains and hoses for assembly.
9. Remove the chain pulley to access the 6. Apply thread-locking compound
pulley bracket assembly mounting bolt. (P/N 1013829) to the threads of the
Remove the pulley bracket assembly from mounting bolt and install the pulley
the piston and set to the side with the bracket assembly.
hoses and cable in place. 7. Install the chain pulley and the free lift
10. Mark the OTM hoses and cable at the chain.
upper free lift cylinder retainer for the 8. Install the OTM upper free lift cylinder
correct stretch when re-assembled. retainer, noting the marks made on the
Remove the retainer. hoses/cable when removed.
11. Using the lifting device, lift and block the 9. Lower the carriage and remove the lifting
carriage assembly to a height that permits device.
access to the tubing at the bottom of the
10. Reconnect the battery connector and turn
cylinder.
the key switch ON.
NOTE: As the carriage is being lifted, feed the 11. Carefully lift the telescopics to access the
right side free lift chain towards the bottom of the free lift cylinder.
operator compartment to avoid jamming
of the chain. 12. Install the OTM hoses/cable clamp at the
bottom of the free lift cylinder. Make sure
there is correct clearance between the
1026304B, 15 July 2007 7-157
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Lift Cylinder, Free Lift, Remove/Install Hydraulic Components, Cylinder
bracket, hoses/cable and the front plate of NOTE: Place a pan below the mainframe to
the tractor. catch any hydraulic fluid when the line
13. Bleed the hydraulic system. See is disconnected.
“Hydraulic System Bleeding” on 12. Remove the set screw at the bottom of the
page 7-134. cylinder.
14. Check the truck for leaks and correct 13. Position the carriage at an appropriate
operation. height to permit removal of the cylinder.
15. Install the mast guard. 14. Using a suitable lifting device, remove the
cylinder.
Right Side Free Lift Cylinder
Installation
Removal 1. Position the cylinder into the truck.
1. Remove the upper eyelet retainer pin. 2. Install the upper eyelet retainer pin.
NOTE: You can gain easier access by raising the 3. Position and block carriage to permit
telescopics. access to bottom of the cylinder.
2. Fully lower the forks to the floor. 4. Install the set screw at the bottom of the
cylinder.
3. Turn the key switch OFF and disconnect
the battery connector. 5. Connect the hydraulic line at the bottom of
the cylinder.
4. Remove the mast guard.
6. Lift the carriage assembly to provide slack
5. Using a suitable lifting device, lift the
to install the free lift chain.
carriage to relieve the tension on the lift
chain. 7. Install the ring adapter. Apply
thread-locking compound (P/N 1013829)
6. Remove the master link from the free lift
to the mounting bolt threads and install
chain at the free lift anchor bolt.
the pulley bracket assembly to the piston.
7. Remove and drape the chain over the
8. Install the chain pulley and the free lift
carriage assembly.
chain.
NOTE: Twist the pulley assembly to permit the 9. Lower the carriage and remove the lifting
removal of the chain. device.
8. Remove the chain pulley to access the 10. Reconnect the battery connector and turn
pulley bracket assembly mounting bolt. the key switch ON.
9. Remove the pulley bracket assembly and 11. Bleed the hydraulic system. See
ring adapter. “Hydraulic System Bleeding” on
10. Using the lifting device, lift and block the page 7-134.
carriage assembly to a height that permits 12. Check the truck for leaks and correct
access to the bottom of the cylinder. operation.
NOTE: As the carriage is being lifted, feed the 13. Install the mast guard.
left side free lift chain toward the
operator compartment to avoid jamming
the chain.
Model 7420/7440
11. Disconnect the hydraulic line at the Left Side Free Lift Cylinder
bottom of the cylinder. Plug and cap the
fitting to avoid contamination from Removal
entering the system.
1. Elevate the fork carriage approximately
4 inches (10 cm) above the floor.
7-158 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Remove/Install
2. Place hardwood blocks under the carriage. 8. Secure the hoses to the hose clamps with
3. Lower the carriage to slacken the chains. cable ties.
4. Request lower and collapse the free lift 9. Reattach the mast guard.
cylinder. This minimizes the amount of 10. Reconnect the battery connector and turn
hydraulic fluid in the cylinder. the key switch ON.
5. Turn the key switch OFF and disconnect 11. Elevate the fork carriage.
the battery connector. 12. Remove blocking.
6. Remove the mast guard. 13. Test lift and lower function for correct
7. Cut the cable ties on the hose clamps. operation. Check for hydraulic leaks.
8. Place a chalk witness mark on the hoses to
aid in reassembly. Right Side Free Lift Cylinder
9. Remove the hose retainer brackets near
the top of the cylinder. Removal
10. Disconnect the free lift chain at the 1. Remove the auxiliary manifold top cover
adjusting chain anchor and feed the chain on the carriage.
over the pulley. 2. Disconnect the over-the-mast (OTM) cable
11. Remove the pulley shaft securing screw, at terminal strip TS-2.
pin, and the pulley. 3. Elevate the fork carriage approximately
12. Remove the pulley bracket from the 4 inches (10 cm) above the floor.
cylinder. 4. Place hardwood blocks under the carriage.
13. Disconnect and cap/plug the hydraulic 5. Lower the carriage to slacken the chains.
line at the bottom of the cylinder. 6. Request lower and collapse the free lift
14. Remove the nut from the cylinder cylinder. This minimizes the amount of
retaining anchor at the inner telescopic hydraulic fluid in the cylinder.
crosstie. 7. Turn the key switch OFF and disconnect
15. Wrap a hoist strap securely around the the battery connector.
cylinder at the retaining bracket. 8. Loosen the U-clamp and feed the OTM
16. Using a hoist or other suitable lifting cable through.
device, carefully lift the cylinder out. 9. Cut the cable ties on the cable clamps.
Installation 10. Feed the OTM cable over the pulley.
1. Wrap a hoist strap securely around the 11. Disconnect the free lift chain at the
cylinder at the retaining bracket. adjusting chain anchor and feed the chain
over the pulley.
2. Using a hoist or other suitable lifting
device, carefully lower the cylinder onto 12. Remove the pulley shaft securing screw,
the two locating pins on the inner pin, and the pulley.
telescopic lower crosstie. 13. Remove the pulley bracket from the
3. Connect the hydraulic line. cylinder.
4. Attach the cylinder retaining nylon nut 14. Disconnect and cap/plug the hydraulic
snug to the shoulder. line at the bottom of the cylinder.
5. Reattach the pulley bracket to the 15. Remove the nut from the cylinder
cylinder. retaining anchor at the inner telescopic
crosstie.
6. Install the pulley, pin, and securing screw.
16. Wrap a hoist strap securely around the
7. Using a new master link, install the free cylinder at the retaining bracket.
lift chain to the upper chain anchor.
1026304B, 15 July 2007 7-159
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Lift Cylinder, Free Lift, Remove/Install Hydraulic Components, Cylinder
17. Using a hoist or other suitable lifting
device, carefully lift the cylinder out.
Installation
1. Wrap a hoist strap securely around the
cylinder at the retaining bracket.
2. Using a hoist or other suitable lifting
device, carefully lower the cylinder onto
the two locating pins on the inner
telescopic lower crosstie.
3. Connect the hydraulic line.
4. Attach the cylinder retaining nylon nut
snug to the shoulder.
5. Reattach the pulley bracket to the
cylinder.
6. Install the pulley, pin, and securing screw.
7. Using a new master link, install the free
lift chain to the upper chain anchor.
8. Route the OTM cable through the spring
tension bracket, over the pulley, and
through the U-clamp to terminal strip TS2
in the auxiliary manifold cover.
9. Hook the cable tensioner to the bracket.
10. Tighten the U-clamp.
11. Connect the OTM cable wires at terminal
strip TS2.
12. Reattach the auxiliary manifold top cover
on the carriage.
13. Secure the cable to the cable brackets with
cable ties.
14. Reattach the mast guard.
15. Reconnect the battery connector and turn
the key switch ON.
16. Elevate the fork carriage.
17. Remove blocking.
18. Test lift and lower function for correct
operation. Check for hydraulic leaks.
7-160 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Exploded Parts Drawing
Lift Cylinder, Free Lift,
Exploded Parts Drawing
Model 7400, Staging (AC Lift)
Lowering Cushion Assembly
O-Ring
Snap
Ring
Decel Piston Retaining
Ring
Piston Ring
Decel Spring
Plug
O-Ring Decel Bearing
Hydraulic Return Spring
Fluid Port
Check Valve
O-Ring
Piston Plug
(Cushion
Housing)
Piston Rod
Pressure Ring
Ram Spacer Ring
Wiper Seal
Backup Ring Piston Ring
Sleeve
O-Ring
Staging Zone Spring
Packing Seal
Bleed
Screw O-Ring
Gland
Snap Ring
Staging Zone Stop
Screw (3)
71023208_G.CGM
Figure 7-178. Free Lift Cylinder, Staging, Model 7400
1026304B, 15 July 2007 7-161
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Lift Cylinder, Free Lift, Exploded Parts Drawing Hydraulic Components, Cylinder
Model 7400, Non-Staging
(DC Lift)
Snap Ring
Lowering Cushion Piston
Cap Screw
Retaining
Seal Ring
Piston Rod
Spring
Square Seal
Wiper Seal
Piston Seal
Gland
71023600_G.CGM
Figure 7-179. Free Lift Cylinder, Non-Staging, Model 7400
7-162 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Exploded Parts Drawing
Model 7420/7440, Staging
Lowering Cushion Assembly O-Ring
Snap
Ring
Decel Piston
Retaining
Piston Ring Ring
Decel Spring
Plug
O-Ring
Decel Bearing
Hydraulic
Fluid Port Return Spring
Check Valve
O-Ring
Piston Plug
(Cushion
Housing)
Piston Rod
Piston Ring
Sleeve
Staging Zone
Stop Screw (3)
Bleed Screw
O-Ring
Packing Pressure Ring
Seal
Staging Zone Spring
Gland
Wiper Seal
71048548_C.CGM
Figure 7-180. Free Lift Cylinder, Staging, Model 7420/7440
1026304B, 15 July 2007 7-163
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Lift Cylinder, Free Lift, Seal Repacking Hydraulic Components, Cylinder
Lift Cylinder, Free Lift, NOTE: If necessary, use the piston to extract
the gland by removing the three staging
Seal Repacking zone stop screws and the bleeder screw
and lifting the cylinder with the use of a
hoist.
Model 7400 10. On a clean work surface, remove the wiper
seal, packing seal, O-rings, and back-up
Series CA/FA (AC lift) ring from the gland. Note the position and
orientation of each when removing.
NOTE: See Figure 7-178 on page 7-161.
11. Inspect the surfaces of the gland for any
Disassembly scratches or damage. Remove minor
imperfections using fine emery cloth.
Trucks with AC lift have a staging zone 12. Clean the gland.
mechanism in the free lift cylinders in addition 13. Inspect the inside of the housing for
to a cushion at the bottom of the cylinder. damage and clean as required.
1. Remove the mast guard.
2. Lower the carriage onto a suitable block Reassembly
and fully lower cylinder to relieve the 1. Lubricate with new hydraulic fluid, the
tension on the hoses, cable, and free lift wiper seal, packing seal, O-rings, and
chains. back-up ring and install into their
3. Turn the key switch OFF and disconnect respective grooves on the gland. Make sure
the battery connector. that they are correctly seated within the
grooves.
4. Remove the free lift chain master link at
the free lift cylinder anchor bolt and lay
Make sure to install the pressure ring with
the chain over the carriage.
the seal towards the open end of the
NOTE: Twist the right side pulley to remove the housing. See Figure 7-181.
chain from the pulley.
5. Remove the chain pulley to access the
pulley bracket mounting bolt.
6. Remove the pulley bracket assembly. Set
the left side to the side with the hoses and
cable in place.
7. For 3 inch lowered height option, remove
the adapter ring.
8. If you are removing the piston, remove the
three staging zone mechanism stop screws
and the bleeder screw. It may be necessary
to loosen the upper OTM retainer to allow
the removal of the three stop screws.
7RPIN06005.JPG
NOTE: Mark the hoses and cable to make sure Figure 7-181. Pressure Ring Orientation
the correct stretch when re-assembled.
2. Lubricate the piston rod with new
9. Remove the snap ring and gland. hydraulic fluid. Carefully slide the gland
NOTE: When the snap ring is removed, a spring over it.
behind the packing plug should push 3. Using the seal installation driver
the gland out of the housing. (P/N 401-000-051), push the gland into
the housing and compress the spring.
7-164 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Seal Repacking
4. Install the snap ring inside the housing. 6. Remove the pulley bracket assembly. Set
Make sure that the snap ring is fully the left side to the side with the hoses and
seated in the groove. cable in place.
5. Wipe away any excess hydraulic fluid. 7. For 3 inch lowered height option, remove
6. Install the three staging zone mechanism the adapter ring.
stop screws, if previously replaced. 8. Using cylinder end cap tool (P/N A9587),
Tighten the upper OTM retainer, if remove the end cap (gland).
previously loosened. 9. On a clean work surface, remove the
7. For 3 inch lowered height option, install piston seal, wiper seal, and square seal
the adapter ring. from the end cap. Note the position and
8. Apply thread-locking compound orientation of each when removing.
(P/N 1013829) to the threads of the 10. Inspect the surfaces of the gland for any
mounting bolt and install the pulley scratches or damage. Use fine emery cloth
bracket assembly. to remove minor imperfections.
9. Install the chain pulley and the free lift 11. Clean the threads on the gland and the
chain. cylinder.
10. Reconnect the battery connector and turn 12. Inspect the inside of the housing for
the key switch ON. damage and clean as required.
11. Remove the block from beneath the
carriage. Reassembly
12. Bleed the hydraulic system. See 1. Lubricate with new hydraulic fluid, the
“Hydraulic System Bleeding” on piston seal, wiper seal, and square seal
page 7-134. and install into their respective grooves on
the gland. Make sure they are correctly
13. Check the truck for leaks and correct seated within the grooves and not twisted.
operation.
2. Apply thread-locking compound
14. Install the mast guard. (P/N 990-571) to the threads of the gland.
3. Lubricate the piston rod with new
Series AA/BA/DA/EA (DC lift) hydraulic fluid, and carefully install the
NOTE: See Figure 7-179 on page 7-162. gland.
4. Torque the end cap to 200 ft lb. (271 Nm).
Disassembly
5. For 3 inch lowered height option, install
1. Remove the mast guard. the adapter ring.
2. Lower the carriage onto a suitable block 6. Apply thread-locking compound
and fully lower cylinder to relieve the (P/N 1013829) to the threads of the
tension on the hoses, cable and free lift mounting bolt and install the pulley
chains. bracket assembly.
3. Turn the key switch OFF and disconnect 7. Install the chain pulley and the free lift
the battery connector. chain.
4. Remove the free lift chain master link at 8. Reconnect the battery connector and turn
the free lift cylinder anchor bolt and lay the key switch ON.
the chain over the carriage. 9. Remove the block from beneath the
NOTE: Twist the right side pulley to remove the carriage.
chain from the pulley. 10. Bleed the hydraulic system. See
5. Remove the chain pulley to access the “Hydraulic System Bleeding” on
pulley bracket mounting bolt. page 7-134.
1026304B, 15 July 2007 7-165
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Lift Cylinder, Free Lift, Seal Repacking Hydraulic Components, Cylinder
11. Check the truck for leaks and correct Do not apply compound to the first
operation. threads to engage.
12. Install the mast guard. 3. Lubricate the piston rod with new
hydraulic fluid. Carefully slide the gland
over the piston rod.
Model 7420/7440
4. Torque the gland to 200 ft. lb. (271 Nm).
NOTE: See Figure 7-180 on page 7-163.
5. Apply thread-locking compound
(P/N 1013829) to the threads of the
Disassembly
mounting bolt and install the pulley
1. Elevate the carriage about 4 inches bracket assembly.
(10 cm) and lower the carriage onto blocks
6. Install the pulley and pulley shaft on the
to slacken the chains.
bracket.
2. Turn the key switch OFF and disconnect
7. Install the pulley shaft locking screw.
the battery connector.
8. Route the free lift chain over the pulley
3. Collapse the cylinder.
and attach to the chain anchor with a
4. Disconnect the lift chain master link from master link.
the chain anchor.
9. Reconnect the battery connector and turn
5. Secure the lift chain to the crosstie with a the key switch ON.
welding or sheet metal locking clamp. This
10. Slowly request lift, lift the carriage, remove
minimizes rethreading of chain later.
the blocking, and lower the carriage.
6. Remove the nut from the tractor side of
11. Bleed the cylinder as required. See
the free lift cylinder mounting bracket.
“Hydraulic System Bleeding” on
7. Remove the locking screw from the pulley page 7-134.
shaft.
12. Test lift and lower functions. Check for
8. Drive out the pulley shaft. leaks.
9. Remove the pulley bracket.
NOTE: With slack in hoses and cable, it is not
necessary to remove the hoses or cable.
10. Using a 2 in. spanner wrench, remove the
end cap (gland).
11. On a clean work surface, remove the wiper
seal, packing seal, and O-ring from the
gland.
12. Inspect the surfaces of the gland for any
scratches or damage. Remove minor
imperfections using fine emery cloth.
Reassembly
1. Lubricate with new hydraulic fluid the
packing seal, wiper seal, and O-ring and
install into their respective grooves on the
gland. Make sure that they are correctly
seated within the grooves.
2. Apply thread-locking compound
(P/N 990-571) to the threads of the gland.
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Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Lift Cylinder, Main, Remove/Install
Lift Cylinder, Main, 12. Place a jack beneath the tractor to slightly
spread the tractor and the attachment to
Remove/Install allow the removal of the connector.
13. Remove the connector.
14. Using a suitable lifting device, remove the
Model 7400 cylinder from the truck.
Left Side Main Lift Cylinder, Model Installation
7400 1. Install the fitting and feed hose at the
bottom of the cylinder.
Removal
2. Attach the mast guard bracket onto the
1. Remove mast guard, top cover and left cylinder.
front cover.
3. Position the cylinder into the truck.
2. Remove the retainer bolt at the bottom of
the cylinder. 4. Apply thread-locking primer
(P/N 990-666) to both the right and left
3. Place a block approximately 18 inches in mast mounting bolt threads and the hole
length between the inner telescopic threads. Permit to dry for several minutes.
crosstie and the outer telescopic crosstie. Apply thread-locking compound
Place a block approx. 12 in. (305 mm) in (P/N 990-544) to the threads of the mast
length between the outer telescopic mounting bolts. Install the mast connector
crosstie and the mainframe crosstie. and torque the bolts to 160/170 ft. lb.
NOTE: This will provide the necessary (217/230 Nm).
hose/cable slack and clearance to 5. Install the mast connector snap ring.
remove the cylinder.
6. Remove the jack.
4. Fully lower the carriage. 7. Connect the feed hose at the bulkhead
5. Turn the key switch OFF and disconnect fitting.
the battery connector. 8. Attach the OTM hose/cable retainer
6. Remove the bolt, washer, and spacer at the bracket to the cylinder.
top of the piston. 9. Install the cylinder mounting L-bracket(s)
7. Remove the cylinder mounting with sleeves and bolts. Do not tighten at
L-bracket(s). this time.
NOTE: Models with an OACH of 131 inches and 10. Reconnect the battery connector and turn
above will have two brackets. the key switch ON.
8. Remove the OTM hose/cable retainer 11. Carefully rotate the lift knob to raise the
bracket from the cylinder. piston to the telescopic crosstie.
9. Place a pan below the tractor and 12. Install the bolt, washer, and spacer at the
disconnect the cylinder feed hose at the crosstie to the top of the piston.
tractor bulkhead fitting. 13. Apply thread-locking compound
(P/N 1013829) to the threads and tighten,
NOTE: The feed hose can remain connected to
leaving a 0.12 in. (3 mm) gap between the
the bottom of the cylinder to assist in
head of the bolt and the washer.
removal.
14. Tighten the cylinder mounting L-bracket
10. From inside the battery compartment, bolts to 55 ft. lb. (75 Nm).
loosen the right side mast connector
mounting bolts. 15. Remove the blocks from the telescopics
and the mainframe.
11. Remove the left side mast bolts and the
mast connector snap ring.
1026304B, 15 July 2007 7-167
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Lift Cylinder, Main, Remove/Install Hydraulic Components, Cylinder
16. Install the retainer bolt at the bottom of 11. Place a jack beneath the tractor to slightly
the cylinder. spread the tractor and attachment to allow
17. Bleed the hydraulic system. See the removal of the connector.
“Hydraulic System Bleeding” on 12. Remove the connector.
page 7-134. 13. Using a suitable lifting device, remove the
18. Check for leaks and correct operation. cylinder from the truck.
19. Install the mast guard, top cover, and left
front cover. Installation
NOTE: The right side main lift cylinder houses
Right Side Main Lift Cylinder, Model a flow limiter located in the manifold
7400 block at the bottom of the cylinder. See
“Flow Limiter, Main Lift” on page 7-184.
Removal 1. Install the flow control, fitting and feed
1. Remove mast guard, top cover, and right hose at the bottom of the cylinder.
front cover. 2. Attach mast guard bracket to cylinder.
2. Elevate telescopics and remove the 3. Position the cylinder into the truck.
retainer bolt at bottom of cylinder.
4. Apply thread-locking primer
3. Place a block at least 12 in. (305 mm) in (P/N 990-666) to mast mounting bolt
length between the mainframe and the threads and the hole threads. Permit to
outer telescopic crosstie and fully lower dry for several minutes. Apply
the carriage. thread-locking compound (P/N 990-544)
NOTE: This length will provide the clearance to the threads of the mast mounting bolts.
required to remove the cylinder. Install the mast connector and torque the
bolts to 160/170 ft. lb. (217/230 Nm).
4. Fully lower the carriage.
5. Install the mast connector snap ring.
5. Turn the key switch OFF and disconnect
6. Remove the jack from the truck.
the battery connector.
7. Connect the feed hose at the tractor
6. Remove the bolt, washer, and spacer at the
bulkhead fitting.
top of the piston and outer telescopic
crosstie. 8. Install the cylinder mounting L-bracket(s)
with sleeves and bolts. Do not tighten at
7. Remove the cylinder mounting
this time.
L-bracket(s).
9. Install the retainer bolt at the bottom of
NOTE: Models with an OACH of 131 inches and the cylinder.
above will have two upper brackets.
10. Reconnect the battery connector and turn
8. Place a pan below the tractor. Disconnect the key switch ON.
the cylinder feed hose at the tractor
11. Carefully rotate the lift knob to raise the
bulkhead. Plug and cap the fittings to
piston to the telescopic crosstie.
prevent contamination from entering the
system. 12. Install the bolt, washer, and spacer at the
crosstie to the top of the piston.
NOTE: The feed hose can remain connected to
the cylinder to assist in removal of the NOTE: Install thread-locking compound
cylinder. (P/N 1013829) to bolt threads and
tighten, leaving a 0.12 in. (3 mm) gap
9. From inside the battery compartment, between head of the bolt and washer.
loosen the left side mast bolts.
13. Tighten the cylinder mounting L-bracket
10. Remove the right side mast bolts and the
bolts to 55 ft. lb. (75 Nm).
mast connector snap ring.
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Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Lift Cylinder, Main, Remove/Install
14. Remove the block from between the 9. Disconnect the main lift hoses at the
telescopic and the mainframe. tractor bulkhead. Cap the hoses and plug
15. Bleed the hydraulic system. See the fittings.
“Hydraulic System Bleeding” on 10. Attach a hoist strap under the top crosstie
page 7-134. of the main frame and support the mast
16. Check the truck for leaks and correct with a 3-ton hoist or other suitable lifting
operation. device.
17. Install the mast guard, top cover and right 11. Place blocks snugly under the tractor near
front cover. the mast. These blocks will take the weight
of the tractor when the tractor is unbolted
Model 7420/7440 from the mast.
12. Working inside the battery compartment,
Left and Right Side Main Lift Cylinder, remove eight mast mounting bolts from
the bottom of the tractor frame.
Model 7420/7440
13. Working from the top of the tractor,
Removal remove two mast mounting bolts from
each side.
1. Turn the key switch OFF and disconnect
the battery connector. 14. Remove the tractor to provide working
space at the mast.
2. Remove the top cover.
15. Wrap hoist straps around each baseleg
3. Remove the mast guard.
where they join the mast. Extend the hoist
4. Disconnect the auxiliary hydraulic hoses straps in the direction of the tractor and
at the main manifold. Cap hoses and plug attach to a 3-ton hoist or other suitable
ports. lifting device.
5. Disconnect the over-the-mast electrical 16. Keeping tension on the top of the mast,
cable at connector JPS3 near the main carefully begin lifting at the baseleg straps.
manifold. The mast will tip forward toward the
6. Remove the battery gate. Using a suitable carriage.
battery moving device, remove the battery. 17. Continue lowering the mast unto jack
7. Remove the battery connector mounting stands.
bracket (for access to the mast mounting 18. Remove the main lift hose at the cylinder
bolts). See Figure 7-182. manifold. Plug the fitting.
Battery
Connector
Mounting
Bracket
7R1008515_B1.CGM
Figure 7-182. Battery Connector and Mast Mounting Block
8. Remove the forks from the fork carriage.
1026304B, 15 July 2007 7-169
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Lift Cylinder, Main, Remove/Install Hydraulic Components, Cylinder
19. Remove the upper and lower cylinder countersunk Allen head screws.
mounting bolts and sleeves at the main See Figure 7-184.
frame crossties.
Hose/Cable
Retaining
Blocks
7DSCF1672bw.jpg
Figure 7-183. Cylinder Mounting Bolts, Model 7420/7440
20. Extend the outer telescopic about 6 in.
(15 cm) to access the cylinder top
mounting bolt.
21. Remove the cylinder top mounting bolt.
22. Left-side only: Remove the two hose/cable 7
retaining block assemblies. Do not Figure 7-184. Hose/Cable Retainer Block Assemblies
disassemble the retainers, but remove the
entire assembly by removing two 23. Remove the set screw at the bottom of the
cylinder.
24. Wrap several turns of a hoist strap around
the lift cylinder at its midpoint.
25. Using a hoist or other suitable lifting
device, carefully remove the cylinder via
the bottom of the mast.
Installation
1. Support the mast securely on jack stands,
carriage side down. Wrap hoist straps
around each baseleg where they join the
mast. Extend the hoist straps in the
direction of the tractor and attach to a
3-ton hoist or other suitable lifting device.
Attach a hoist strap under the top crosstie
of the main frame.
2. Wrap several turns of a hoist strap around
the lift cylinder at its midpoint.
3. Using a hoist or other suitable lifting
device, carefully guide the cylinder into
position via the bottom of the mast,
7-170 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Lift Cylinder, Main, Remove/Install
engaging the cylinder mounting studs on 21. Test lift and lower functions for correct
the main frame crossties. operation. Check for hydraulic fluid leaks.
4. Install the cylinder top mounting bolt.
5. Left-side only: Attach the two hose/cable
retaining block assemblies, using two
countersunk Allen head screws for each.
6. Attach the main lift hose at the cylinder
manifold.
7. Install the upper and lower cylinder
mounting bolts and sleeves at the main
frame crossties. Torque bolts to 55 ft. lb.
(75 Nm).
8. Using a hoist of other suitable lifting
device, carefully lift the mast by the hoist
strap at the top until the mast is erect.
9. Move the tractor into location with the
mast. Support the tractor frame near the
mast with blocks to align the mast
mounting bolt holes.
10. Working inside the battery compartment,
install eight mast mounting bolts at the
bottom of the tractor frame. Apply
threading-locking compound
(P/N 990-669) and torque to 170 ft. lb.
(230 Nm).
11. Working from the top of the tractor, install
two mast mounting bolts on each side.
Apply threading-locking compound
(P/N 990-669) and torque to 170 ft. lb.
(230 Nm).
12. Connect the main lift hoses at the tractor
bulkhead.
13. Connect the auxiliary hydraulic hoses at
the main manifold.
14. Connect the over-the-mast electrical cable
at connector JPS3 near the main manifold.
15. Attach the forks onto the fork carriage.
16. Attach the battery connector mounting
bracket near the mast mounting bolts on
the right side.
17. Using a suitable battery moving device,
install the battery. Install the battery gate.
18. Install the mast guard.
19. Install the top cover.
20. Reconnect the battery connector and turn
the key switch ON.
1026304B, 15 July 2007 7-171
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Lift Cylinder, Main Lift, Exploded Parts Drawing Hydraulic Components, Cylinder
Lift Cylinder, Main Lift,
Exploded Parts Drawing
Model 7400
Snap Ring
Lowering Cushion Piston
Cap Screw
Retaining
Seal
Ring
Piston Rod
Spring
Square Seal
Wiper Seal
Piston Seal
Gland
71024919_E1.CGM
Figure 7-185. Main Lift Cylinder, Model 7400
7-172 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Lift Cylinder, Main Lift, Exploded Parts Drawing
Model 7420/7440
Snap Ring
Lowering Cushion Piston
Cap Screw
Seal Retaining
Ring
Piston Rod
Spring
Square Seal
Wiper Seal
Piston Seal
Gland
71054090_B.CGM
Figure 7-186. Main Lift Cylinder, Model 7420/7440
1026304B, 15 July 2007 7-173
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Lift Cylinder, Main, Seal Repacking Hydraulic Components, Cylinder
Lift Cylinder, Main, Seal 5. Reconnect the battery connector and turn
the key switch ON.
Repacking 6. Carefully rotate the lift knob to raise the
piston to the telescopic crosstie.
7. Install the bolt, washer, and spacer at the
Model 7400 crosstie to the top of the piston.
NOTE: See Figure 7-185 on page 7-172. NOTE: Apply thread-locking compound
(P/N 1013829) to the threads of the bolt
Disassembly
and tighten, leaving a 0.12 in. (3 mm)
1. Slightly elevate the mast and place a block gap between the head of the bolt and the
between the outer telescopic crosstie and washer.
the mainframe.
8. Remove the block from between the outer
2. Fully lower the carriage. telescopic crosstie and the mainframe.
3. Turn the key switch OFF and disconnect 9. Bleed the hydraulic system.
the battery connector.
10. Check the truck for leaks and correct
4. Remove the bolt, washer, and spacer at the operation.
top of the piston and the outer telescopic
crosstie.
Model 7420/7440
5. Retract the piston into the housing enough
to allow the removal of the end cap (gland). NOTE: See Figure 7-186 on page 7-173.
6. Using cylinder end cap tool (P/N A9587),
remove the end cap (gland). Disassembly
7. On a clean working surface, remove the 1. Elevate the mast to produce a 6 to 8 inch
packing seal, wiper seal, and square seal (15 to 20 cm) gap between the outer
from the end cap. Note position and telescopic crosstie and the mainframe.
orientation of each when removing. 2. Block the mast between the inner and
8. Inspect the surfaces of the gland for any outer telescopics and between the outer
scratches or damage. Remove minor telescopic and the main frame.
imperfections using fine emery cloth. 3. Remove the cylinder mounting bolt at the
9. Inspect the inside of the housing for top of the cylinder.
damage and clean as required. 4. Collapse the cylinder (push on cylinder
10. Clean the threads on the gland and the while requesting lower).
cylinder. 5. Turn the key switch OFF and disconnect
the battery connector.
Reassembly 6. Using a 2 inch spanner wrench, remove
1. Lubricate with new hydraulic fluid, the the end cap (gland).
packing seal, wiper seal, and square seal 7. On a clean working surface, remove the
and install into their respective grooves on packing seal, wiper seal, and O-ring from
the gland. Make sure they are correctly the gland. Note position and orientation of
seated within the grooves and are not each when removing.
twisted.
8. Inspect the surfaces of the gland for any
2. Apply thread-locking compound scratches or damage. Remove minor
(P/N 990-571) to the threads of the gland. imperfections using fine emery cloth.
3. Lubricate the piston rod with new 9. Clean the threads on the gland and the
hydraulic fluid and carefully install the cylinder.
gland.
4. Torque the gland to 200 ft. lb. (271 Nm).
7-174 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Lift Cylinder, Main, Seal Repacking
Reassembly
1. Lubricate with new hydraulic fluid, the
packing seal, wiper seal, and square seal
and install into their respective grooves on
the end cap. Make sure they are correctly
seated within the grooves and are not
twisted.
2. Apply thread-locking compound
(P/N 990-571) to the threads of the gland.
3. Lubricate the piston rod with new
hydraulic fluid and carefully install the
gland.
4. Torque the gland to 200 ft. lb. (271 Nm).
5. Reconnect the battery connector and turn
the key switch ON.
6. Carefully rotate the lift knob to raise the
piston to the telescopic crosstie.
7. Install the bolt, washer, and spacer at the
crosstie to the top of the piston.
NOTE: Apply thread-locking compound
(P/N 1013829) to the threads of the bolt
and tighten, leaving a 0.12 in. (3 mm)
gap between the head of the bolt and the
washer.
8. Remove the blocking from between the
inner and outer telescopics and between
the outer telescopic and the main frame.
9. Bleed the hydraulic system.
10. Check the lift truck for leaks and correct
operation.
1026304B, 15 July 2007 7-175
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Lift Cylinder Lowering Cushion Hydraulic Components, Cylinder
Lift Cylinder Lowering Reassembly
Cushion 1. Lubricate the inside of the piston surface
with clean hydraulic fluid.
2. Lubricate the seal with clean hydraulic
Model 7400/7420/7440 Main fluid and install on the cushion. Install the
Lift Cylinders retainer ring on the cushion.
3. Insert and seat the cushion spring in the
NOTE: For Model 7400, see Figure 7-185 on center of the piston. Insert and seat the
page 7-172. For Models 7420/7440, see cushion on the end of the cushion spring.
Figure 7-186 on page 7-173.
4. Compress the spring and hold it in place
with a drill bit or drift pin inserted in one
Removal of the hydraulic fluid ports in the cushion
1. Remove the main lift cylinder. housing.
a. For Model 7400, see “Lift Cylinder, 5. Install the snap ring.
Main, Remove/Install”, “Model 7400” 6. Carefully release cushion pressure.
on page 7-167.
7. Reassemble the cylinder. See “Lift
b. For Model 7420/7440, see “Lift Cylinder, Main, Seal Repacking” on
Cylinder, Main, Remove/Install”, page 7-174.
“Model 7420/7440” on page 7-169.
8. Install the cylinder.
2. Remove the piston rod from the cylinder. a. For Model 7400, see“Lift Cylinder,
See “Lift Cylinder, Main, Seal Repacking” Main, Remove/Install”, “Model 7400”
on page 7-174. on page 7-167.
3. Place the piston rod on a clean padded
b. For Model 7420/7440, see “Lift
working surface.
Cylinder, Main, Remove/Install”,
4. Compress the spring and hold it in place “Model 7420/7440” on page 7-170.
with a drill bit or drift pin inserted in one
of the hydraulic fluid ports in the cushion
housing.
Model 7400/7420/7440 Free
Lift Cylinders, Series CA/FA (AC
lift)
When the snap ring is removed, the NOTE: For Model 7400 Series CA/FA, see
cushion spring will eject the cushion Figure 7-178 on page 7-161. For Model
from the piston. Keep body away from 7420/7440, see Figure 7-180 on
the piston end when performing this page 7-163.
procedure.
Removal
5. Remove the snap ring from inside of the
cylinder. Model 7400/7420/7440 lift trucks with AC lift
6. Release the cushion slowly. have a staging zone mechanism in the free lift
cylinders in addition to a cushion at the bottom
7. Remove the ring retainer and seal from the
of the cylinder.
cushion.
1. Using an eye bolt and hoist, remove the
8. Replace the cushion, spring, seal, and/or
piston rod from the cylinder.
retainer components as necessary. If
replacing the cushion, install the cap a. For Model 7400, do steps 1 through 9
screw in the end of the cushion. of “Lift Cylinder, Free Lift, Seal
Repacking”, “Model 7400”, “Series
7-176 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Lift Cylinder Lowering Cushion
CA/FA (AC lift)”, “Disassembly” on 6. Install the other spring.
page 7-164. 7. Install new O-rings on the inside and
b. For Model 7420/7440, do steps 1 outside of the retaining ring.
through 10 of “Lift Cylinder, Free Lift, 8. Install the retaining ring on the shaft of
Seal Repacking”, “Model 7420/7440”, the decel piston.
“Disassembly” on page 7-166,
9. Compress the spring and hold it in place
2. Place the piston rod on a clean padded with a drill bit or drift pin inserted in one
working surface. of the hydraulic fluid ports in the cushion
3. Compress the spring and hold it in place housing.
with a drill bit or drift pin inserted in one 10. Install the snap ring in the cushion
of the hydraulic fluid ports in the cushion housing.
housing.
11. Release the cushion slowly.
12. Reassemble the cylinder.
a. For Model 7400, do steps 2 through 14
When the snap ring is removed, the of “Lift Cylinder, Free Lift, Seal
cushion spring will eject the cushion Repacking”, “Model 7400”, “Series
from the piston. Keep body away from CA/FA (AC lift)”, “Reassembly” on
the piston end when performing this page 7-164.
procedure.
b. For Model 7420/7440, do steps 3
4. Remove the snap ring from inside of the through 12 of “Lift Cylinder, Free Lift,
cylinder. Seal Repacking”, “Model 7420/7440”,
“Reassembly” on page 7-166.
5. Release the cushion slowly.
6. Remove the retaining ring and the two
O-rings on the inside and outside of the Model 7400 Free Lift Cylinders,
ring. Series AA/BA/DA/EA (DC lift)
7. Remove the spring and decel piston.
NOTE: For Model 7400 Series AA/BA/DA/EA,
8. Remove the decel bearing and piston ring see Figure 7-179 on page 7-162.
from the decel piston.
9. Remove the spring and plug from the Removal
cushion housing (piston plug).
1. Using an eye bolt and hoist, remove the
10. Remove the O-ring from the plug.
piston rod from the cylinder. Do steps 1
through 8 of “Lift Cylinder, Free Lift, Seal
Reassembly Repacking”, “Model 7400”, “Series
AA/BA/DA/EA (DC lift)”, “Disassembly”
1. Lubricate new O-rings, piston ring, and
on page 7-165.
decel bearing with clean hydraulic fluid.
2. Place the piston rod on a clean padded
2. Install the new piston ring and decel
working surface.
bearing in the decel piston.
3. Compress the cushion to relieve the
3. Lubricate the inside of the piston surface
pressure on the snap ring.
with clean hydraulic fluid.
4. Compress the spring and hold it in place
4. Install the new O-ring in the groove in the
with a drill bit or drift pin inserted in one
plug and install the plug in the cushion
of the hydraulic fluid ports in the cushion
housing.
housing.
5. Seat the plug in the housing by inserting
the spring and the decel piston in the
cushion housing.
1026304B, 15 July 2007 7-177
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Lift Cylinder Lowering Cushion Hydraulic Components, Cylinder
When the snap ring is removed, the
cushion spring will eject the cushion
from the piston. Keep body away from
the piston end when performing this
procedure.
5. Remove the snap ring from inside of the
cylinder.
6. Release the cushion slowly.
7. Remove the ring retainer and seal from the
cushion.
8. Replace the cushion, spring, seal, and/or
retainer components as necessary. If
replacing the cushion, install the cap
screw in the end of the cushion.
Reassembly
1. Lubricate the inside of the piston surface
with clean hydraulic fluid.
2. Lubricate the seal with clean hydraulic
fluid and install on the cushion. Install the
retainer ring on the cushion.
3. Insert and seat the cushion spring in the
center of the piston. Insert and seat the
cushion on the end of the cushion spring.
4. Compress the spring and hold it in place
with a drill bit or drift pin inserted in one
of the hydraulic fluid ports in the cushion
housing.
5. Install the snap ring.
6. Carefully release cushion pressure.
7. Reassemble the cylinder. Do steps 3
through 12 of “Lift Cylinder, Free Lift, Seal
Repacking”, “Model 7400”, “Series
AA/BA/DA/EA (DC lift)”, “Reassembly” on
page 7-165.
7-178 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Reach Cylinder
Reach Cylinder 9. Clamp the rod at the wrench flats or clevis
in a soft-jawed vise. Loosen the retaining
nut on the piston assembly.
Reach Cylinder, Standard and 10. Slide the piston assembly off the end of the
Deep-Reach rod.
11. Slide the cushion sleeve off the rod. Note
Removal the direction of the taper.
12. Remove the head assembly.
1. Remove the mast guard.
13. Remove the head static seal O-rings,
2. Raise the carriage until the reach cylinder
back-up washers, rod inside diameter
is accessible from the operator’s
dynamic seal, and the rod wiper. Use care
compartment.
to avoid scratching the groove.
3. Fully retract the carriage.
14. Remove the O-ring and back-up washers
4. Turn the key switch OFF and disconnect from the piston assembly.
the battery connector.
5. Place a pan below the reach cylinder. Reassembly
6. Remove and cap the reach hoses at the
1. Remove any burrs or sharp edges caused
reach cylinder.
from disassembly before installing the new
7. Remove the screw and cotter pin holding seals.
the piston yoke in place.
2. Clean all parts with solvent. Lubricate
8. Remove the clevis pin and spacers. parts with petroleum jelly or clean
9. Remove the screw and cotter pin at the hydraulic fluid as indicated.
housing end. 3. Lubricate and install the new rod,
10. While supporting the cylinder, remove the dynamic seal, and rod wiper in their
clevis pin and spacers holding the cylinder respective inside grooves of the head
in place. assembly.
4. Lubricate and install the new head static
Disassembly seal O-rings and head static seal back-up
washers on the outside grooves of the head
1. With the cylinder removed, drain all assembly.
hydraulic fluid from the cylinder assembly.
2. Clamp the cylinder base end in a bench
vise. Cover the ports with a clean rag.
3. Remove the external lock ring.
4. Push the head assembly into the tube
assembly approximately 3/4 in. (19 mm).
5. Remove the spacer.
6. Remove the internal lock ring.
7. Important: Look for and remove any sharp
edges from the back corner of the internal
lock ring groove, if present.
8. Grip the rod firmly and pull the rod
assembly out of the tube assembly. (Oil
can spray out of the cylinder ports).
1026304B, 15 July 2007 7-179
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Reach Cylinder Hydraulic Components, Cylinder
5. Lubricate the head assembly inside seals 12. Grip the rod firmly and pull outward until
and carefully slide the head assembly onto the head assembly is tight against the lock
the rod assembly. ring.
13. Install the spacer and external lock ring in
the head assembly.
Installation
1. Place the spacers on the cylinder (hold
them in place with grease) and position the
cylinder housing into the yoke on the
carriage. Insert the clevis pin and secure
with the cotter pin and screw.
2. Place the spacers on the carriage bracket
(hold them in place with grease). Position
the piston yoke and insert the clevis pin.
Secure with the cotter pin and screw.
3. Reconnect the hydraulic hoses.
4. Reconnect the battery connector and turn
the key switch ON.
5. Bleed the hydraulic system.
6. Adjust the reach cylinder. See
“Adjustment” on page 7-181.
7. Check the truck for leaks and correct
operation.
8. Install the mast guard.
7R1022181_B.CGM
Figure 7-187. Reach Cylinder
6. Install the piston O-ring and back-up
washers in the outside groove of the piston
assembly.
7. Slide the cushion sleeve onto the rod.
NOTE: The taper on the cushion faces the head
assembly.
8. Carefully slide the piston assembly onto
the rod assembly. Install a new prevailing
torque nut and tighten.
9. Lubricate the piston and head assembly
and carefully slide it into the tube
assembly.
10. Push the head assembly into the tube
assembly approximately 3/4 inch
(19 mm).
11. Install a new internal lock ring in the
groove in the tube assembly bore.
7-180 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Reach Cylinder
Adjustment 3. Apply thread-locking compound
(P/N 1013829) to the threads on the
The top of the scissor roller must not protrude piston and torque the jam nut to 175 ft. lb.
more than 0.90 in. (22.8 mm) from the top of (237 Nm).
the roller channel on the fork carriage. This
takes precedence over the extended dimension. Retract Adjustment
Model 7400/7420/7440 lift trucks are designed
with reach and retract stops inside the reach
cylinder at both ends of the stroke. When the
scissors mechanism is fully retracted, there
should be a gap between the plastic block and
the metal block (Deep-Reach) or fixed carriage
(Standard Reach). This is a backup stop only.
Shim the plastic block to produce a gap of:
Carriage Type Gap
7R1022231_A.CGM
Figure 7-188. Scissor Roller Dimension Standard Reach 0.125 to 0.250 in.
(3.2 to 6.4 mm)
When the reach is fully extended, the
dimension from the front of the mainframe to Deep-Reach 0.125 to 0.375 in.
the face of the forks when level should be: (3.2 to 9.5 mm)
Carriage Model Dimension Reach Scissor Roller Shimming
R35TT 28.25 in. (717.6 mm) Make sure at least half of the thickness of the
scissor roller is running on the roll plate wear
R45TT 28.38 in. (720.00 mm)
bar. Shim as needed between the shoulder of
DR32TT 53.40 in. (1356.4 mm) the scissor arm stud and the bearing inner
race. See 7-190.
Shim Here
7R1022231_A.CGM
Figure 7-189. Reach Fully Extended Dimension
7RSB05013.JPG
The face of the fork to the front of the load Figure 7-190. Reach Scissor Roller Bearing Shimming
wheel (or wheel box) should be a minimum of
0.50 in. (13 mm). If not:
1. Loosen the jam nut that holds the piston
to the yoke.
2. Turn the piston to obtain the correct
dimension.
1026304B, 15 July 2007 7-181
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Tilt Cylinder Hydraulic Components, Cylinder
Tilt Cylinder 7. Clamp the rod in a bench vise at the pin
hole end.
Removal Head Static Seal
Back-up Washer
1. Extend and block the scissor assembly so Internal Lock
it cannot retract. Head Static Ring
2. Position and block the carriage at a Seal O-ring
Spacer
comfortable working height.
3. Spread the forks on the carriage to gain External Lock
complete access to the tilt cylinder. Ring
4. Tilt the forks completely up.
Rod Wiper
5. Turn the key switch OFF and disconnect
the battery connector. Rod Wear
Ring
6. Remove the snap rings from the tilt pin. Rod Dynamic
Tube Seal
7. Place a block between the fork carriage
Assembly
and the carriage frame.
Piston
8. Remove the tilt pin. Assembly
9. Place a pan below the tilt cylinder and Head Assembly
disconnect and cap the hydraulic hoses.
Note the orientation of the fittings and
position of the hoses.
10. Support the tilt cylinder and remove the
mounting bolts from the mounting blocks.
Pin Hole
Disassembly Base
End
With the cylinder removed, drain all hydraulic
fluid from the cylinder assembly. Clamp the Rod
cylinder at the base end in a bench vise. Cover
the ports with a clean rag. Refer to Figure 7-191
for the following steps.
Piston
1. Remove the external lock ring. Wear
Ring
2. Remove the spacer.
3. Push the head assembly into the tube
assembly approximately 3/4 in. (19 mm). Piston
Seal
4. Remove the internal lock ring.
5. Important: Remove the sharp edge from the
back corner of the internal lock ring
Rod Piston
groove.
O-ring
6. Grip the rod through the hole in the pin
and pull the rod assembly out of the tube
assembly.
7CYLASSY.WMF
Figure 7-191: Tilt Cylinder, Disassembly
7-182 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Tilt Cylinder
8. Loosen the piston assembly with a 10. Push the head assembly into the tube
spanner wrench. Unthread the piston assembly approximately 3/4 in. (19 mm).
assembly from the rod. 11. Install a new internal lock ring in the
9. Slide the head assembly off the rod from groove in the tube assembly bore.
the piston end. 12. Grip the rod through the pin hole and pull
10. Clean the male threads of the rod. Remove outward until the head assembly is tight
the rod piston O-ring. against the lock ring.
11. Remove the head static seal O-ring, 13. Install the spacer and external lock ring on
back-up washer, wear ring, rod dynamic the head assembly.
seal, and rod wiper. Use care to avoid 14. Stroke the cylinder rod back and forth by
scratching grooves. hand. It should move smoothly, without
12. Remove the wear ring and piston dynamic binding or heavy drag.
seal from the piston assembly. Use care to 15. Install the cylinder assembly in the lift
avoid scratching grooves. truck.
13. Clean all parts in solvent.
Installation
Reassembly
1. Make sure the hydraulic fittings are in the
1. Remove any burrs or sharp edges caused same orientation on the cylinder as when
from disassembly before installing new removed.
seals. 2. Install the yokes on the cylinder and
2. Lubricate parts as indicated below with position the cylinder in place. Bolt the
petroleum jelly or clean hydraulic fluid. yokes to the carriage.
3. Lubricate and install a new rod wear ring, 3. Connect the hydraulic hoses noting their
rod dynamic seal, and rod wiper in their correct orientation and position.
respective inside grooves of the head 4. Coat the tilt cylinder pin with all weather
assembly. grease (P/N 1012992). Install the tilt
4. Lubricate and install a new head static cylinder pin and snap rings.
seal, O-ring, and head static seal back-up 5. Reconnect the battery connector and turn
washer on the outside grooves of the head the key switch ON.
assembly.
6. Remove the blocks.
5. Lubricate the head assembly inside seals
with hydraulic fluid and carefully slide the 7. Check for clearance between the free lift
head assembly onto the rod assembly. feed hose assembly, tilt hoses, and fittings
when the carriage is fully lowered and
6. Install the piston wear ring and piston seal retracted.
in their respective outside grooves of the
piston assembly. 8. Check the tilt function for correct
operation and leaks.
7. Install the rod piston O-ring in the groove
of the rod. 9. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on
8. Apply red thread-locking compound page 7-134.
(P/N 990-571) to the male threads of the
piston. Carefully thread the piston
assembly onto the rod assembly. Torque to
200 ft. lbs. (271 Nm).
9. Lubricate the piston and head assembly
with hydraulic fluid and carefully slide it
into the tube assembly.
1026304B, 15 July 2007 7-183
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Flow Limiter, Main Lift Hydraulic Components, Cylinder
Flow Limiter, Main Lift 2. Install the fitting in the manifold block.
3. Reconnect the hose to the cylinder.
In Model 7400, the single main lift flow limiter 4. Reconnect the battery connector and turn
is located in the manifold block at the bottom of the key switch ON.
the right side main lift cylinder. The flow limiter 5. Bleed the hydraulic system. See
can be replaced without removing the cylinder. “Hydraulic System Bleeding” on
page 7-134.
In Models 7420 and 7440, there are two main
6. Check the truck for leaks and correct
lift flow limiters, one each in the manifold block
operation.
at the bottom of the main lift cylinder. The flow
limiter can be replaced without removing the 7. Install the top and front covers.
cylinder.
Removal
1. Fully lower the carriage to the floor.
2. Turn the key switch OFF and disconnect
the battery connector.
3. Remove the top cover and front cover(s).
4. Place a pan below the baseleg at the
cylinder.
5. Disconnect and cap the hose at the bottom
of the cylinder.
6. Remove the fitting from the manifold
block.
7. Remove the flow limiter noting the
direction of the arrow.
7R1022231_A.CGM
Figure 7-192. Flow Limiter
Installation
1. Install the flow limiter. Make sure the
arrow points in the up direction.
7-184 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Hydraulic Components, Cylinder Flow Limiter, Free Lift
Flow Limiter, Free Lift 11. Remove the flow limiter noting the
direction of the arrow.
In Model 7400, the free lift flow limiter is
located in the manifold block at the bottom of Flow Limiter
the left side free lift cylinder.
In Models 7420 and 7440, the free lift flow
limiter is located inline between the free lift
cylinder and hydraulic line. The number and
location of flow limiter(s) may vary among
trucks.
Model 7400
Removal
71045742_D5.CGM
1. Remove the mast guard. Figure 7-193. Free Lift Flow Limiter, Model 7400
2. Raise the telescopics until the bottom of
the left free lift cylinder is accessible from
Installation
the operator’s compartment. 1. Install the flow limiter. On Model 7400,
3. Place a block of sufficient length make sure the arrow points in the down
(approximately 24 in./610 mm) between direction.
the outer telescopic crosstie and the 2. Install the fitting in the manifold block.
mainframe to hold the position in step 2.
3. Install the set screw at the bottom of the
4. Fully lower the carriage. cylinder.
5. Extend the reach mechanism to allow 4. Reconnect the hydraulic line at the bottom
easier removal of the free lift lines and of the cylinder.
fittings.
5. Reconnect the battery connector and turn
6. Turn the key switch OFF and disconnect the key switch ON.
the battery connector.
6. Remove the block between the outer
7. Place a pan below the baseleg at the left telescopic and mainframe.
free lift cylinder.
7. Bleed the hydraulic system. See
8. From the operator’s compartment, remove “Hydraulic System Bleeding” on
and cap the hydraulic line at the bottom of page 7-134.
the free lift cylinder. See Figure 7-193.
8. Check the truck for leaks and correct
9. Remove the set screw at the bottom of the operation.
free lift cylinder to permit the cylinder to
9. Install the mast guard.
rotate for the removal of the fitting.
10. Remove the fitting from the manifold
block.
1026304B, 15 July 2007 7-185
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Flow Limiter, Free Lift Hydraulic Components, Cylinder
Model 7420/7440 6. Check the truck for leaks and correct
operation.
NOTE: The number and location of flow
limiter(s) may vary among trucks.
Removal
1. Fully lower the mast.
2. Turn the key switch OFF and disconnect
the battery connector.
3. Using a suitable hoist, raise the carriage at
least 4 feet (1.2 m) and secure.
4. Place a shallow pan below the flow limiter.
Flow
5. Disconnect and cap the hydraulic hose at Limiter
the bottom of the cylinder.
6. Remove the flow limiter from the cylinder,
noting the direction of the arrow.
Installation 71067160_C1.CGM
Figure 7-194. Free Lift Flow Limiter, Model 7420/7440
1. Install the flow limiter in the cylinder.
Make sure the arrow points toward the
outside of the truck.
2. Reconnect the hydraulic hose at the
bottom of the cylinder.
3. Reconnect the battery connector and turn
the key switch ON.
4. Using the hoist, lower the carriage
completely.
5. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on
page 7-134.
7-186 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable
Mast, Chain, Hose, Cable
Section 7. Component Procedures
1026304B, 15 July 2007 7-187
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Chain, Hose, Cable Component Procedures Summary Mast, Chain, Hose, Cable
Mast, Chain, Hose, Cable
Component Procedures
Summary
Table 7-20. Mast, Chain, Hose, Cable Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Baseleg Procedure: Baseleg mounting Baseleg weighs over 100 lb. (45 kg).
page 7-191 bolts: P/N 990-544/ Apply anti-seize compound (P/N 990-638) to
165 ft. lb. (223 Nm) locating pins.
Load wheel plate
mounting bolts:
P/N 990-536/50 ft. lb.
(68 Nm)
Bearings, Procedure:
See procedure.
Reach Carriage page 7-193
Bearings, Procedure:
See procedure.
Telescopic page 7-194
Bow Pads Procedure:
Model 7400 only
page 7-196
Cable, Procedure: For terminal strip addition for bulk cable
Over-the-Mast page 7-220, use, see page 7-229.
page 7-229
Carriage Procedure:
Model 7400:
page 7-198 See procedure.
Model 7440:
page 7-199
Chain anchors Procedure:
7400 Main:
page 7-201
7420 Main:
page 7-202
7440 Main:
See procedure.
page 7-204
7400 Free:
page 7-206
7420/7440
Free:
page 7-207
Chains, Procedure:
See procedure.
Free Lift page 7-211
7-188 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Chain, Hose, Cable Component Procedures Summary
Table 7-20. Mast, Chain, Hose, Cable Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Chains, Procedure:
Main Lift Model 7400:
page 7-208
Model 7420: See procedure.
page 7-209
Model 7440:
page 7-210
Forks Inspection
procedure See procedure.
page 7-213
Height Encoder Procedure:
Belt Model 7420:
page 7-214 See procedure.
Model 7440:
page 7-216
Hose/Tubing, Procedure:
Free Lift page 7-234
See procedure.
Carriage Feed
Inner
Hose/Tubing, Procedure:
Free Lift page 7-234
See procedure.
Carriage Feed
Outer
Hose, Free Lift Procedure:
Carriage Tractor page 7-234 See procedure.
to Bulkhead
Hose, Main Lift Procedure:
See procedure.
page 7-219
Hose, Procedure: Pulley stud: N/A
Over-the-Mast Model 7400: P/N 1013289/
page 7-220 130 ft. lb. (174 Nm)
1026304B, 15 July 2007 7-189
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Chain, Hose, Cable Component Procedures Summary Mast, Chain, Hose, Cable
Table 7-20. Mast, Chain, Hose, Cable Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Mast Disassembly Mast to Tractor: N/A
procedure: P/N 990-666 primer
Model 7400: P/N 990-544 locker/
page 7-235 165 ft. lb. (224 Nm)
Model 7420:
page 7-247
Model 7440:
page 7-258
Assembly
procedure:
Model 7400
page 7-239
Model 7420:
page 7-252
Model 7440:
page 7-262
Pulleys, No Pulley stud: N/A
Over-the-Mast P/N 1013289/
130 ft. lb. (174 Nm)
Stops, Carriage No P/N 990-536/ N/A
35 ft. lb. (47.5 Nm)
7-190 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Baseleg
Baseleg 7. Remove the bolts holding the baseleg to
the main frame.
Removal
1. Lower the mast and retract the carriage Baseleg weighs over 100 pounds
completely. (45 kg). Use a suitable lifting device to
2. Turn the key switch OFF and disconnect assist in removing baseleg.
the battery connector.
8. Slide the baseleg off the locating pins. See
3. Remove the right or left front cover. Figure 7-196. If added force is needed to
4. Remove the battery gate on the side being separate the baseleg from the mast,
repaired. protect the casting from direct blows.
Use extreme caution whenever the lift
truck is jacked up. Never block the lift
truck between the telescopic and the
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
vehicle while jacking the lift truck. After
the lift truck is jacked, place solid blocks
or jack stands beneath it to support it.
DO NOT rely on the jack alone to Locating
support the lift truck. See “Jacking Pins
Safety” on page 2-11.
5. Jack and block the lift truck under the 71015167
Figure 7-196. Baseleg Removal, Model 7400 shown
side of the tractor.
6. Remove the bolts holding the load wheel
plates to the baseleg. Slide the load wheel
assembly forward off the baseleg. See
Figure 7-195.
71040465_B.CGM
Figure 7-195. Load Wheel Assembly and Baseleg
(closed toe version shown)
1026304B, 15 July 2007 7-191
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Baseleg Mast, Chain, Hose, Cable
Installation 10. Install battery gate.
1. Apply anti-seize compound (P/N 990-452)
to the baseleg alignment pins and mating
surfaces of mainframe, baseleg, and
baseleg shim, if used. Insert locating pins
into the mast.
2. Using a suitable lifting device to assist,
mount the baseleg over the alignment
pins.
3. Apply thread-locking compound
(P/N 990-669) to the baseleg mounting
bolts.
4. Install baseleg mounting bolts and
washers. Torque as shown in the table
below.
Model 7400 Model 7420/7440
165 ft. lb. (223 Nm) 295 ft. lb. (434 Nm)
5. Slide load wheel assembly over baseleg.
6. To the outside of the mounting bolt sleeve
and the inside of the baseleg hole, apply
solvent (P/N 990-589), primer
(P/N 990-533), and retaining compound
(P/N 990-575).
7. Apply thread-locking compound
(P/N 1013829) to the load wheel plate
mounting bolts. Install mounting bolts,
washers and nuts. Torque as shown in the
following table:
Bolt Torque
Wheel Plate Mounting, 50 ft. lb. (68 Nm)
7400
Wheel Plate Mounting, 150 ft. lb. (203 Nm)
7420/7440
Wheel Plate Top Bolt 21 ft. lb. (28 Nm)
Nose Bolt, Closed Toe 55 ft. lb. (74.5 Nm)
8. Remove blocking and lower the baseleg to
the floor.
9. Install right or left front cover.
7-192 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Bearings, Reach Carriage
Bearings, Reach 4. If the inner race of the bearing does not
protrude past the end of the shaft when
Carriage the bearing is fully seated, bend the flat
washer to contact the bearing so the
bearing does not walk on the shaft.
The upper reach carriage roller bearing is
accessible when the carriage is elevated. You 5. Repeat steps 1 thru 4 for the five
must remove the reach carriage to access the remaining bearings.
middle and lower bearings. The bearings are 6. Clean and re-grease the telescopic
shimmed at the factory to a 0.000 ±.010 overall channels.
interference between the bearings and the inner 7. Re-install the carriage. See “Carriage” on
telescopic after the inner telescopic is shimmed page 7-198.
and inserted in the outer telescopic. Inspect
bearings for damage or wear and replace as 8. Test the lift and lower functions of the
required. carriage.
Removal
1. Remove the carriage. See “Carriage” on
page 7-198.
2. Remove the socket head cap screw and
washer on the end of the bearing.
3. The bearing should slide off the shaft with
hand pressure. A suitable bearing puller
can be used if required.
Installation
Shim the top and middle bearings to obtain an
overall width equal to the minimum inner
telescopic dimension (±0.010 in.) taken from
the inside to inside of the I-beam webs at the
front flange of the inner telescopic.
Shim the bottom bearings to obtain an overall
width equal to the minimum inner telescopic
dimension (±0.010 in.) taken from the inside to
inside of the I-beam webs at the rear of the
inner telescopic.
If possible, maintain an equal amount of shim
thickness on each side of the carriage when
shimming the bearings.
1. Install or remove the required amount of
shims.
2. Install the bearing on the shaft.
3. Apply thread-locking compound
(P/N 990-536) to the socket head cap
screw and fasten the screw and washer in
place.
1026304B, 15 July 2007 7-193
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Bearing Shimming, Mast Telescopics Mast, Chain, Hose, Cable
Bearing Shimming, Mast 8. Shim the outer telescopic upper bearing
set to 0.000 ±0.010 in. overall
Telescopics interference with the inner telescopic after
the top mainframe bearings have been
correctly shimmed.
Shimming a mast makes a smooth running unit
which is not too tight or too loose. If you find 9. Shim the inner telescopic lower bearing set
any marks within the telescopics or mainframe to 0.030 ±0.010 in. overall interference
where the rollers have been running, remove with the outer telescopic after the outer
them, using a sanding disc and 80 grit paper. telescopic lower bearings have been set.
Do not attempt to remove all marks, only the 10. Install or remove the required amount of
ridges. Shim the bearings to the tightest spot on shims.
the assembly (as the rollers run up and down 11. Install the bearing on the shaft.
the rail). Buff small areas that are slightly
higher than the rest of the web to avoid 12. Apply thread-locking compound
shimming the major portion of the rail too loose. (P/N 990-536) to the socket head cap
The shims used under each roller bearing come screw and fasten the screw and washer in
in the following sizes: thin, medium and thick. place.
Although you can use different combinations of 13. If the inner race of the bearing does not
shims to obtain the correct adjustment, you protrude past the end of the bearing stud
should try to maintain equal shim thickness on when the bearing is fully seated, bend the
each side of the mast. flat washer to contact the bearing to
prevent the bearing from walking on the
Shimming Procedure stud shaft.
1. Elevate the mast to gain access to the
bearings.
2. Place a block between the outer telescopic
crosstie and the mainframe.
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
7R1022231_A.CGM
respective mast or telescopic. Figure 7-197. Inner Race
6. Remove the bearing.
14. Install the bearing assembly into its
NOTE: It may be necessary to drive a wedge respective mast or telescopic. Make sure
between the respective telescopics to that the flat spot of the bearing stud aligns
provide clearance for removal and with the welded stop on the mast or
installation. telescopic.
7. Remove the socket head cap screw and 15. Install the roller stud sleeve.
washer retaining the bearing on the stud.
16. Apply thread-locking compound
NOTE: Shim the mainframe top bearing and the (P/N 1013829) to the threads of the
outer telescopic lower bearing set to a mounting bolt and torque to 260 ft. lb.
0.030 ±0.010 in. overall interference. (352.5 Nm).
7-194 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Bearing Shimming, Mast Telescopics
17. Reconnect the battery connector and turn
the key switch ON.
18. Remove the block from between the outer
telescopic and the mainframe.
19. Test the operation of the elevating
assembly.
1026304B, 15 July 2007 7-195
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Bow Pads Mast, Chain, Hose, Cable
Bow Pads
NOTE: Only Model 7400 trucks have bow pads.
Models 7420 and 7440 do not.
Inspection and Adjustment
1. DR32TT and R45TT: Elevate the mast to
expose the bow pads mounted on the
outside of the inner telescopic. Pads are on
the leading (forks side) edge of the rail.
See Figure 7-201 on page 7-197.
2. R35TT: Elevate the mast to expose the bow
pads mounted on the outside of the inner
telescopic and the outside of the outer 7RPINRCH06R008_IMAGE006.jpg
telescopic. Pads are on both leading and Figure 7-199. Inner Telescopic Bow Pads
trailing edges of the rail. See Figure 7-201
on page 7-197. 4. Shim as required to obtain a gap of 0.03
in. to 0.09 in. (0.8mm to 2.3mm). On the
3. DR32TT, R45TT and R35TT: Examine each
R35TT mast, measure the gaps between
bow pad and measure its thickness. If the
the outer telescopic and mainframe by
thickness is less than 0.187 in. (4.75mm),
elevating the mast so that the pads are at
replace the pad. Lower the mast. Using a
the top of the mainframe.
suitable feeler gauge, check the clearance
gap of the bow pads between the inner
telescopic and the outer telescopic.
7RPINRCH06R008_IMAGE002.jpg
Figure 7-198. Inner Telescopic Bow Pads Model 7400
R45TT/R45TT/DR32TT Mast
7RPINRCH06R008_IMAGE010.JPG
Figure 7-200. Outer Telescopic Bow Pads Model 7400
R35TT Mast
5. Shim part numbers are:
• 1028983 (0.040 in.)
• 1033489 (0.125 in.)
• 1028969 (0.250 in.)
7-196 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Bow Pads
R35TT Mast R45TT/DR32TT
Mast
2 Bow Pads on each 3 Bow Pads on each
leading and trailing edge of leading edge of
inner and outer telescopic — inner telescopic —
total of 16 pads total of 6 pads
7
Figure 7-201. Bow Pad Locations
1026304B, 15 July 2007 7-197
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Carriage Mast, Chain, Hose, Cable
Carriage 14. Carefully lift the carriage assembly out of
the mast assembly.
NOTE: Twist the left side free lift pulley to allow
Model 7400 the carriage stop mounting block to
clear.
The carriage is removed from the top of the
mast.
Installation
1. Lower the carriage assembly into
telescopic.
A standard carriage without forks 2. Continue lowering carriage to an
weighs approximately 880 lbs. appropriate height and reconnect freelift
(363 kg). A Deep-Reach ® carriage chains to the anchors.
without forks weighs approximately 3. Connect the OTM hoses to the auxiliary
1100 lbs. (500 kg). manifold.
4. Remove the lifting device.
Removal
5. Connect the cable to JS2 at carriage and
1. Remove mast guard and top cover. JPS3 in tractor.
2. Remove forks. 6. Attach the manifold cover to the carriage.
3. Remove the mounting bolts from the Apply thread-locking compound
hose/cable guide and retainer at the back (P/N 1013829) to the mounting bolts and
of the carriage. torque to 30 ft. lb. (42 Nm).
4. Retract scissor assembly. 7. Mount the auxiliary manifold to the
carriage. Apply thread-locking compound
5. Disconnect the OTM cable at JPS3 in the
(P/N 990-536) to the mounting bolts and
tractor.
torque to 21 ft. lb. (29 Nm).
6. Remove the auxiliary manifold cover and
8. Extend the reach. Block the carriage at an
disconnect the over-the-mast (OTM) cable
appropriate height to relieve the tension
at TS2. Remove the auxiliary manifold
on the OTM hoses and cable to install the
mounting screws.
hose/cable guide retainer at the back of
7. Elevate the carriage to gain access from the carriage.
the operator’s compartment to the carriage
9. Apply thread-locking compound
stops and the OTM hose fittings at the
(P/N 1013829) to the mounting bolts and
auxiliary manifold.
install the hose/cable guide retainer at the
8. Turn the key switch OFF and disconnect back of the carriage.
the battery.
10. Install the carriage stops.
9. Remove the OTM hoses from the carriage
11. Install the forks.
manifold. Cap hoses and plug the fittings.
12. Check the tension of the hoses, cable, and
10. Remove the carriage stops.
free lift chains and adjust as required.
11. Using a suitable lifting device, lift the
13. Bleed the hydraulic system. See
carriage assembly to relieve the tension
“Hydraulic System Bleeding” on
from the free lift chains.
page 7-134.
12. Remove the master link from the freelift
14. Check for leaks and test the truck for
chains at the free lift cylinder anchor
correct operation.
bolts. Twist the right side pulley to allow
the removal of the chain. 15. Install the top cover and mast guard.
13. Drape the chains over the carriage
assembly.
7-198 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Carriage
Model 7440 11. Loosen and remove the auxiliary hose
clamp on the carriage See Figure 7-202.
The carriage is removed from the top of the
mast.
A standard carriage without forks
weighs approximately 880 lbs.
(363 kg). A Deep-Reach ® carriage
without forks weighs approximately
1100 lbs. (500 kg).
Removal
1. Using a suitable work platform, remove
the carriage stops at the top of the inner
telescopic.
2. Remove the mast guard and top cover.
3. Remove the forks.
4. Elevate the carriage approximately 3 feet
(1 meter) for access to the auxiliary
manifold.
5. Slightly extend the carriage. Attach hoist
straps at three points to keep the carriage
level.
6. Using a hoist or other suitable lifting Remove
these
device, lift the carriage slightly to slacken
screws
the chains.
7. Remove the auxiliary manifold cover.
8. Disconnect the over-the-mast (OTM) cable
at terminal strip TS2, marking wires as
needed to aid in reconnection.
9. Loosen the auxiliary manifold mounting
bolts.
10. Remove the auxiliary hoses at the
auxiliary manifold, marking them if Do not
necessary for re-assembly. remove
these
screws
71051959_B3.CGM 1051959_B10.CGM
Figure 7-202. Model 7440 Auxiliary Hose CLamp
12. Loosen the U-clamp and feed the OTM
cable through.
13. Disconnect the OTM tensioning spring and
feed the cable through the bracket on the
free lift cylinder.
1026304B, 15 July 2007 7-199
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Carriage Mast, Chain, Hose, Cable
14. Remove the button head screw from both 5. Reattach the auxiliary hose bracket.
chain anchor pin retainers. Remove the 6. Reconnect the auxiliary hoses to the
pins to free the chains from the anchors. auxiliary manifold.
15. Using a hoist or other suitable lifting 7. Tighten the auxiliary manifold mounting
device, carefully lift the carriage out the bolts.
top of the mast.
8. Feed the over-the-mast cable through the
NOTE: Note the four kickback pads and shims U-clamp and tighten the U-clamp snug.
located between the carriage and the Do not over-tighten.
inner telescopic. They may fall out as
9. Connect the over-the-mast cable wires at
the carriage emerges from the mast.
terminal strip TS-2.
10. Reinstall the auxiliary manifold cover.
11. Release hoist tension on the carriage.
Remove hoist straps.
12. Reinstall the forks.
13. Reinstall the mast guard and top cover.
14. Reconnect the battery connector and turn
the key switch ON.
15. Test all carriage functions for correct
operation. Check for hydraulic leaks.
Kickback Pad and Shims
(both sides)
71036594_A.CGM
Figure 7-203. Carriage Kickback Pads
Installation
1. Make sure the free lift cylinder pulleys are
pivoted 90 degrees.
2. Make sure the top carriage bearing
keepers are in place.
3. Using a hoist or other suitable lifting
device, carefully lower the carriage into the
mast.
NOTE: Make sure the four kickback pads are in
place and shimmed snug to the mast as
the carriage is lowered into the mast. A
dab of grease will hold the pads and
shims in place while lowering.
4. Pivot the free lift cylinder pulleys fore-aft.
7-200 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Chain Anchors
Chain Anchors Upper Chain Anchor Removal, 7400 ML
1. Remove the chain anchor bolt and the
anchor pin retainer. See Figure 7-205.
Main Lift Chain Anchors
Model 7400 Main Lift (ML)
Preparation for Removal
1. Place a block between the outer telescopic
crosstie and the mainframe crosstie and a
slightly longer block between the inner
telescopic crosstie and the outer telescopic
crosstie. This will provide the required
slack in the chains. See Figure 7-204.
7R1022231_A.CGM
Figure 7-205. Upper Main Lift Chain Anchor Removal,
Model 7400
2. Grasp the chain and remove the anchor
pin.
NOTE: You can remove the pin by using a slide
hammer or by using a large socket
Blocking (1 1/16 in.), a M8 x 50 mm bolt and
washers to act as a pulling device.
7DSCF1361.JPG See Figure 7-206.
Figure 7-204. Blocking Telescopics
2. Lower the carriage and block at a height
that will allow access to the lower chain
anchors at the bottom of the inner
telescopic. If only the upper anchors are
being removed, fully lower the carriage.
3. Turn the key switch OFF and disconnect
the battery connector.
7R1022231_A.CGM
Figure 7-206. Anchor Pin Removal, Model 7400
3. To hold the chain in position, attach a pair
of locking pliers to the chain nearest the
chain sheave.
1026304B, 15 July 2007 7-201
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Chain Anchors Mast, Chain, Hose, Cable
4. Remove the chain anchor from the lift 4. Remove the chain anchor from the
chain. telescopic.
Upper Chain Anchor Installation, 7400 ML
1. Install the mast stop to the chain anchor.
2. Attach the chain anchor to the lift chain,
making sure that the two holes in the Master Link
anchor are facing towards the outside.
Cotter
3. Remove the locking pliers, position the
Pin
chain anchor and install the anchor pin. Chain
You can install the chain anchor bolt Anchor
temporarily to assist in the installation of
the pin.
Chain Anchor
4. Install the chain anchor pin retainer. Block
Apply thread-locking compound
(P/N 1013829) to the threads of the
Adjusting
anchor bolt and torque to 130 ft. lb.
Nut
(174 Nm).
5. Reconnect the battery connector and turn Cotter Pin
the key switch ON.
6. Remove the blocks from between the 7R1022231_A.CGM
telescopic crossties. Figure 7-207. Lower Main Lift Chain Anchor, Model 7400
7. Adjust the lift chains until there is a
Lower Chain Anchor Installation, 7400 ML
0.25 in. (6.4 mm) gap at the narrowest
point between the inner and outer 1. Reinstall the master link to the lift chain
telescopics when the carriage is fully and chain anchor.
lowered. Make sure there is equal tension 2. Install the chain anchor into the chain
on the lift chains after the adjustment. anchor block and thread the adjusting nut
8. Test the truck for correct operation. on to the distance recorded earlier. Install
the cotter pin at the end of the chain
Lower Chain Anchor Removal, 7400 ML anchor.
1. Disconnect the lift chain master link from 3. Reconnect the battery connector and turn
the chain anchor at the bottom of the the key switch ON.
inner telescopic. 4. Remove the blocks from between the
2. Note the distance of the adjusting nut. telescopic crossties.
This distance will be used as a preliminary 5. Adjust the lift chains until there is a
adjustment when re-installing. 0.25 in. (6.4 mm) gap at the narrowest
3. Remove the cotter pin and chain anchor point between the inner and outer
adjusting nut. telescopics when the carriage is fully
lowered. Make sure there is equal tension
on the lift chains after the adjustment.
6. Test the truck for correct operation.
Model 7420 Main Lift (ML)
Preparation for Removal
1. Place a block between the outer telescopic
crosstie and the mainframe crosstie and a
7-202 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Chain Anchors
slightly longer block between the inner (1 1/16 in.), a M8 x 50 mm bolt and
telescopic crosstie and the outer telescopic washers to act as a pulling device.
crosstie. This will provide the required
slack in the chains. See Figure 7-204 on
page 7-201.
2. Lower the carriage and block at a height
that will allow access to the lower chain
anchors at the bottom of the inner
telescopic. If only the upper anchors are
being removed, fully lower the carriage.
3. Turn the key switch OFF and disconnect
the battery connector.
Upper Chain Anchor Removal, 7420 ML
1. Remove the chain anchor bolt and the
anchor pin retainer. See Figure 7-208.
7R1022231_A.CGM
Figure 7-209. Anchor Pin Removal
3. To hold the chain in position, attach a pair
of locking pliers to the chain nearest the
chain sheave.
4. Remove the chain anchor from the lift
chain.
Upper Chain Anchor Installation, 7420 ML
1. Install the mast stop to the chain anchor.
Pin 2. Attach the chain anchor to the lift chain,
making sure that the two holes in the
Anchor anchor are facing towards the outside.
Pin
Block 3. Remove the locking pliers, position the
Retainer
chain anchor and install the anchor pin.
Bolt
You can install the chain anchor bolt
71051418_E5.CGM
temporarily to assist in the installation of
Figure 7-208. Upper Main Lift Chain Anchor Removal, the pin.
Model 7420
4. Install the chain anchor pin retainer.
2. Grasp the chain and remove the anchor Apply thread-locking compound
pin. (P/N 1013829) to the threads of the
anchor bolt and torque to 130 ft. lb.
NOTE: You can remove the pin by using a slide (174 Nm).
hammer or by using a large socket
5. Reconnect the battery connector and turn
the key switch ON.
6. Remove the blocks from between the
telescopic crossties.
7. Adjust the lift chains until there is a
0.375 in. (9.5 mm) gap at the narrowest
point between the inner and outer
telescopics when the carriage is fully
1026304B, 15 July 2007 7-203
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Chain Anchors Mast, Chain, Hose, Cable
lowered. Make sure there is equal tension 3. Install the chain anchor into the chain
on the lift chains after the adjustment. anchor block and thread the adjusting nut
8. Test the truck for correct operation. on to the distance recorded earlier.
4. Reinstall the anti-kickback pad and block
Lower Chain Anchor Removal, 7420 ML at the bottom of the inner telescopic.
1. Remove the anti-kickback pad and block 5. Reconnect the battery connector and turn
from the bottom of the inner telescopic. the key switch ON.
See Figure 7-210. 6. Remove the blocks from between the
telescopic crossties.
7. Adjust the lift chains until there is a
0.375 in. (9.5 mm) gap at the narrowest
point between the inner and outer
telescopics when the carriage is fully
lowered. Make sure there is equal tension
on the lift chains after the adjustment.
8. Test the truck for correct operation.
Model 7440 Main Lift (ML)
Upper Chain Anchor Removal, 7440 ML
1. Place a block between the outer telescopic
crosstie and the mainframe crosstie and a
slightly longer block between the inner
telescopic crosstie and the outer telescopic
Anti-Kickback Anti-Kickback crosstie. This will provide the required
Pad Block slack in the chains. See Figure 7-204 on
page 7-201.
71051418_E8.CGM
Figure 7-210. Anti-Kickback Pad and Block, Model 7420 2. Turn the key switch OFF and disconnect
the battery connector.
2. Note the distance of the adjusting nut
3. Disconnect the lift chain master link from
threads. This distance will be used as a
the chain anchor.
preliminary adjustment when
re-installing. 4. Note the distance of the adjusting nut.
This distance will be used as a preliminary
3. Remove the nut from the chain anchor
adjustment when re-installing.
bolt.
5. Remove the adjusting nut from the anchor.
4. Remove the chain anchor from the
telescopic by pulling the chain out at the
main lift pulley.
5. Disconnect the lift chain master link from
the chain anchor.
Lower Chain Anchor Installation, 7420 ML
1. Reinstall the master link to the lift chain
and chain anchor.
2. Feed the lift chain over the main lift chain
pulley and down the telescopic.
7-204 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Chain Anchors
6. Remove the chain anchor from the 5. Disconnect the lift chain master link from
telescopic. the chain anchor. Twist the chain if
necessary to reveal the master link.
6. Unscrew the chain anchor from the chain
anchor block.
Master Link
Master Link Chain Anchor
Cotter Pin
Chain Anchor
Chain Anchor
Block
Chain Anchor
Block
Bearing Boss
Bearing
Adjusting Nut Boss
71051602_C2A.CGM
Mounting
Figure 7-211. Upper Main Lift Chain Anchor, Model 7440 Bolt
Upper Chain Anchor Installation, 7440 ML
71051602_C8.CGM
1. Install a new master link to the lift chain Figure 7-212. Lower Main Lift Chain Anchor, Model 7440
anchor and secure with a new cotter pin.
2. Install the chain anchor into the chain Lower Chain Anchor Installation, 7440 ML
anchor block and thread the adjusting nut 1. Thread the chain anchor into the chain
on to the distance recorded earlier. anchor block.
3. Reconnect the battery connector and turn 2. Install a new master link to the lift chain
the key switch ON. and chain anchor and secure with a new
4. Remove the blocks from between the cotter pin.
telescopic crossties. 3. Reattach the lower bearing bosses and
5. Adjust the lift chains until there is a bearings in the inner telescopic. Apply
0.5 in. (12.7 mm) gap at the narrowest thread-locking compound (P/N 1013829)
point between the inner and outer to the bosses and torque to 260 ft. lb.
telescopics when the carriage is fully (353 Nm).
lowered. Make sure there is equal tension 4. Lower the inner telescopic to slacken the
on the lift chains after the adjustment. hoist strap. Remove the strap.
6. Test the truck for correct operation. 5. Adjust the lift chains until there is a
0.5 in. (12.7 mm) gap at the narrowest
Lower Chain Anchor Removal, 7440 ML point between the inner and outer
1. Attach a hoist strap around the top plate telescopics when the carriage is fully
of the inner telescopic. lowered. Make sure there is equal tension
on the lift chains after the adjustment.
2. Using a suitable hoist, lift the inner
telescopic to slacken the chains. 6. Test the truck for correct operation.
3. Remove the lower bearings in the inner
telescopic by removing the mounting bolts
for the bosses. See Figure 7-212 on
page 7-205.
4. Use a pry bar to increase the access space
between the inner and outer telescopics.
1026304B, 15 July 2007 7-205
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Chain Anchors Mast, Chain, Hose, Cable
Free Lift Chain Anchors 5. Reinstall the mast guard.
6. Reconnect the battery connector and turn
Model 7400 Free Lift (FL) the key switch ON.
7. Remove blocking from carriage.
Upper Chain Anchor Removal, 7400 FL 8. Test the truck for correct operation.
1. Elevate and block the carriage at a
convenient working height. Lower Chain Anchor Removal, 7400 FL
2. Lower the carriage to relieve tension on the NOTE: Model 7400 right side lower free lift
chains. chain anchors are welded to the
3. Turn the key switch OFF and disconnect carriage. Use the following procedure to
the battery connector. remove the left side chain anchor.
4. Remove the mast guard. 1. Elevate and block the carriage at a
5. Left side only: Remove the hose/cable convenient working height.
retaining block. 2. Lower the carriage to relieve tension on the
6. Disconnect the lift chain master link from chains.
the chain anchor. 3. Turn the key switch OFF and disconnect
7. Note the distance of the adjusting nut. the battery connector.
This distance will be used as a preliminary 4. Remove the mast guard.
adjustment when re-installing.
5. Disconnect the lift chain master link from
8. Remove the nut from the chain anchor the chain anchor.
bolt. Remove anchor from anchor block.
6. Unscrew the anchor from the anchor
block.
Master Link
Chain Anchor Master Link
Chain Anchor Chain Anchor
Block
Chain Anchor
Adjusting Nut Block
7R1022604_A4.CGM
Figure 7-213. Upper Free Lift Chain Anchor, Model 7400
7R1022604_A1.CGM
Figure 7-214. Lower Free Lift Chain Anchor, Model 7400
Upper Chain Anchor Installation, 7400 FL
1. Insert the chain anchor in the chain Lower Chain Anchor Installation, 7400 FL
anchor block.
1. Screw the chain anchor into the chain
2. Install a new master link to the lift chain anchor block.
anchor and secure with a new cotter pin.
2. Attach a new master link to the chain
3. Thread the adjusting nut on the chain anchor block and secure with a new cotter
anchor bolt to the distance recorded pin.
earlier.
3. Reinstall the mast guard.
4. Left side only: Reattach the hose/cable
retaining block,
7-206 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Chain Anchors
4. Reconnect the battery connector and turn 5. Test the truck for correct operation.
the key switch ON.
5. Remove blocking from the carriage
6. Test truck for correct operation.
Master Link
Model 7420/7440 Free Lift (FL)
Chain Anchor
Upper Chain Anchor Removal, 7420/7440 FL
1. Elevate the carriage to a convenient Chain Anchor
working height. Block
2. Lower the carriage onto blocks to slacken
Adjusting Nut
the chains.
3. Turn the key switch OFF and disconnect
the battery connector. 71067328_A.CGM
Figure 7-215. Upper Free Lift Chain Anchor,
4. Disconnect the master link from the chain
Model 7420/7440
anchor.
5. Note the distance of the adjusting nut. Lower, 7420/7440 FL
This distance will be used as a preliminary
adjustment when re-installing. Model 7420/7440 lower free lift chain anchors
6. Remove the chain anchor from the free lift are welded to the carriage.
cylinder.
Upper Chain Anchor Installation,
7420/7440 FL
1. Install a new master link to the lift chain
anchor and secure with a new cotter pin.
2. Install the chain anchor into the chain
anchor block and thread the adjusting nut
on to the distance recorded earlier.
3. Reconnect the battery connector and turn
the key switch ON.
4. Elevate the carriage, remove blocks, and
lower carriage completely.
1026304B, 15 July 2007 7-207
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Chains Mast, Chain, Hose, Cable
Chains 3. Position the upper chain anchor and
install the anchor pin. You can install the
chain anchor bolt temporarily to assist in
Chains, Main Lift the installation of the pin.
4. Install the anchor pin retainer. Apply
Model 7400 thread-locking compound (P/N 1013829)
to the threads of the anchor bolt and
Removal torque to 130 ft. lb. (174 Nm).
1. Place a block between the outer telescopic 5. Attach the chain and the lower chain
crosstie and the mainframe crosstie and a anchor, using a new master link and cotter
slightly longer block between the inner pin.
telescopic crosstie and the outer telescopic 6. Remove the blocks between the telescopics
crosstie. This will provide the required and the mainframe and fully lower the
slack in the chains for their removal. See forks to the floor.
Figure 7-204 on page 7-201 7. Adjust the lift chains until there is a
2. Lower the carriage and block at a height 0.25 in. (6.4 mm) gap at the narrowest
that allows access to the chain anchor at point between the inner and outer
the bottom of the inner telescopic. telescopics when the carriage is fully
3. Turn the key switch OFF and disconnect lowered. Make sure there is equal tension
the battery connector. on the lift chains after the adjustment.
4. Disconnect the lift chain master link from 8. Lubricate the chains and test the truck
the lower chain anchor at bottom of inner operation.
telescopic.
Chain Sheave Alignment Adjustment
5. Remove the chain anchor bolt and the
anchor pin retainer. See Figure 7-208 on If the main lift chain sheave becomes
page 7-203. misaligned so that the chain scrubs one side
6. Grasp the chain and remove the anchor wall of the sheave, install a new shaft with an
pin. See Figure 7-206 on page 7-201. eccentric bushing to correct the alignment:
NOTE: You can remove the pin by using a slide 1. Elevate and block the mast to provide
hammer or by using a large socket slack in the main lift chain.
(1 1/16 in.), an M8 x 50 mm bolt and 2. Turn the key switch OFF and disconnect
washers to act as a pulling device. See the battery connector.
7. Remove the chain anchor and chain from 3. Disconnect the main lift chain from the
the telescopic. inner telescopic chain anchor bolt.
8. Remove the master link between chain 4. Loosen the set screw and remove the
and chain anchor. pulley shaft.
5. Insert the new pulley shaft into position.
Installation
NOTE: Replace both chains when either is bad.
1. Attach the upper chain anchor to the new
chain using a new master link and cotter
pin.
2. Make sure the two holes in the upper
chain anchor are facing towards the
outside. Feed the chain from the outside to
the inside over the chain sheave.
7-208 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Chains
6. Insert the eccentric bushing. (Two Model 7420
different bushings are available,
depending on the amount of eccentricity.) Removal
1. Place a block between the outer telescopic
crosstie and the mainframe crosstie and a
Eccentric slightly longer block between the inner
Bushing telescopic crosstie and the outer telescopic
crosstie. This will provide the required
slack in the chains for their removal. See
Figure 7-204 on page 7-201.
Chain
Sheave 2. Lower the carriage and block at a height
that allows access to the chain anchor at
the bottom of the inner telescopic.
Shaft 3. Turn the key switch OFF and disconnect
the battery connector.
4. Remove the anti-kickback pad and block
7RSBRCH07004A.JPG from the bottom of the inner telescopic.
Figure 7-216. Eccentric Bushing for Main Lift Chain Sheave
See Figure 7-217.
7. Reconnect the lift chain to the chain
anchor block.
8. Remove the blocks to permit normal
operation of the mast.
9. Adjust the eccentric bushing with a
spanner wrench until the lift chain is
tracking parallel with the telescopic
profile.
10. Reconnect the battery connector and turn
the key switch ON.
11. Cycle the telescopic several times to make
sure the lift chain is tracking correctly.
12. Prick punch the eccentric bushing
through the existing set screw hole.
13. Drill a hole 0.13 in. deep on the prick
punch mark, using the following drill Anti-Kickback Anti-Kickback
sizes: Pad Block
71051418_E8.CGM
R45TT/DR32TT Mast 7/32 in. (5.5 mm) Figure 7-217. Anti-Kickback Pad and Block, Model 7420
R35TT Mast 5/32 in. (4 mm) 5. Note the distance of the adjusting nut
threads. This distance will be used as a
preliminary adjustment when
14. Apply thread-locking compound to the re-installing.
threads of the set screw and install the set 6. Remove the nut from the chain anchor
screw to lock the eccentric bushing in bolt.
place.
1026304B, 15 July 2007 7-209
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Chains Mast, Chain, Hose, Cable
7. Remove the upper chain anchor bolt and to the threads of the anchor bolt and
the anchor pin retainer. See Figure 7-218. torque to 130 ft. lb. (174 Nm).
5. Feed the lift chain over the main lift chain
pulley and down the telescopic.
6. Install the chain anchor into the chain
anchor block and thread the adjusting nut
on to the distance recorded earlier.
7. Reinstall the anti-kickback pad and block
at the bottom of the inner telescopic.
8. Remove the blocks between the telescopics
and the mainframe and fully lower the
forks to the floor.
Pin 9. Adjust the lift chains until there is a
0.375 in. (9.5 mm) gap at the narrowest
Anchor point between the inner and outer
Pin
Block telescopics when the carriage is fully
Retainer
lowered. Make sure there is equal tension
Bolt on the lift chains after the adjustment.
71051418_E5.CGM 10. Lubricate the chains and test the truck
Figure 7-218. Upper Main Lift Chain Anchor Removal, operation.
Model 7420
8. Grasp the chain and remove the anchor Model 7440
pin. See Figure 7-206 on page 7-201.
Removal
NOTE: You can remove the pin by using a slide
hammer or by using a large socket 1. Attach a hoist strap around the top plate
(1 1/16 in.), an M8 x 50 mm bolt and of the inner telescopic.
washers to act as a pulling device. 2. Using a suitable hoist, lift the inner
telescopic to slacken the chains.
9. Remove the chain anchors and chain from
the telescopic. 3. Remove the lower bearings in the inner
telescopic by removing the mounting bolts
10. Disconnect the master links between
for the bosses.
chain and chain anchors.
4. Use a pry bar to increase the access space
Installation between the inner and outer telescopics.
NOTE: Replace both chains when either is bad. 5. Remove the cotter pin and disconnect the
lift chain master link from the lower chain
1. Attach the chain anchors to the new chain anchor. Twist the chain if necessary to
using new master links and cotter pins. reveal the master link.
2. Make sure the two holes in the upper 6. Remove the cotter pin and disconnect the
chain anchor are facing towards the lift chain master link from the upper chain
outside. Feed the chain from the outside to anchor.
the inside over the chain sheave.
3. Position the upper chain anchor and Installation
install the anchor pin. You can install the 1. Connect the chain to the upper chain
chain anchor bolt temporarily to assist in anchor with a new master link and new
the installation of the pin. cotter pin.
4. Install the anchor pin retainer. Apply
thread-locking compound (P/N 1013829)
7-210 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Chains
2. Route the chain over the main lift chain 3. Turn the key switch OFF and disconnect
pulley and between the inner and outer the battery connector.
telescopics. 4. Remove the mast guard
3. Connect the chain to the lower chain 5. Remove the master links at the adjustable
anchor with a new master link and new chain anchors.
cotter pin.
6. Remove the master links at the carriage
4. Reattach the lower bearing bosses and chain anchors.
bearings in the inner telescopic. Torque to
130 ft. lb. (176 Nm). a. Model 7400: The right side requires the
removal of a retainer tab and pin rather
5. Lower the inner telescopic to slacken the than a cotter pin.
hoist strap. Remove the strap.
b. Model 7420/7440: Both sides require
6. Adjust the lift chains until there is a the removal of a retainer tab and pin
0.5 in. (12.7 mm) gap at the narrowest rather than a cotter pin.
point between the inner and outer
telescopics when the carriage is fully
lowered. Make sure there is equal tension
on the lift chains after the adjustment.
7. Lubricate the chains and test the truck
operation.
Chains, Free Lift
Removal
1. For easy access to the lift chain master
links at the carriage anchor blocks, elevate
the carriage to a convenient working
height. Using a suitable hoist or stand,
secure the carriage at this height.
7R1022231_A.CGM
Figure 7-220. Retainer Tab (right side)
7. Remove the chains.
Installation
1. Position the chain over the pulley and
fasten the chain to the carriage anchor
with a new master link.
a. Model 7400: Secure the left side with a
cotter pin and the right side with the
pin and retainer tab, applying
thread-locking compound
(P/N 1013829) to the threads of the
retainer screw.
7R1022231_A.CGM b. Model 7420/7440: Secure both sides
Figure 7-219. Carriage Chain Anchor with the pin and retainer tab, applying
thread-locking compound
2. Activate “lower” to relieve the tension on (P/N 1013829) to the threads of the
the free lift chains. retainer screw.
1026304B, 15 July 2007 7-211
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Chains Mast, Chain, Hose, Cable
2. Fasten the chain to the adjustable chain
anchor with a new master link and secure
with a new cotter pin.
NOTE: Bend the ends of the cotter pins over 90°
after installation.
3. Reinstall the mast guard.
4. Reconnect the battery connector and turn
the key switch ON.
5. Slowly raise the carriage, using the lift
button to place the weight of the carriage
on the free lift chains.
6. Remove the hoist.
7. Fully lower the carriage.
8. With the reach mechanism retracted, forks
level with the floor and the key switch
OFF, adjust the anchor nuts equally until
the forks are approximately 3 in. (76 mm)
off the floor (or just touching the floor with
the floor lower height option). Make sure
there is equal pressure on the chains
when the carriage is fully lowered.
7-212 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Forks
Forks untapered base of the fork, replace the
fork.
Fork Inspection
Visually inspect all fork surfaces for signs of
damage, including, but not limited to: excessive
wear, bends, cracks, welding arcs, excessive
Shank
(un-worn portion)
heat, or unauthorized modifications.
Inspect forks for amount of wear on the bottom
surface, as follows:
1. Using “Fork Wear Calipers” (P/N 922-369,
Figure 7-221), set the outer-most points of
the wear caliper to the thickness of the
unworn vertical shank. See Figure 7-222. Un-tapered portion
7FORKS.EPS
Figure 7-222. Fork Wear Inspection
Unworn thickness
Minimum
worn thickness
43
255
DS2
DS#
7CALIPERS.EPS
Figure 7-221. Fork Wear Calipers
2. Without changing the setting, move to the
untapered portion of the base of the fork.
The inner points of the caliper represent
the minimum acceptable thickness. If the
inner points pass over any portion of the
1026304B, 15 July 2007 7-213
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Height Encoder Belt Mast, Chain, Hose, Cable
Height Encoder Belt as they hold the encoder assembly
together. See Figure 7-224.
Model 7420 Do Not Remove These Screws
Removal
1. Lift and block the mast high enough to
access the belt and its mounting eye.
NOTE: The tensioning spring is at the bottom of
the belt, hooked to a bracket.
2. Turn the key switch OFF and disconnect
the battery connector.
3. Access the height encoder assembly.
Remove These Screws
a. If there is an access plate secured by
77420HTEncoderAssy.jpg
diagonally opposed nuts, remove the Figure 7-224. Height Encoder Assembly, 7420
nuts. Do not remove the bottom
button-head screws. See Figure 7-223.
4. Remove the old belt. Make sure you
retrieve the tension spring through the
Remove These Nuts
access hole at the bottom of the outer
telescopic.
Installation
Access
Plate 1. Using cable ties, make a 1 inch (25 mm)
loop in the bottom of the new encoder belt
and attach it to the tension spring.
2. Attach a small weight on the tension
spring. Drop the weighted spring down the
mast channel. Clamp the belt at the top so
Do Not Remove These Screws it does not fall completely down into the
channel.
77420HTEncoderAssy.jpg
Figure 7-223. Height Encoder Assembly, 7420
b. If there is no access plate, remove the
bottom two button-head screws. Do not
remove the diagonally opposed screws,
7-214 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Height Encoder Belt
3. Accessing the spring through the hole at 6. Loop the belt around the eye at the top of
the bottom of the mast channel, attach the the mast and clamp it temporarily in
spring to the bracket. See Figure 7-225. place.
7. Secure the height encoder assembly.
a. If there is an access plate, install the
access plate with the nylon locking
nuts. See Figure 7-223.
b. If there is no access plate, fit the
encoder assembly back into the mast
channel. Keep slight tension on the belt
and make sure the belt wraps correctly
around the gear and idler. Secure the
encoder assembly with mounting
screws. See Figure 7-224.
8. Make sure the belt feeds past the mast
bearing without becoming entangled in the
bearing. See Figure 7-227.
71051604_D5.CGM
Figure 7-225. Height Encoder Belt Tension Spring, 7420
Belt
4. Thread the belt through the encoder
assembly, making sure it is routed
correctly around the toothed gear and Mast Bearing
idler. See Figure 7-226.
Belt
Idler
77420HTEncodeMastBearing.JPG
Figure 7-227. Height Encoder Belt and Mast Bearing, 7420
9. With the belt snug around the hook eye,
trim the belt 1 inch (25 mm) longer. Attach
two cable ties loosely to form a loop of the
belt around the hook eye. With the belt
snug, pull the belt approximately 0.5 inch
Toothed Gear (12 mm) tighter to apply tension to the
spring, and tighten the cable ties. Trim
Encoder Assembly
Mounting Screws
71051604_D4.CGM
Figure 7-226. Height Encoder Belt Routing, 7420
5. Attach the top end of the belt to a stiff wire
and feed the belt up through the encoder
assembly hole.
1026304B, 15 July 2007 7-215
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Height Encoder Belt Mast, Chain, Hose, Cable
any excess belt at the loop. See nuts. Do not remove the top button-head
Figure 7-228. screws. See Figure 7-229.
Do Not Remove These Screws
Hook Eye
Access
Plate
Add Cable
Ties Here
Remove These Nuts
77440HTEncoderAssy.jpg
Figure 7-229. Height Encoder Assembly, 7440
Belt
b. If there is no access plate, remove the
top two button-head screws. Do not
remove the diagonally opposed screws,
as they hold the encoder assembly
71051604_D6.CGM
Figure 7-228. Height Encoder Belt, Top, 7420 together. See Figure 7-230.
10. Reconnect the battery connector and turn
the key switch ON. Remove These Screws
11. Elevate the mast, remove the blocking. Lift
and lower the carriage to test correct
operation.
Model 7440
Removal
1. Lift and block the mast high enough to
access the belt and its mounting eye. Do Not Remove These Screws
NOTE: The tensioning spring is at the top of the 77440HTEncoderAssy.jpg
belt, hooked to a bracket. Figure 7-230. Height Encoder Assembly, 7440
2. Turn the key switch OFF and disconnect 4. Remove the old belt. Make sure you
the battery connector. retrieve all the broken pieces. There is an
3. Access the height encoder assembly. access hole at the bottom of the outer
a. If there is an access plate secured by telescopic.
diagonally opposed nuts, remove the
Installation
1. Attach a small weight to the belt. Drop the
weighted belt down the mast channel.
Clamp the belt at the top so it does not fall
completely down into the channel.
7-216 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Height Encoder Belt
2. Accessing the bracket through the hole at 4. Attach the top end of the belt to a stiff wire
the bottom of the mast channel, loop the and feed the belt up through the encoder
belt through the bracket to form a 1 inch assembly hole.
(25 mm) loop. Secure the loop with cable 5. Loop the belt around the eye at the top of
ties. See Figure 7-231. the mast and clamp it temporarily in
place.
Belt Access Hole
6. Secure the height encoder assembly.
a. If there is an access plate, install the
Add Cable access plate with the nylon locking
Ties Here nuts. See Figure 7-229.
b. If there is no access plate, fit the
encoder assembly back into the mast
channel. Keep slight tension on the belt
and make sure the belt wraps correctly
Bracket
around the gear and idler. Secure the
encoder assembly with mounting
screws. See Figure 7-230.
7. With the belt snug around the hook eye,
trim the belt 1 inch (25 mm) longer. Attach
71051604_D5.CGM two cable ties loosely to form a loop of the
Figure 7-231. Height Encoder Belt Tension Spring, 7440 belt around the hook eye. With the belt
snug, pull the belt approximately 0.5 inch
3. Thread the belt through the encoder
(12 mm) tighter to apply tension to the
assembly, making sure it is routed
spring, and tighten the cable ties. Trim
correctly around the toothed gear and
any excess belt at the loop. See
idler. See Figure 7-232.
Figure 7-228.
Encoder Assembly
Mounting Screws
Idler
Hook Eye
Add Cable
Ties Here
Belt
Toothed Gear
Belt
71051604_D4.CGM
Figure 7-232. Height Encoder Belt Routing, 7440 71051604_D6.CGM
Figure 7-233. Height Encoder Belt, Top, 7420
1026304B, 15 July 2007 7-217
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Height Encoder Belt Mast, Chain, Hose, Cable
8. Reconnect the battery connector and turn
the key switch ON.
9. Elevate the mast, remove the blocking. Lift
and lower the carriage to test correct
operation.
7-218 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Hose, Main Lift
Hose, Main Lift 8. Install the top cover and the right and left
front cover.
Removal
1. Fully lower forks to the floor.
2. Turn the key switch OFF and disconnect
the battery connector.
3. Remove the battery from the truck to
access the display and lift motor mounting
bracket bolts.
4. Remove the top cover and the front left
and right covers.
5. Remove the 4 mounting bolts from both
the display bracket and the lift motor
mounting bracket to gain access to the lift
hose.
6. If applicable, remove the lift amp/shroud
assembly as one unit. It is retained by four
bolts on the mast side of the front tractor
plate.
7. Disconnect and cap the main lift cylinder
feed hoses at the front tractor plate.
NOTE: Place a small container below the
fittings to allow the main lift hose to
drain.
8. Disconnect the lift hose from the main
manifold and remove from the truck.
Installation
1. Position the lift hose in the truck.
2. Connect the fittings at the manifold and
the main lift cylinder feed hoses.
3. If applicable, reinstall the lift amp/shroud
assembly. See “Power Amplifier, Lift Series
CA/FA (AC lift)” on page 7-110.
4. Position and reinstall the display and lift
motor mounting bolts. See “Lift Motor” on
page 7-109.
5. Reconnect the battery connector and turn
the key switch ON.
6. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on
page 7-134.
7. Check the truck for leaks and correct
operation.
1026304B, 15 July 2007 7-219
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Hose and Cable, Over-the-Mast Mast, Chain, Hose, Cable
Hose and Cable,
Over-the-Mast
Main Lift
Cylinder
Hose/Cable
Retainer Upper Free Lift
Cylinder
Hose/Cable
Retainer
Carriage
Hose/Cable
Retainer
Lower Free Lift
Cylinder
Hose/Cable
Retainer
7R1018766_C03.CGM
Figure 7-235. Over-the-Mast Hose/Cable, view from forks
7R1018766_C1.CGM
Figure 7-234. Over-the-Mast Hose/Cable, view from tractor
7-220 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Hose and Cable, Over-the-Mast
NOTE: For replacement of the over-the-mast 6. Remove auxiliary manifold mounting
electrical cable only, see “Cable, screws to permit access to the
Over-the-Mast” on page 7-229. over-the-mast hose fittings at the
manifold.
Removal NOTE: There may be shims between the
manifold and carriage.
1. Remove top cover, left front cover and
mast guard. 7. Disconnect and plug/cap the
over-the-mast hoses and fittings at the
2. Lower carriage to floor and block scissor
auxiliary manifold.
assembly. See Figure 7-236.
8. Reconnect the battery connector and turn
the key switch ON.
9. Elevate and block carriage at an
appropriate height to access the
hose/cable retainer and guide at the back
of the carriage from the tractor side.
10. Turn the key switch OFF and disconnect
the battery connector.
11. Remove hose/cable retaining block from
back of carriage. See Figure 7-238.
7OTM_1.JPG
Figure 7-236. Blocking Scissor Assembly
3. Turn the key switch OFF and disconnect
the battery connector.
4. Disconnect the over-the-mast cable at
connector JPS3 in tractor.
5. Remove auxiliary manifold cover from
carriage and disconnect the over-the-mast
cable at terminal strip TS2.
See Figure 7-237.
7OTM_2.JPG
Figure 7-238. Hose/Cable Retainer on Carriage
12. Feed hoses and cable through guide at
back of carriage.
13. Feed hoses and cable through pulley
bracket at top of free lift cylinder.
14. Remove upper hose/cable retainer from
free lift cylinder. See Figure 7-235 on
page 7-220.
15. Reconnect the battery connector and turn
the key switch ON.
16. Carefully elevate the telescopics high
enough to access the lower retainer on free
Figure 7-237. Auxiliary Manifold access
7DSC_942A.JPG
lift cylinder and the retainer on the
telescopic from the tractor side. Place a
1026304B, 15 July 2007 7-221
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Hose and Cable, Over-the-Mast Mast, Chain, Hose, Cable
hardwood block of sufficient length Installation
between the outer and inner telescopics.
This will remove tension from the NOTE: To help install the retainers, use two
over-the-mast hoses and the lift hose and modified (M6-1 x 70) bolts to locate and
make the removal and installation of the support the retainer during assembly.
retainers easier. Carefully lower the mast See Figure 7-240.
until you have the desired tension. See
Figure 7-239.
7OTM_4.JPG
Figure 7-240. Positioning hose retainer
7OTM_3.JPG
Figure 7-239. Blocking telescopics NOTE: Over-the-mast hose lengths on
Model 7400 lift trucks are equal.
17. Turn the key switch OFF and disconnect Reference Figure 7-271 on page 7-243
the battery connector. for correct hose/cable routing.
18. Remove the lower free lift cylinder 1. While observing correct routing, connect
hose/cable retainer and the hose/cable hoses to auxiliary manifold at carriage and
retainer from the bottom of the inner the cable to terminal strip TS2.
telescopic.
2. Mount auxiliary manifold to carriage.
19. Feed hoses and cable through pulley at Apply thread-locking compound (P/N
top of inner telescopic. 990-536) to mounting bolt threads and
20. Remove hose/cable retainer at left main torque to 21 ft. lb. (29 Nm).
lift cylinder. 3. Reconnect the battery connector and turn
21. Reconnect the battery connector and turn the key switch ON.
the key switch ON. 4. Carefully elevate and block carriage high
22. Carefully elevate telescopics and remove enough to access the hose/cable retainer
blocking. and guide at the back of the carriage.
23. Fully lower mast and carriage. 5. Turn the key switch OFF and disconnect
the battery connector.
24. Turn the key switch OFF and disconnect
the battery connector. 6. Feed hoses and cable through guide and
retainer.
25. Disconnect and plug/cap hoses and
fittings at A1 and A2 on the main 7. Remove slack from hoses and cable
manifold. between retainer and manifold. Adjust and
tension the cable to allow the cable to loop
26. Feed hoses and cable through opening in
away at the bottom edge of the hose/cable
tractor bulkhead.
bracket on the carriage. This loop should
be 0.75 in.± 0.25 in. below the bracket.
Make sure the cable is long enough to
7-222 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Hose and Cable, Over-the-Mast
remove the auxiliary manifold cover and other. The electrical cable is in the
access TS2. Tighten the retainer. See left-hand position.
Figure 7-241.
Aux Hose A2
Aux Hose A2
Aux Hose A1
Aux Hose A1 Electrical Cable
Electrical Cable
71045742_B7.CGM
Figure 7-242. Free Lift Pulley Routing of Hoses and Cable
71045742_D6.CGM
Figure 7-241. Carriage Hose/Cable Retainer
13. Install hoses, cable and retainer at top of
8. Attach manifold cover to carriage. Apply free lift cylinder. See Figure 7-243.
thread-locking compound (P/N 990-536)
to the mounting bolt threads and torque to
30 ft. lb. (42 Nm). Main Lift
Retainer
9. Reconnect the battery connector and turn
the key switch ON.
10. Fully lower carriage to the floor.
11. Turn the key switch OFF and disconnect
the battery connector.
12. Feed hoses and cable through free lift
pulley, from fork side to tractor side. Make
sure hoses and cable do not cross each Free Lift
Retainer
7R1018766_C4.CGM
Figure 7-243. Upper Hose/Cable Retainer, Main Lift and
Free Lift Cylinders
14. Remove slack from hoses and cable
between upper free lift cylinder and
carriage retainers. Temporarily tighten
retainer.
15. Find the correct L2 value from Table 7-21
on page 7-226. Measure and mark hoses
1026304B, 15 July 2007 7-223
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Hose and Cable, Over-the-Mast Mast, Chain, Hose, Cable
above the upper free lift cylinder retainer, 22. Reconnect the battery connector and turn
using the L2 value. L2 equals the length the key switch ON. Remove blocking from
the hoses are to be stretched over the free telescopics. Turn the key switch OFF and
lift cylinder. See Figure 7-244. disconnect the battery connector.
23. Feed hoses and cable through pulleys at
stretch top of telescopic, from fork side to tractor
side. Make sure hoses and cable do not
cross each other.
24. Install over-the-mast hoses, lift hose, and
cable in retainer at left main lift cylinder.
L2 dimension 25. Remove slack from hoses and cable.
Adjust cable grip and spring so that spring
is stretched to an overall length of 1.75
±0.12 in. (44.5 ±3 mm). Leave sufficient
bend of slack hose so that an additional
0.5 in. (13 mm) of cable length can be
taken up if required. Temporarily tighten
7OTM_5.CGM
retainer.
Figure 7-244. Marking L2 dimension
26. Measure and mark the lift hose above the
retainer with the appropriate L3 value in
16. Reconnect the battery connector and turn
Table 7-21 on page 7-226. Measure and
the key switch ON.
mark the over-the-mast hoses above the
17. Place block under carriage and lower retainer with the appropriate L1 value in
carriage to relieve tension on hoses. Table 7-21 on page 7-226.
18. Pull down on the hoses until marks are 27. Repeat step 17 of installation procedure.
flush with top of retainers. Tighten the
28. Pull down on the hoses until marks are
four retainer bolts. Do not tighten the
flush with the top of the retainers. Tighten
lower clamp bolts on the retainer assembly
retainers.
yet.
29. Reconnect the battery connector and turn
19. Install hoses, cable, retainer and clamp at
the key switch ON. Remove blocking from
bottom of free lift cylinder and inner
telescopics. Turn the key switch OFF and
telescopic. Carefully elevate the telescopics
disconnect the battery connector.
high enough to access the lower retainer
on free lift cylinder and the retainer on the 30. Tighten two lower clamp bolts on upper
telescopic from the tractor side. Place a free lift cylinder hose/cable retainer.
hardwood block of sufficient length 31. Secure hoses and cable to the free lift
between the outer and inner telescopics. cylinder with cable ties every 16 to 24 in.
Carefully lower the mast until you have (40 to 60 cm).
the desired tension. Observe correct
32. Route hoses and cable through the tractor
routing to make sure hoses and cable have
opening, along the tractor bulkhead and
sufficient clearance. See Figure 7-239 on
page 7-222.
20. Turn the key switch OFF and disconnect
the battery connector.
21. Remove slack from hoses and cable
between inner telescopic retainer and
upper retainer on free lift cylinder.
Temporarily tighten retainer and clamp.
7-224 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Hose and Cable, Over-the-Mast
attach with the hose/cable clamps. See
Figure 7-245.
7R1018766_C7.CGM
Figure 7-245. Hose/Cable Retainer Clamps on Tractor
33. Observing correct routing, connect
over-the-mast hoses to A1 and A2 at the
main manifold. Connect the over-the-mast
cable to connector JPS3.
34. Reconnect the battery connector and turn
the key switch ON. Test the lift truck for
correct operation and check for leaks.
35. Cycle all auxiliary functions several times
to purge air from the hydraulic system.
36. Check hydraulic fluid level and add fluid
as required.
37. Install mast guard and covers.
1026304B, 15 July 2007 7-225
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Hose and Cable, Over-the-Mast Mast, Chain, Hose, Cable
Table 7-21. Over-the-Mast Hose stretching values (in inches)
L1 (OTM hoses L2 (over free lift L3
OACH over tele) cylinder) (lift hose over tele)
in. mm in. mm in. mm
87 1.29 32.8 0.87 22.1 1.45 36.8
95 1.53 38.9 0.93 23.6 1.69 42.9
100 1.68 42.7 0.97 24.6 1.84 46.7
102 1.74 44.2 0.98 24.9 1.90 48.3
104 1.80 45.7 1.00 25.4 1.96 49.8
107 1.89 48.0 1.02 25.9 2.05 52.1
110 1.98 50.3 1.04 26.4 2.14 54.4
114 2.10 53.3 1.07 27.2 2.26 57.4
118 2.22 56.4 1.10 27.9 2.38 60.5
122 2.34 59.4 1.13 28.7 2.50 63.5
128 2.52 64.0 1.18 30.0 2.68 68.1
131 2.61 66.3 1.20 30.5 2.77 70.4
133 2.67 67.8 1.21 30.7 2.83 71.9
135 2.73 69.3 1.23 31.2 2.89 73.4
138 2.82 71.6 1.25 31.8 2.98 75.7
141 2.91 73.9 1.27 32.3 3.07 78.0
143 2.97 75.4 1.29 32.8 3.13 79.5
146 3.09 78.5 1.31 33.3 3.25 82.6
7-226 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Hose and Cable, Over-the-Mast
Hose Guard Addition Later Model 7400 lift trucks use studs and lock
nuts in this retainer. This revision helps prevent
Service Kit P/N 1061876 contains parts to add hose damage from the retainer hardware.
a hose guard to retain slack hoses on the
pulleys in the event forks hang up in the rack
as the mast begins to lower.
1. Apply thread-locking compound
(P/N 1013829) to the M6x12 flat socket
head screws. Attach the guard weldment
to the new hose guard, but do not tighten Main Lift
the screws. Cylinder
Hose/Cable
2. Remove and discard the existing hose Retainer
guard from the pulleys by removing two
M10x16 flat socket head screws. Save
screws,
3. Apply thread-locking compound
(P/N 1013829) to the M10x16 screws.
Install the new hose guard assembly,
using the M10 screws saved in previous
step.
4. Adjust the guard weldment so the 0.5 inch
(12.7 mm) diameter bar sits approximately
0.125 inch (3 mm) from the surface of the
auxiliary hoses. Tighten the M6x12 screws
the secure the guard.
New Guard
Reuse M10
Screw
Bar 7R1018766_C03.CGM
New M6 Figure 7-247. Main Lift Cylinder Hose/Cable Retainer
Screws Location
New
Weldment Use the following procedure to convert to the
newer style hose/cable retainer hardware:
Reuse M10 1. Remove the mast guard
Screw
2. Place a 4 in. x 4 in. block between the
7
Figure 7-246. OTM Hose Pulley Guard inner and outer telescopic upper crossties
to provide slack in the over-the-mast
hoses and cable.
Hose/Cable Retainer Upgrade
3. Fully lower the carriage.
Early Model 7400 lift trucks used hex head cap 4. Turn the key switch OFF and disconnect
screws in the main lift cylinder hose/cable the battery connector.
retainer. 5. Mark the over-the-mast hoses and cable to
aid in tensioning when re-assembling.
6. One at a time, remove the four hex head
cap screws from the standoff plate and
1026304B, 15 July 2007 7-227
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Hose and Cable, Over-the-Mast Mast, Chain, Hose, Cable
replace them with studs and lock nuts.
Use thread-locking compound
(P/N 990-669) on the stud threads.
The insertion end of the stud (end with
shorter length of thread) should not
protrude beyond the front face of the
standoff plate,
Old Style: Hex Head Cap Screws
New Style: Studs and Lock Nuts
7R1018766_C4.cgm 1045742_D8.cgm
Figure 7-248. Old and New Style Retainer Hardware
7. Make sure the over-the-mast hoses and
cable are correctly tensioned.
8. Reconnect the battery connector and turn
the key switch ON. Elevate the carriage
and remove the block. Lower the carriage.
9. Reinstall the mast guard.
7-228 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Cable, Over-the-Mast
Cable, Over-the-Mast and 1.25 in. from the inside edge of frame
to edge of strip. See Figure 7-249.
Terminal Strip Addition for Bulk
Cable Use
Use the following procedure to convert a Model
7400 lift truck for the use of bulk electrical
cable in the over-the-mast (OTM) application.
Table 7-22. Parts for Terminal Strip Conversion
Part Part Number
Terminal strip 1-030-010
Terminal Strip 1-030-009
numbers Figure 7-249. Terminal Strip TS3 Location
7DSCF0420.JPG
18 spade lugs 1-010-256
4. If the tractor frame has pre-drilled holes
Mounting screws (2) 5-014-004 for the terminal strip, omit steps 4, 5, and
8.
Lock washers (2) 5-019-002
5. Using the terminal strip as a template,
Drill bit #36 or 0.107 in. center punch the tractor frame for the top
Cable tie 611-028 mounting hole.
6. Drill a hole through the deck using a #36
Adhesive-backed cable 611-044
or 0.107 in. bit.
tie anchor
7. Mount the terminal strip with a
thread-forming screw and lock washer.
1. Turn lift truck OFF and disconnect the 8. Center punch and drill the second hole.
battery connector.
9. Fasten the terminal strip with the second
2. Remove the left front cover. thread-forming screw and lock washer.
3. Locate the terminal strip (TS3) on the 10. Cut the electrical OTM cable at deck
outside of the tractor frame between the height.
power amplifier mounting bolts, 3.75 in.
from tractor deck top edge to top of strip 11. Strip 3 in. of insulation from tractor end of
OTM cable, strip wires ends and attach
spade lugs.
12. Attach wires to terminal strip (TS3). See
Table 7-23 and Figure 7-250.
13. Secure cable to frame with cable tie and
adhesive-backed cable tie anchor.
1026304B, 15 July 2007 7-229
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Cable, Over-the-Mast Mast, Chain, Hose, Cable
2. Remove the top cover, left front cover, and
mast guard.
Table 7-23. OTM Cable Connections
3. Turn the key switch OFF and disconnect
New Carriage the battery connector.
Tractor
Terminal Terminal 4. Disconnect the OTM cable at connector
Connector
Strip Strip JPS3 in the tractor.
JPS3
TS3 TS2 5. Remove the auxiliary manifold cover from
JS3-1 TS3-1 TS2-1 the carriage and disconnect the OTM cable
at TS2.
JS3-2 TS3-2 TS2-2
6. Reconnect battery connector and turn key
JS3-3 TS3-3 TS2-3 switch ON.
7. Elevate and block the carriage at an
JS3-4 TS3-4 TS2-4 appropriate height to access the
JS3-5 TS3-5 TS2-5 hose/retainer and guide at the back of the
carriage from the operator compartment.
JS3-6 TS3-6 TS2-6 This will also relieve tension on the hoses
for easier assembly. See Figure 7-251.
7DSCF0427.JPG
Figure 7-251. Blocking the Carriage
7DSCF0424.JPG
Figure 7-250. OTM Cable from Tractor to TS3
8. Turn the key switch OFF and disconnect
the battery connector.
Over-the-Mast Cable
9. Remove the cable from the retainer/guide
Replacement at the back of the carriage and the free lift
cylinder pulley. See Figure 7-235 on
This procedure describes the installation of the page 7-220.
new cable as the old one is being removed. You
can use this procedure either with or without 10. Position the cable grip onto the
the terminal strip modification for bulk cable replacement cable so that the spring
use. anchor end of the cable grip is oriented
towards the TS2 end of the cable and the
1. Mark the OTM hoses at all the hose/cable
loop is approximately 20 inches (51cm)
retainers to assure the correct stretch
when reassembled. (If required use
Table 7-21, “Over-the-Mast Hose
stretching values (in inches),” on
page 7-226.)
7-230 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Cable, Over-the-Mast
from the end of the cable. See cylinder retainer. Do not tighten at this
Figure 7-252. time.
NOTE: Remove all twist from the cable when
installing.
21. Turn the key switch ON. Elevate and block
carriage. Turn the key switch OFF.
22. Adjust and tension the cable to allow the
cable to loop away at the bottom edge of
the hose/cable bracket on the carriage.
This loop should be 0.75 in.± 0.25 in.
below the bracket. See Figure 7-253.
Carriage
Hose/Cable
Guide
7DSCF1362.JPG
Figure 7-252. Cable Grip on TS2 end of OTM cable
11. If installing bulk cable, strip 3 in. of
insulation from cable, strip wires, and
attach spade lugs. Service Loop
12. Attach a cable tie around the braided end
of the cable grip to prevent the grip from
slipping. Do not tighten at this time.
13. Install the new cable in the carriage
retainer/guide and route to TS2.
Tension Spring
NOTE: Position the hoses using the marks
made in step 1 and make sure that there
is enough slack in the cable for the
installation and removal of the auxiliary 71045742_b5.JPG
manifold cover. Figure 7-253. Service Loop (Standard Carriage shown)
14. Reconnect battery connector and turn key 23. Position the hoses and cable using the
switch ON. Remove blocking and lower the marks made in step 1 and tighten the
carriage. Turn key switch OFF and upper 4 bolts, but not the bottom 2 bolts
disconnect battery connector. of the upper free lift cylinder retainer.
15. Connect cable spade lugs to TS2. 24. Set the tension on the spring at the
16. Attach aux manifold cover to carriage. carriage by sliding the cable grip to
produce a length of 1.75 in. ± 0.12 in. over
17. Reconnect the battery connector and turn the coils. Do not over tension. Tighten the
the key switch ON. Elevate and block cable tie on the cable grip.
carriage as in step 7. Turn the key switch See Figure 7-253.
OFF.
NOTE: Orient the loop of the cable grip fore-aft
18. Tighten the carriage hose and cable
so, as the cable passes through the loop
retainer.
of the cable grip and the latch of the
19. Turn the key switch ON. Remove blocking cable tie, it does not interfere with the
and lower the carriage. Turn the key free lift cylinder mounting pin.
switch OFF.
25. Turn the key switch ON. Carefully elevate
20. Feed the cable through the free lift pulley the telescopics high enough to access the
and position it in the upper free lift
1026304B, 15 July 2007 7-231
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Cable, Over-the-Mast Mast, Chain, Hose, Cable
lower retainer on the free lift cylinder and must enlarge the passage hole. To do
the retainer on the telescopic from the this, remove both parts of the retainer,
operator’s compartment. clamp them together, and drill out the
26. Place a hardwood block of sufficient length passage hole for the electrical cable (not
(approximately 30 inches) between the the hoses) with a 9/16 inch drill bit.
outer and inner telescopics. This will Reassemble the retainer, aligning
remove the tension from the OTM hoses witness marks on the hoses, and
and the lift hose to make the removal and tighten the bolts. Insert the new cable
installation of the retainers easier. through the passage hole.
Carefully lower the mast until you have See Figure 7-255.
the desired tension. See Figure 7-254.
Electrical Lift Hose Aux Hose
Cable Hole Hole Hole
7DSCF1361.JPG
Figure 7-254. Blocking Telescopics
27. Turn the key switch OFF.
28. Remove and install the cable at the lower
free lift cylinder and bottom inner 71045742_D8.CGM
Figure 7-255. Retainer Modification for Electrical Cable
telescopic hose/cable retainers. Observe
correct routing to make sure hoses and
31. If installing bulk cable, install cable grip
cable have sufficient clearance. Tighten
with the loop pointing down towards the
the retainers.
tractor. Go to step 33.
29. Remove and feed the cable through the 32. Exact replacement cable: In order to pass
pulley at the top of the inner telescopic. connector PS3 past the main lift cylinder
Observe correct routing and make sure the retainer, disassemble the retainer. Remove
cable is not twisted. the old cable, insert the new cable.
30. For exact replacement cable install, go to Reassemble the retainer, but do not
step 32. tighten.
For bulk cable installation: 33. Turn the key switch ON. Remove the
a. If old cable is loose in the main lift blocking between the inner and outer
cylinder cable retainer, the passage telescopic.
hole in the retainer has already been
34. Tighten the bottom two bolts of the free lift
enlarged. Remove the old cable and
cylinder hose/cable retainer.
insert the new cable through the
passage hole. 35. Secure hoses and cable to the free lift
cylinder with cable ties every 16 to 24 in.
b. If the old cable is held in place by the as you lower the carriage all the way. Turn
main lift cylinder cable retainer, you the key switch OFF.
7-232 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Cable, Over-the-Mast
36. If installing exact replacement cable, pull 45. Connect the OTM cable to connector JPS3.
the cable through the main lift cylinder Go to step 50.
retainer until all slack is removed. Mark
the cable at the top of the retainer. Tighten For bulk cable installation, do the following:
the retainer bolts.
37. Set the spring tension to 1.75 in. ± 0.12 in. 46. Cut the OTM cable 20 in. past the bottom
by sliding the cable grip. Do not over of the main lift cylinder retainer.
tension. Tighten the cable tie on the cable 47. Strip 3 in. of insulation from the cable,
grip. strip the wires, and attach spade lugs.
48. Connect the wires to the terminal strip.
See Table 7-23 on page 7-230.
NOTE: Note: Colors will not match at TS2.
49. Attach cable to frame with cable tie and
self-adhesive cable tie anchor. See
Figure 7-257.
7DSCF1352.JPG
Figure 7-256. Main LIft Cylinder Retainer Cable Spring
Tension
38. For bulk cable installation, go to step 46.
For exact replacement cable installation,
do the following:
7SCF0449.JPG
39. Turn the key switch ON. Elevate the Figure 7-257. Cabling at Terminal Strip
carriage and place a hardwood block
between the inner and outer telescopic. 50. Install the mast guard, top cover and front
Carefully lower the carriage to relieve the left cover.
hose and cable tension. Turn the key
switch OFF.
40. Position the cable so that the mark on the
cable is 0.5 in. above the retainer.
41. Position the OTM hoses and the lift hose
as marked in step 1 and tighten the
retainer.
42. Turn the key switch ON. Remove the block
between the inner and outer telescopic.
43. Lower the carriage. Turn the key switch
OFF.
44. Remove and route the cable along the
tractor bulkhead, through the tractor
opening and attach with the hose/cable
clamps.
1026304B, 15 July 2007 7-233
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Hose/Tubing, Free Lift Feed Mast, Chain, Hose, Cable
Hose/Tubing, Free Lift 6. Install the mast guard.
Feed
Removal
1. Remove the mast guard.
2. Raise the telescopics until the bottom of
the free lift feed tubing is accessible from
the operator’s compartment.
3. Place a block of sufficient length between
the outer telescopic crosstie and the
mainframe to hold the position in step 2.
4. Fully lower the carriage. 71045742_D5.CGM
Figure 7-258. Free Lift Feed Hose/Tube, Model 7400
5. Extend the reach mechanism to allow
easier removal of the free lift feed tubing.
6. Turn the key switch OFF and disconnect
the battery connector.
7. Place a pan below the free lift tubing.
8. Remove the necessary components. See
Figure 7-258 and Figure 7-259.
Installation
1. Replace the necessary components. Make
sure the assembly is tight and correctly
positioned on the crosstie.
2. Reconnect the battery connector and turn
the key switch ON.
3. Remove the block between the outer
telescopic crosstie and the mainframe.
71067160_C1.CGM
4. Bleed the hydraulic system. See Figure 7-259. Free Lift Tubing, Model 7420/7440
“Hydraulic System Bleeding” on
page 7-134.
5. Check the truck for leaks and correct
operation.
7-234 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7400 (Complete Disassembly)
Mast, Model 7400 needed for correct reassembly. Feed hoses
through opening in tractor bulkhead.
(Complete Disassembly) 12. Disconnect the main lift hose fitting at the
left side of the tractor.
Series CA/FA (AC lift)
Separation of Tractor and Mast Make sure the weight of the mast is fully
supported by the hoist and the tractor is
blocked where it meets the mast before
loosening the mast mounting bolts.
• Do this procedure with a minimum 13. Place blocks snugly under the tractor near
of two technicians in a shop the mast.
equipped with a suitable hoist.
14. Attach a lifting strap around the top
• Do not permit observers to stand
crossties of all three mast sections. Draw
nearby.
tight with hoist. Make sure the weight of
• Wear gloves, safety glasses, the mast is supported by the hoist.
steel-toed safety boots, and a safety
helmet (hard hat). 15. Use an impact wrench to remove the mast
mounting bolts inside the battery
1. Lower and retract the fork carriage
compartment, four on the top, eight on the
completely.
bottom.
2. Turn the key switch OFF and disconnect 16. Using a lift truck, carefully separate the
the battery connector. Remove battery tractor about 6 inches (15 cm).
gates. Using a suitable battery removal
device, remove the battery. 17. Remove the hose/cable retaining bracket
on the front of the tractor bulkhead.
3. Remove the top cover and the left and right
front covers. 18. Remove the hose/cable retainer on the
main lift cylinder.
4. Remove the mast guard.
5. Secure a hoist strap around the overhead 19. Reinstall mast mounting bolts and
guard. Take the weight off the guard. washers and tighten lightly (to prevent
Remove mounting bolts. Remove the misplacing them).
guard.
6. Disconnect and cap right side main lift Hose/Cable, Free Lift Cylinder,
hose at the tractor bulkhead fitting. and Carriage Removal
7. Disconnect the ambient temperature
20. Remove the auxiliary manifold cover from
sensor connector JPA on the tractor deck.
the carriage. See Figure 7-260 on
8. Disconnect the mast switch connector page 7-236.
JPS4 (near the lift pump). Feed harness
through tractor opening at left side. 21. Disconnect the wires of the over-the-mast
cable from the terminal strip, labeling as
9. Disconnect over-the-mast cable connector needed for reconnection.
JPS3 on the tractor deck.
22. Remove auxiliary manifold mounting
10. Disconnect the hose/cable retaining screws to permit access to the
clamp from the left front corner of the over-the-mast hose fittings at the
tractor near the opening in the bulkhead. manifold.
11. Disconnect and plug hydraulic hoses A1 NOTE: There may be shims between the
and A2 at the main manifold, labeling as manifold and carriage.
1026304B, 15 July 2007 7-235
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7400 (Complete Disassembly) Mast, Chain, Hose, Cable
NOTE: There may be shims between the 34. Remove the upper hose/cable pulley from
manifold and carriage. the top of the outer telescopic.
35. Disconnect the tee tubing to the right side
main lift cylinder.
36. Disconnect and cap the hose to the left
main lift cylinder.
37. Rig lifting straps around the carriage.
Using a hoist, carefully lift the carriage out
of the inner telescopic and lower the
carriage to the floor.
Main Lift Chain Removal
38. Rig a lifting strap of one hoist around the
lower crosstie of the main frame (the one
where the overhead guard attaches).
7DSC_942A.JPG
Figure 7-260. Auxiliary Manifold Access 39. Rig a lifting strap of another hoist around
the top crossties of both inner and outer
23. Disconnect and plug/cap the telescopics. Using the hoist, raise the
over-the-mast hoses and fittings at the telescopics about 10 in. (25 cm).
auxiliary manifold. Label as needed to 40. Remove chain anchor bolt and access
assure correct reconnection. cover from sides of main frame.
24. Remove cable ties on upper hose retaining 41. Remove the chain anchor pin by using a
block. Loosen upper and lower hose/cable slide hammer or by using a large socket
retaining blocks. (1 1/16 in.), an M8 x 50 mm bolt and
25. Jack carriage up about 3 in. (7.5 cm). washers to act as a pulling device.
Remove master links on free lift chains. See Figure 7-261 this page and
Feed free lift chains through pulleys and Figure 7-206 on page 7-201.
drape over front of carriage.
26. Remove hose/cable retaining block on Bolt
back of carriage.
27. Remove hoses and cable from guide at Cover
back of carriage.
28. Remove upper and lower hose/cable
retainers from free lift cylinder. Pin
29. Feed hoses and cable through right side
free lift cylinder pulley. Chain
30. Remove tee tubing from free lift cylinders. Anchor
31. Remove set screws from bottom of right
free lift cylinders. Lift each free lift cylinder
off the mounting hook at the top and the 7R1020561_A1.CGM
mounting block at the bottom. Install set Figure 7-261. Main Lift Chain Upper Chain Anchor
screws so they are not misplaced.
42. Pull the chain anchor/mast stop out of the
32. Remove carriage stops from back of
main frame.
carriage.
43. Feed main lift chains from inside to
33. Remove the lower hose/cable pulley from
outside over the chain sheave.
the top of the outer telescopic.
7-236 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7400 (Complete Disassembly)
Separation of Telescopics 48. Remove anti-rattle pads and shims from
bottom of outer telescopic. See
44. Using the hoists, carefully lower the mast Figure 7-264.
to a horizontal position on jack stands.
45. Loosen the L-bracket bolts holding the
main lift cylinders to the telescopic.
46. Remove the top mounting bolt, washer, Shim
and sleeve holding the main lift cylinder to
the outer telescopic. See Figure 7-262.
Mounting Bolt
Washer
Sleeve
Pad Cover
7R1020561_A4.CGM
Figure 7-264. Outer Telescopic Lower Bearing and
Anti-Rattle Pads
Outer
Telescopic 49. Remove anti-rattle pads and shims from
bottom of inner telescopic. See
Figure 7-265.
7R1020561_A2.CGM
Figure 7-262. Main Lift Cylinder Mounting Hardware
47. Remove main lift chain sheaves from top of Shim
outer telescopic. Sheaves attach with a pin
and a set screw on the inside. See
Pad
Figure 7-263.
Sheave Set Screw
Spacer Chain
Bearing
Snap Ring
Pin Shim
Pad
71043786_A7.CGMs
Figure 7-263. Main LIft Chain Sheave
7 1043786_A6.CGM
Figure 7-265. Inner Telescopic Lower Bearing and
Anti-Rattle Pads
1026304B, 15 July 2007 7-237
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7400 (Complete Disassembly) Mast, Chain, Hose, Cable
50. Using a suitable hoist, pull the inner 56. Remove the lower roller bearings and
telescopic halfway out of the outer shims from the outer telescopic. See
telescopic. Figure 7-264.
51. Remove the upper roller bearings and 57. Using a suitable hoist, remove the outer
shims from the top of the outer telescopic. telescopic from the main frame.
See Figure 7-266.
Sleeve
Stud
Shims
Bearing
7R1020561_A6.CGM
Figure 7-266. Outer Telescopic Upper Bearing
52. Remove the lower roller bearings and
shims from the bottom of the inner
telescopic. See Figure 7-265.
53. Using a suitable hoist, remove the inner
telescopic from the outer telescopic.
54. Using a suitable hoist, pull the outer
telescopic halfway out of the main frame.
55. Remove the upper roller bearings and
shims from the main frame. See
Figure 7-267.
Bolt
Stud
Shims
Bearing
71043786_A10.CGM
Figure 7-267. Main Frame Upper Bearing
7-238 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7400 (Complete Assembly)
Mast, Model 7400 prevent the bearing from walking on the
stud shaft. See Figure 7-268.
(Complete Assembly)
Assembling and Shimming
Outer Telescopic to Main Frame
Lower Bearings of Outer Telescopic
1. Begin the assembly with the main frame
positioned horizontally on jack stands.
2. Attach the lower roller bearing to one side
of the outer telescopic. Make sure the flat
spot on the bearing outer stud is correctly
positioned against the mast. This is
important because the correct bearing
alignment is canted with respect to the 7R1022231_A.CGM
Figure 7-268. Inner Race
channel. See Figure 7-264.
3. Using a suitable hoist, insert the outer
9. Using the hoist, slide the outer telescopic
telescopic into the main frame as far as
the entire length of the main frame,
the crosstie.
checking for binding. The tightest spots
4. Attach the lower roller bearing to the other will generally be at the crossties. Add or
side of the outer telescopic. remove shims as necessary to maintain a
5. Using a pry bar, move the outer telescopic snug but free-running fit.
and bearing to one side.
6. Use spare shims as a gauge to determine Upper Bearings of Main Frame
the amount of shims required to cause the
10. With the outer telescopic inserted halfway
roller bearing to contact the main frame.
into the main frame, attach the upper
7. Remove both lower bearings. Install one roller bearing to one side of the main
half of the total shim thickness required to frame. Make sure the flat spot on the
each roller bearing. Reinstall the bearings. bearing outer stud is correctly positioned
Apply thread-locking compound against the mast. See Figure 7-267.
(P/N 990-536) to the bearing mounting
11. Attach but do not tighten the upper roller
bolt and torque to 260 ft. lb. (352 Nm).
bearing to the other side of the main
8. If the inner race of the bearing does not frame.
protrude past the end of the bearing stud
12. Use spare shims as a gauge to determine
when the bearing is fully seated, bend the
the amount of shims required to cause the
flat washer to contact the bearing to
roller bearing to contact the outer
telescopic.
13. Remove both upper bearings. Install one
half of the total shim thickness required to
each roller bearing. Reinstall the bearings.
Apply thread-locking compound
(P/N 990-536) to the bearing mounting
bolt and torque to 260 ft. lb. (352 Nm).
14. If the inner race of the bearing does not
protrude past the end of the bearing stud
1026304B, 15 July 2007 7-239
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7400 (Complete Assembly) Mast, Chain, Hose, Cable
when the bearing is fully seated, bend the 24. Using the hoist, slide the inner telescopic
flat washer to contact the bearing to the entire length of the outer tele, checking
prevent the bearing from walking on the for binding. Add or remove shims as
stud shaft. See Figure 7-268. necessary to maintain a snug but
15. Using the hoist, slide the outer telescopic free-running fit.
the entire length of the main frame,
checking for binding. Add or remove shims Upper Bearings of Outer Telescopic
as necessary to maintain a snug but
25. With the inner telescopic inserted halfway
free-running fit.
into the main frame, attach the upper
16. R35TT mast only: Check the clearance roller bearing to one side of the outer tele.
gap of the bow pads between outer Make sure the flat spot on the bearing
telescopic and main frame. Shim as outer stud is correctly positioned against
required to obtain a gap of 0.03 to 0.09 the mast. See Figure 7-266.
inch (0.8 to 2.3 mm).
26. Attach but do not tighten the upper roller
bearing to the other side of the outer
Assembling and Shimming telescopic.
Inner Telescopic to Outer 27. Use spare shims as a gauge to determine
Telescopic the amount of shims required to cause the
roller bearing to contact the inner
Lower Bearings of Inner Telescopic telescopic.
28. Remove both upper bearings. Install one
17. Attach the lower roller bearing to one side half of the total shim thickness required to
of the inner telescopic. Make sure the flat each roller bearing. Reinstall the bearings.
spot on the bearing outer stud is correctly Apply thread-locking compound
positioned against the mast. See (P/N 990-536) to the bearing mounting
Figure 7-265. bolt and torque to 260 ft. lb. (352 Nm).
18. Using a suitable hoist, insert the inner 29. If the inner race of the bearing does not
telescopic into the outer telescopic as far protrude past the end of the bearing stud
as the crosstie. when the bearing is fully seated, bend the
19. Attach the lower roller bearing to the other flat washer to contact the bearing to
side of the inner telescopic. prevent the bearing from walking on the
20. Using a pry bar, move the inner telescopic stud shaft. See Figure 7-268.
and bearing to one side. 30. Using the hoist, slide the inner telescopic
21. Use spare shims as a gauge to determine the entire length of the outer telescopic,
the amount of shims required to cause the checking for binding. Add or remove shims
roller bearing to contact the outer tele. as necessary to maintain a snug but
free-running fit.
22. Remove both lower bearings. Install one
half of the total shim thickness required to 31. Check the clearance gap of the bow pads
each roller bearing. Reinstall the bearings. between inner telescopic and outer
Apply thread-locking compound telescopic. Shim as required to obtain a
(P/N 990-536) to the bearing mounting gap of 0.03 to 0.09 inch (0.8 to 2.3 mm).
bolt and torque to 260 ft. lb. (352 Nm).
23. If the inner race of the bearing does not Main Lift Chain Installation
protrude past the end of the bearing stud
32. Install anti-rattle pads and shims at
when the bearing is fully seated, bend the
bottom of inner and outer telescopics.
flat washer to contact the bearing to
Shim so pads are snug against mast. See
prevent the bearing from walking on the
Figure 7-264 and Figure 7-265.
stud shaft. See Figure 7-268.
7-240 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7400 (Complete Assembly)
33. Install the main lift chain sheaves to the Shimming Carriage to Inner
top of the outer telescopic. Sheaves install
with a large pin and a set screw on the
Telescopic
inside. See Figure 7-263. 45. Drape the free lift chains forward over the
34. Install but do not tighten a new sleeve and carriage back rest. Rig lifting straps
collar, washer, and mounting bolt through around the carriage.
the telescopic crosstie and into the 46. Install the lower set of roller bearings,
cylinder housing of each main lift cylinder. without shims, in the carriage.
See Figure 7-262.
47. Using a hoist, carefully lift the carriage
35. Rig lifting straps around the upper and insert it into the inner telescopic until
crossties of all three mast sections. the bearings just enter the telescopic.
36. Using a suitable hoist, raise the mast to a 48. Using a pry bar, move the carriage
vertical position. bearings to one side.
37. Rig a lifting strap of one hoist around the 49. Use spare shim(s) as a gauge to determine
lower crosstie of the main frame (the one the amount of shims required to remove
where the overhead guard attaches). side play.
38. Rig a lifting strap of another hoist around 50. Remove the carriage from the inner
the top crossties of both inner and outer telescopic far enough to expose the
telescopics. Using the hoist, lower the bearings being shimmed.
telescopics to about 10 in. (25 cm) from
51. Remove the bearings being shimmed from
the floor.
the carriage. Install one half of the total
39. Make sure the two holes in the upper shim thickness required to each roller
chain anchor block are towards the bearing.
outside. Feed the main lift chain from the
52. Using the hoist, reinsert the carriage into
outside to the inside over the chain
the inner telescopic. Check for tight areas
sheave.
while moving the carriage to the bottom of
40. Feed the upper chain anchor block down the inner telescopic.
between the main frame and outer
53. Remove the carriage from the inner
telescopic until holes are aligned between
telescopic far enough to expose the
block and main frame. Insert the chain
bearings being shimmed.
anchor bolt (without the access cover) and
lightly tighten the bolt to draw the chain 54. Remove the bearings being shimmed from
anchor block to the main frame. the carriage.
41. Thread a bolt into the hole in the chain NOTE: The carriage may have to be removed
anchor retaining pin. Insert the pin and several times to obtain the correct fit.
drive it in. Remove the bolt from the pin.
55. Install the center set of roller bearings,
42. Remove the chain anchor bolt. Apply without shims, in the carriage.
thread-locking compound (P/N 990-544)
56. Repeat steps 48 through 54 for the center
to bolt threads. Install access cover and
set of bearings.
torque bolt to 130 ft. lb. (174 Nm).
57. Install the upper set of roller bearings,
43. Lower the telescopics into the main frame
without shims, in the carriage.
approx. 3 in. (7.5 cm) from the floor.
58. Repeat steps 48 through 54 for the upper
44. Install master links to attach the main lift
set of bearings.
chains to the lower chain anchor blocks.
Lower the telescopics completely. Tighten
the chain anchor nuts until the inner
telescopic just lifts off its stops.
1026304B, 15 July 2007 7-241
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7400 (Complete Assembly) Mast, Chain, Hose, Cable
Carriage, Free Lift Cylinder, and
Hose/Cable Installation
Torque to 130 ft. lb. (174 Nm)
59. Drape the free lift chains forward over the
carriage back rest. Rig lifting straps
around the carriage. Using a hoist,
carefully lift the carriage and insert it into
the inner telescopic and lower the carriage
to about 3 in. (7.5 cm) above the floor.
60. Route cable and hoses around upper
pulleys. Attach upper hose/cable pulley to
the top of the outer telescopic. Apply
thread-locking compound (Raymond
P/N 1013829) to the threads of the studs
and torque as shown in Figure 7-269 and
Figure 7-270. Torque to 43 ft. lb. (58 Nm)
71045742_D2.CGM
61. Route auxiliary hoses around lower Figure 7-270. Over-the-Mast Hose/Cable Pulleys
pulleys. Attach lower hose pulley to the (newer style)
top of the outer telescopic. Apply
thread-locking compound (Raymond
62. Install carriage stops. Apply
P/N 1013829) to the threads of the studs
thread-locking compound (P/N 990-536)
and torque as shown in Figure 7-269 and
to mounting bolts and torque to 35 ft. lb.
Figure 7-270.
(47.5 Nm).
63. Remove set screws from free lift mounting
Torque to blocks. Lift each free lift cylinder into place
130 ft. lb. over the mounting hook at the top and the
(174 Nm) mounting block at the bottom. Apply
thread-locking compound (P/N 990-403) to set
screw threads and install set screws in
mounting blocks.
64. Reference Figure 7-271 for the following
steps, which route the hoses/cable.
NOTE: Lift trucks below s/n 03069 require
rerouting of the over-the-mast cable and
hoses and/or modification. See
7R1018766_C6.CGM
Figure 7-269. Over-the-Mast Hose/Cable Pulleys
(older style)
7-242 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7400 (Complete Assembly)
Raymond Service Bulletin RCH-05-018 65. Connect tee tubing to free lift cylinders.
dated 30 August 2005. See Figure 7-272.
7R1018766_C2.CGM
Figure 7-272. Free Lift Cylinder Tee Tubing
66. Feed hydraulic hoses and electrical cable
through the free lift pulley, from tractor
side to forks side. The electrical cable
must be on the left-hand side.
See Figure 7-273.
Aux Hose A2
Aux Hose A1
Electrical Cable
71045742_B7.jpg
Figure 7-273. OTM Hoses and Cable at Free Lift Pulley
7R1018766_C1.CGM
Figure 7-271. Over-the-Mast Hose and Cable Installation
1026304B, 15 July 2007 7-243
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7400 (Complete Assembly) Mast, Chain, Hose, Cable
67. Attach, but do not tighten, the hose/cable bottom of the hose guide. See
retainer bracket at the bottom of the free Figure 7-276.
lift cylinder. See Figure 7-274.
Gap
7R1027396_DB.CGM
Figure 7-274. Lower Hose/Cable Retainer, Free Lift
Cylinder
68. Assemble, but do not tighten, the
hose/cable retainer at the top of the free
lift cylinder. See Figure 7-275. 71045742_D6.CGM
Figure 7-276. Hose/Cable Guide on Carriage
70. Feed the free lift chains over free lift
pulleys, from forks side to tractor side.
Install master links to attach the free lift
chains to the chain anchor blocks.
71045742_D8.CGM
Figure 7-275. Upper Hose/Cable Retainer, Free Lift
Cylinder
69. Feed hoses and cable around the guide on
the carriage. Attach the cable tension
spring and position the cable grip to
provide a 0.75 in. gap between the
over-the-mast electrical cable and the
7-244 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7400 (Complete Assembly)
71. Take slack out of hoses and cable. Make 75. With the auxiliary manifold removed from
sure hoses do not cross each other. the carriage, connect auxiliary hydraulic
hoses to the manifold, making sure to
observe correct labeling.
76. Attach the manifold to the carriage. Apply
Aux Hose A2 thread-locking compound (P/N 990-536)
to the mounting bolt threads and torque to
Aux Hose A1 21 ft. lb. (29 Nm).
77. Connect the over-the-mast cable wires to
the terminal block on the auxiliary
Electrical Cable manifold cover. Attach the manifold cover
to the carriage. Apply thread-locking
compound (P/N 990-536) to the mounting
bolt threads and torque to 30 ft. lb.
(42 Nm).
78. Assemble, but do not tighten, the
hose/cable retainer on the left side main
lift cylinder. See Figure 7-275.
79. Secure the mast with hoist lifting strap
wrapped loosely around the top crossties
of all three mast sections. Wrap the lifting
strap of a second hoist around the upper
crosstie of the inner telescopic. Using the
hoist, lift the inner telescopic about 6 in.
(15 cm).
Aux Hose A2
80. Tighten the hose/cable retainer on the left
Aux Hose A1
side main lift cylinder.
Electrical Cable 81. Lower the inner telescopic.
Mating Tractor to Mast
82. Position the tractor about 10 in. (25 cm)
from the mast. Place blocks under the
tractor near the mast to match the bolt
hole height in tractor and mast.
83. Attach the hose/cable retaining bracket on
the front (mast side) of the tractor
bulkhead. See Figure 7-278.
84. With the mast secured by a hoist, use a lift
71045742_B7.JPG and 1045742_D4.CGM truck to mate the tractor to the mast.
Figure 7-277. OTM hose and cable routing
85. Apply thread-locking primer
(P/N 990-666) to mast mounting bolt
72. Install hose/cable retainer on carriage. threads and hole threads. Permit to dry for
See Figure 7-276. several minutes.
73. Lower the carriage all the way to the floor. 86. Apply thread-locking compound
74. Tighten the upper and lower hose/cable (P/N 990-544) to threads of mast
retainers on the free cylinders. Attach two mounting bolts.
cable ties on the upper retainer.
1026304B, 15 July 2007 7-245
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7400 (Complete Assembly) Mast, Chain, Hose, Cable
87. From the battery compartment thread 95. Secure a hoist strap around the overhead
eight mounting bolts and washers through guard or position a lift truck with pallet
bottom of the tractor frame into the mast. under the overhead guard. Lift the guard
Thread four mounting bolts and washers into position at the lower crosstie of the
through the top of the tractor frame into main frame.
the mast. Torque to 165 ft. lb. (224 96. Apply thread-locking compound
Nm)bolts. (P/N 990-536) to the mounting bolt
88. Connect the main lift hose fitting at the left threads. Install mounting bolts and torque
side of the tractor. to 130 ft. lb. (174 Nm).
89. Route the auxiliary hoses and electrical 97. Install the mast guard.
cable through the tractor opening. Secure 98. Using a suitable battery moving device,
hoses and cable with retainer clamp. See install the battery. Install battery gates.
Figure 7-278.
99. Attach front covers and top cover.
100. Make sure all hoist straps and blocks are
removed.
101. Reconnect the battery connector and turn
the key switch ON.
102. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on
page 7-134.
Retainer
Clamps 103. Test all lift truck functions.
104. Elevate the inner telescopic about 12 in.
(30 cm). Torque the main cylinder top
mounting bolts. Tighten main lift cylinder
L-bracket mounting bolts to 55 ft. lb.
(74.5 Nm).
105. Using a work basket and lift truck, grease
the channels of all sections of the mast.
7R1018766_C7.CGM
Figure 7-278. Hose/Cable Retainer Clamps on Tractor
90. Connect auxiliary hoses A1 and A2 at the
main manifold, observing labels.
91. Connect over-the-mast cable connector
JPS3 on the tractor deck. See
Figure 7-233.
92. Feed the mast switch harness into the
tractor, across the top of the deck to the
right side near the lift pump. Connect
connector JPS4.
93. Connect the ambient temperature sensor
cable connector JPA on the tractor deck.
94. Connect the right side main lift hose to the
fitting on the tractor bulkhead.
7-246 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7420 (Complete Disassembly)
Mast, Model 7420 11. Disconnect the main lift hose fitting at the
left side of the tractor.
(Complete Disassembly)
Series CA/FA (AC lift) Make sure the weight of the mast is fully
supported by the hoist and the tractor is
Separation of Tractor and Mast blocked where it meets the mast before
loosening the mast mounting bolts.
12. Place blocks snugly under the tractor near
the mast.
• Do this procedure with a minimum 13. Attach a lifting strap around the top
of two technicians in a shop crossties of all three mast sections. Draw
equipped with a suitable hoist. tight with hoist. Make sure the weight of
• Do not permit observers to stand the mast is supported by the hoist.
nearby.
14. Remove the battery connector bracket to
• Wear gloves, safety glasses, permit access to the top right mast
steel-toed safety boots, and a safety mounting bolts.
helmet (hard hat).
15. Use an impact wrench to remove the mast
1. Lower and retract the fork carriage
mounting bolts inside the battery
completely.
compartment, four on the top, eight on the
2. Turn the key switch OFF and disconnect bottom.
the battery connector. Remove battery 16. Using a lift truck, carefully separate the
gates. Using a suitable battery removal tractor about 6 inches (15 cm).
device, remove the battery.
3. Remove the top cover and the left and right 17. Reinstall mast mounting bolts and
front covers. washers and tighten lightly (to prevent
misplacing them).
4. Remove the mast guard.
5. Secure a hoist strap around the overhead
guard. Take the weight off the guard. Hose/Cable, Free Lift Cylinder,
Remove mounting bolts. Remove the and Carriage Removal
guard.
18. Remove the auxiliary manifold cover from
6. Disconnect and cap right side main lift the carriage. See Figure 7-279 on
hose at the tractor bulkhead fitting. page 7-248.
7. Disconnect the ambient temperature 19. Disconnect the wires of the over-the-mast
sensor connector JPA on the tractor deck. cable from terminal strip TS-2, labeling as
8. Disconnect the mast switch connector needed for reconnection.
JPS4 (near the lift pump). Feed harness 20. Remove auxiliary manifold mounting
through tractor opening at right side. screws to permit access to the
9. Disconnect over-the-mast cable connector over-the-mast hose fittings at the
JPS3 on the tractor deck. manifold.
10. Disconnect and plug hydraulic hoses A1
and A2 at the main manifold, labeling as
needed for correct reassembly. Feed hoses
through opening in tractor bulkhead.
1026304B, 15 July 2007 7-247
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7420 (Complete Disassembly) Mast, Chain, Hose, Cable
NOTE: There may be shims between the 24. Loosen the U-clamp on the right side free
manifold and carriage. lift cylinder and feed the over-the-mast
(OTM) cable through. See Figure 7-281.
7DSC_942A.JPG
U-clamp
Figure 7-279. Auxiliary Manifold Access
21. Disconnect and plug/cap the
over-the-mast hoses and fittings at the
auxiliary manifold. Label as needed to 71066854_B2.CGM
assure correct reconnection. Figure 7-281. U-clamp, OTM Electrical Cable
22. Place a chalk witness mark on the hoses to
25. Cut cable ties on hose clamps on left side
aid in reassembly.
free lift cylinder.
23. Remove hose retaining clamp near top of
26. Loosen the hose retaining clamp on the
the left side free lift cylinder.
carriage near the bottom of the left side
See Figure 7-280.
free lift cylinder. Slide clamp inward to free
the hoses. See Figure 7-282.
Hose
Retaining
Clamp
Hose
Retaining
Clamp
71066854_B13.CGM 71066854_B13.CGM
Figure 7-280. Hose Retaining Clamp, Left Free Lift Cylinder Figure 7-282. Hose Retaining Clamp, Left Free Lift Cylinder,
Bottom
7-248 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7420 (Complete Disassembly)
27. Feed hoses and cable through free lift stud at the top and off the pin at the
cylinder pulleys. bottom. See Figure 7-283.
28. Jack carriage up about 3 in. (7.5 cm) to
provide slack in chains. Remove master
links on free lift chains. Feed free lift Free Lift Cylinder
Mounting Stud
chains through pulleys and drape over
front of carriage.
29. Remove carriage stops at the top of the
inner telescopic.
30. Rig lifting straps around the carriage.
Using a hoist, carefully lift the carriage out
of the inner telescopic and lower the
carriage to the floor.
31. Disconnect and plug the hydraulic supply
hose at the bottom of the free lift cylinders.
32. Disconnect the free lift crossover hose and
cap both cylinders.
33. Remove the nylon locking nut from the
mounting stud on the free lift cylinder. Lift Free Lift Cylinder
each free lift cylinder off the mounting Mounting Pin
71051676_D.CGM
Figure 7-283. Free Lift Cylinder Mounting Stud and Pin
Main Lift Chain Removal
34. Rig a lifting strap of one hoist around the
lower crosstie of the main frame (the one
where the overhead guard attaches).
35. Rig a lifting strap of another hoist around
the top crossties of both inner and outer
telescopics. Using the hoist, raise the
telescopics about 10 in. (25 cm).
1026304B, 15 July 2007 7-249
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7420 (Complete Disassembly) Mast, Chain, Hose, Cable
36. Remove the kickback block, pads, and 41. Feed main lift chains from inside to
shims at the bottom of the inner outside over the chain sheave.
telescopic. See Figure 7-284.
Separation of Telescopics
Kickback 42. Using the hoists, carefully lower the mast
Block to a horizontal position on jack stands.
43. Loosen the L-bracket bolts holding the
main lift cylinders to the telescopic.
Mounting
Screws (2)
44. Remove the top mounting bolt, washer,
and sleeve holding the main lift cylinder to
the outer telescopic. See Figure 7-286.
Kickback Kickback Mounting Bolt
Pad Shim
Washer
71051418_E8.CGM
Figure 7-284. Inner Telescopic Kickback Block, Pad, Shims Sleeve
37. Remove the chain anchor retaining nut
from the chain anchor block at the bottom
of the inner telescopic.
38. Remove the bolt and access cover to the
upper chain anchor at the sides of main
frame. See Figure 7-285. Outer
Telescopic
39. Remove the chain anchor pin by using a
71051674_B.CGM
slide hammer or by using a large socket Figure 7-286. Main Lift Cylinder Mounting Hardware
(1 1/16 in.), an M8 x 50 mm bolt and
washers to act as a pulling device. 45. Remove main lift chain sheaves from top of
See Figure 7-285 this page and outer telescopic. Sheaves attach with a pin
Figure 7-206 on page 7-201. and a retaining screw on the front. See
Figure 7-287.
Bolt
Sheave
Cover
Spacer Chain
Pin
Bearing
Chain
Anchor Snap Ring
Pin
7R1020561_A1.CGM Retaining Screw
Figure 7-285. Main Lift Chain Upper Chain Anchor
40. Pull the chain anchor/mast stop out of the 71051418_E6.CGMs
main frame. Figure 7-287. Main LIft Chain Sheave
7-250 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7420 (Complete Disassembly)
46. Remove anti-rattle pads and shims from 52. Remove the upper roller bearings and
bottom of outer telescopic. See shims from the main frame. See
Figure 7-288. Figure 7-290.
Bolt
Stud
Bearing
Retaining
Shim Screw and
Washer
Bearing
Pad Shim Cover
71051418_E7.CGM 71051418_E5.CGM
Figure 7-288. Outer Telescopic Lower Bearing and Figure 7-290. Main Frame Upper Bearing
Anti-Rattle Pads
53. Remove the lower roller bearings and
47. Using a suitable hoist, pull the inner shims from the outer telescopic. See
telescopic halfway out of the outer Figure 7-288.
telescopic. 54. Using a suitable hoist, remove the outer
48. Remove the upper roller bearings and telescopic from the main frame.
shims from the top of the outer telescopic.
See Figure 7-289.
Stud
Shim
Bearing
Bearing Retaining
Screw and Washer
71051418_E6.CGM
Figure 7-289. Outer Telescopic Upper Bearing
49. Remove the lower roller bearings and
shims from the bottom of the inner
telescopic. See Figure 7-284.
50. Using a suitable hoist, remove the inner
telescopic from the outer telescopic.
51. Using a suitable hoist, pull the outer
telescopic halfway out of the main frame.
1026304B, 15 July 2007 7-251
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7420 (Complete Assembly) Mast, Chain, Hose, Cable
Mast, Model 7420 prevent the bearing from walking on the
stud shaft. See Figure 7-291.
(Complete Assembly)
Assembling and Shimming
Outer Telescopic to Main Frame
Lower Bearings of Outer Telescopic
1. Begin the assembly with the main frame
positioned horizontally on jack stands.
2. Attach the lower roller bearing to one side
of the outer telescopic. Make sure the flat
spot on the bearing outer stud is correctly
positioned against the mast. This is
important because the correct bearing
alignment is canted with respect to the 7R1022231_A.CGM
Figure 7-291. Inner Race
channel. See Figure 7-288.
3. Using a suitable hoist, insert the outer
9. Using the hoist, slide the outer telescopic
telescopic into the main frame as far as
the entire length of the main frame,
the crosstie.
checking for binding. The tightest spots
4. Attach the lower roller bearing to the other will generally be at the crossties. Add or
side of the outer telescopic. remove shims as necessary to maintain a
5. Using a pry bar, move the outer telescopic snug but free-running fit.
and bearing to one side.
6. Use spare shims as a gauge to determine Upper Bearings of Main Frame
the amount of shims required to cause the
10. With the outer telescopic inserted halfway
roller bearing to contact the main frame.
into the main frame, attach the upper
7. Remove both lower bearings. Install one roller bearing to one side of the main
half of the total shim thickness required to frame. Make sure the flat spot on the
each roller bearing. Reinstall the bearings. bearing outer stud is correctly positioned
Apply thread-locking compound against the mast. See Figure 7-290.
(P/N 990-536) to the bearing mounting
11. Attach but do not tighten the upper roller
bolt and torque to 260 ft. lb. (352 Nm).
bearing to the other side of the main
8. If the inner race of the bearing does not frame.
protrude past the end of the bearing stud
12. Use spare shims as a gauge to determine
when the bearing is fully seated, bend the
the amount of shims required to cause the
flat washer to contact the bearing to
roller bearing to contact the outer
telescopic.
13. Remove both upper bearings. Install one
half of the total shim thickness required to
each roller bearing. Reinstall the bearings.
Apply thread-locking compound
(P/N 990-536) to the bearing mounting
bolt and torque to 260 ft. lb. (352 Nm).
14. If the inner race of the bearing does not
protrude past the end of the bearing stud
7-252 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7420 (Complete Assembly)
when the bearing is fully seated, bend the Upper Bearings of Outer Telescopic
flat washer to contact the bearing to
prevent the bearing from walking on the 24. With the inner telescopic inserted halfway
stud shaft. See Figure 7-291. into the main frame, attach the upper
roller bearing to one side of the outer tele.
15. Using the hoist, slide the outer telescopic
Make sure the flat spot on the bearing
the entire length of the main frame,
outer stud is correctly positioned against
checking for binding. Add or remove shims
the mast. See Figure 7-284.
as necessary to maintain a snug but
free-running fit. 25. Attach but do not tighten the upper roller
bearing to the other side of the outer
telescopic.
Assembling and Shimming
26. Use spare shims as a gauge to determine
Inner Telescopic to Outer the amount of shims required to cause the
Telescopic roller bearing to contact the inner
telescopic.
Lower Bearings of Inner Telescopic 27. Remove both upper bearings. Install one
half of the total shim thickness required to
16. Attach the lower roller bearing to one side
each roller bearing. Reinstall the bearings.
of the inner telescopic. Make sure the flat
Apply thread-locking compound
spot on the bearing outer stud is correctly
(P/N 990-536) to the bearing mounting
positioned against the mast. See
bolt and torque to 260 ft. lb. (352 Nm).
Figure 7-284.
28. If the inner race of the bearing does not
17. Using a suitable hoist, insert the inner
protrude past the end of the bearing stud
telescopic into the outer telescopic as far
when the bearing is fully seated, bend the
as the crosstie.
flat washer to contact the bearing to
18. Attach the lower roller bearing to the other prevent the bearing from walking on the
side of the inner telescopic. stud shaft. See Figure 7-290.
19. Using a pry bar, move the inner telescopic 29. Using the hoist, slide the inner telescopic
and bearing to one side. the entire length of the outer telescopic,
20. Use spare shims as a gauge to determine checking for binding. Add or remove shims
the amount of shims required to cause the as necessary to maintain a snug but
roller bearing to contact the outer tele. free-running fit.
21. Remove both lower bearings. Install one 30. Check the clearance gap of the bow pads
half of the total shim thickness required to between inner telescopic and outer
each roller bearing. Reinstall the bearings. telescopic. Shim as required to obtain a
Apply thread-locking compound gap of 0.03 to 0.09 inch (0.8 to 2.3 mm).
(P/N 990-536) to the bearing mounting
bolt and torque to 260 ft. lb. (352 Nm). Main Lift Chain Installation
22. If the inner race of the bearing does not
protrude past the end of the bearing stud 31. Install anti-rattle pads and shims at
when the bearing is fully seated, bend the bottom of inner and outer telescopics.
flat washer to contact the bearing to Shim so pads are snug against mast. See
prevent the bearing from walking on the Figure 7-288 and Figure 7-284.
stud shaft. See Figure 7-291. 32. Install the main lift chain sheaves to the
23. Using the hoist, slide the inner telescopic top of the outer telescopic. Sheaves install
the entire length of the outer tele, checking with a large pin and a retaining screw on
for binding. Add or remove shims as the front. See Figure 7-287.
necessary to maintain a snug but 33. Install but do not tighten a new sleeve and
free-running fit. collar, washer, and mounting bolt through
the telescopic crosstie and into the
1026304B, 15 July 2007 7-253
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7420 (Complete Assembly) Mast, Chain, Hose, Cable
cylinder housing of each main lift cylinder. 45. Install the lower set of roller bearings,
See Figure 7-286. without shims, in the carriage.
34. Rig lifting straps around the upper 46. Using a hoist, carefully lift the carriage
crossties of all three mast sections. and insert it into the inner telescopic until
35. Using a suitable hoist, raise the mast to a the bearings just enter the telescopic.
vertical position. 47. Using a pry bar, move the carriage
36. Rig a lifting strap of one hoist around the bearings to one side.
lower crosstie of the main frame (the one 48. Use spare shim(s) as a gauge to determine
where the overhead guard attaches). the amount of shims required to remove
37. Rig a lifting strap of another hoist around side play.
the top crossties of both inner and outer 49. Remove the carriage from the inner
telescopics. Using the hoist, lower the telescopic far enough to expose the
telescopics to about 10 in. (25 cm) from bearings being shimmed.
the floor. 50. Remove the bearings being shimmed from
38. Make sure the two holes in the upper the carriage. Install one half of the total
chain anchor block are towards the shim thickness required to each roller
outside. Feed the main lift chain from the bearing.
outside to the inside over the chain 51. Using the hoist, reinsert the carriage into
sheave. the inner telescopic. Check for tight areas
39. Feed the upper chain anchor block down while moving the carriage to the bottom of
between the main frame and outer the inner telescopic.
telescopic until holes are aligned between 52. Remove the carriage from the inner
block and main frame. Insert the chain telescopic far enough to expose the
anchor bolt (without the access cover) and bearings being shimmed.
lightly tighten the bolt to draw the chain
anchor block to the main frame. 53. Remove the bearings being shimmed from
the carriage.
40. Thread a bolt into the hole in the chain
anchor retaining pin. Insert the pin and NOTE: You might need to remove the carriage
drive it in. Remove the bolt from the pin. several times to obtain the correct fit.
41. Remove the chain anchor bolt. Apply 54. Install the center set of roller bearings,
thread-locking compound (P/N 990-544) without shims, in the carriage.
to bolt threads. Install access cover and 55. Repeat steps 47 through 53 for the center
torque bolt to 130 ft. lb. (174 Nm). set of bearings.
42. Lower the telescopics into the main frame 56. Install the upper set of roller bearings,
approx. 3 in. (7.5 cm) from the floor. without shims, in the carriage.
43. Insert chain anchor bolts into chain 57. Repeat steps 47 through 53 for the upper
anchor blocks. Lower the telescopics set of bearings.
completely. Tighten the chain anchor nuts
until the inner telescopic is 3/8 in. off of
the outer telescopic. Carriage, Free Lift Cylinder, and
Hose/Cable Installation
Shimming Carriage to Inner 58. Drape the free lift chains forward over the
Telescopic carriage back rest. Rig lifting straps
around the carriage. Using a hoist,
44. Drape the free lift chains forward over the carefully lift the carriage and insert it into
carriage back rest. Rig lifting straps the inner telescopic and lower the carriage
around the carriage. to about 3 in. (7.5 cm) above the floor.
7-254 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7420 (Complete Assembly)
59. Route lift hose and cable around upper Raymond Service Bulletin RCH-05-018
pulleys. See Figure 7-292. dated 30 August 2005.
60. Route auxiliary hoses around lower
pulleys. See Figure 7-292.
Torque to 130 ft. lb. (174 Nm)
Cable
Main Lift
Aux Lift
Torque to 43 ft. lb. (58 Nm)
71045742_D2.CGM
Figure 7-292. Over-the-Mast Hose/Cable Pulleys
(newer style)
61. Install carriage stops at top of inner
telescopic. Apply thread-locking
compound (P/N 990-536) to mounting
bolts and torque to 35 ft. lb. (47.5 Nm).
62. Lift each free lift cylinder into place over
the mounting stud at the top and the pin
at the bottom. See Figure 7-283 on
page 7-249.
63. Reference Figure 7-293 for the following
steps, which route the hoses/cable.
NOTE: Lift trucks below s/n 03069 require
rerouting of the over-the-mast cable and
hoses and/or modification. See
U-Clamp
71066854_B2.CGM
Figure 7-293. Over-the-Mast Hose and Cable Installation
1026304B, 15 July 2007 7-255
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7420 (Complete Assembly) Mast, Chain, Hose, Cable
64. Connect supply hose and crossover tubing 66. Feed hydraulic hoses and electrical cable
to free lift cylinders. See Figure 7-294. through the free lift pulleys, from tractor
side to forks side. See Figure 7-296.
Aux Hoses Electrical Cable
Supply Hose
Crossover Tubing
71066854_B9.CGM
Figure 7-294. Free Lift Cylinder Hose Connection
65. Attach and tighten the hose retainer
bracket at the bottom of the free lift
cylinder. See Figure 7-295.
71066854_B3.CGM
Figure 7-296. OTM Hoses and Cable at Free Lift Pulley
67. Attach and tighten the hose retaining
clamp on the carriage near the bottom of
the left side free lift cylinder. See
Figure 7-282 on page 7-248.
68. Replace cable ties on hose clamps on left
side free lift cylinder.
69. Feed the over-the-mast (OTM) electrical
cable through the U-clamp on the right
side free lift cylinder. See Figure 7-293 on
page 7-255.
70. Attach and tighten the hose retaining
clamp near top of the left side free lift
cylinder.
71066854_B4.CGM See Figure 7-280 on page 7-248.
Figure 7-295. Lower Hose/Cable Retainer, Free Lift
Cylinder 71. Feed the free lift chains over free lift
pulleys, from forks side to tractor side.
Install master links to attach the free lift
chains to the chain anchor blocks.
72. Take slack out of hoses and cable.
73. Lower the carriage all the way to the floor.
74. Tighten the upper and lower hose clamps
on the free cylinders.
7-256 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7420 (Complete Assembly)
75. With the auxiliary manifold removed from 87. Feed the mast switch harness into the
the carriage, connect auxiliary hydraulic tractor near the lift pump. Connect
hoses to the manifold, making sure to connector JPS4.
observe correct labeling. 88. Connect the ambient temperature sensor
76. Attach the manifold to the carriage. Apply cable connector JPA on the tractor deck.
thread-locking compound (P/N 990-536) 89. Connect the right side main lift hose to the
to the mounting bolt threads and torque to fitting on the tractor bulkhead.
21 ft. lb. (29 Nm).
90. Secure a hoist strap around the overhead
77. Connect the over-the-mast cable wires to guard or position a lift truck with pallet
the terminal block on the auxiliary under the overhead guard. Lift the guard
manifold cover. Attach the manifold cover into position at the lower crosstie of the
to the carriage. Apply thread-locking main frame.
compound (P/N 990-536) to the mounting
bolt threads and torque to 30 ft. lb. 91. Apply thread-locking compound
(42 Nm). (P/N 990-536) to the mounting bolt
threads. Install mounting bolts and torque
to 130 ft. lb. (174 Nm).
Mating Tractor to Mast 92. Install the mast guard.
78. Position the tractor about 10 in. (25 cm) 93. Using a suitable battery moving device,
from the mast. Place blocks under the install the battery. Install battery gates.
tractor near the mast to match the bolt
94. Attach front covers and top cover.
hole height in tractor and mast.
95. Make sure all hoist straps and blocks are
79. With the mast secured by a hoist, use a lift
removed.
truck to mate the tractor to the mast.
96. Reconnect the battery connector and turn
80. Apply thread-locking primer
the key switch ON.
(P/N 990-666) to mast mounting bolt
threads and hole threads. Permit to dry for 97. Bleed the hydraulic system. See
several minutes. “Hydraulic System Bleeding” on
page 7-134.
81. Apply thread-locking compound
(P/N 990-544) to threads of mast 98. Test all lift truck functions.
mounting bolts. 99. Elevate the inner telescopic about 12 in.
82. From the battery compartment thread (30 cm). Torque the main cylinder top
eight mounting bolts and washers through mounting bolts. Tighten main lift cylinder
bottom of the tractor frame into the mast. L-bracket mounting bolts to 55 ft. lb.
Thread four mounting bolts and washers (74.5 Nm).
through the top of the tractor frame into 100. Using a work basket and lift truck, grease
the mast. Torque to 165 ft. lb. (224 the channels of all sections of the mast.
Nm)bolts.
83. Connect the main lift hose fitting at the left
side of the tractor.
84. Route the auxiliary hoses and electrical
cable through the tractor opening.
85. Connect auxiliary hoses A1 and A2 at the
main manifold, observing labels.
86. Connect over-the-mast cable connector
JPS3 on the tractor deck. See
Figure 7-233.
1026304B, 15 July 2007 7-257
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7440 (Complete Disassembly) Mast, Chain, Hose, Cable
Mast, Model 7440 needed for correct reassembly. Feed hoses
through opening in tractor bulkhead.
(Complete Disassembly)
Series CA/FA (AC lift) Make sure the weight of the mast is fully
supported by the hoist and the tractor is
Separation of Tractor and Mast blocked where it meets the mast before
loosening the mast mounting bolts.
11. Place blocks snugly under the tractor near
the mast.
• Do this procedure with a minimum 12. Attach a lifting strap around the top
of two technicians in a shop crossties of all three mast sections. Draw
equipped with a suitable hoist. tight with hoist. Make sure the weight of
• Do not permit observers to stand the mast is supported by the hoist.
nearby.
13. Remove the battery connector bracket to
• Wear gloves, safety glasses, permit access to the top right mast
steel-toed safety boots, and a safety mounting bolts.
helmet (hard hat).
14. Use an impact wrench to remove the mast
1. Lower and retract the fork carriage
mounting bolts inside the battery
completely.
compartment, four on the top, eight on the
2. Turn the key switch OFF and disconnect bottom.
the battery connector. Remove battery 15. Using a lift truck, carefully separate the
gates. Using a suitable battery removal tractor about 6 inches (15 cm).
device, remove the battery.
3. Remove the top cover and the left and right 16. Reinstall mast mounting bolts and
front covers. washers and tighten lightly (to prevent
misplacing them).
4. Remove the mast guard.
5. Remove or disconnect any options
mounted on the overhead guard. Secure a Hose/Cable, Free Lift Cylinder,
hoist strap around the overhead guard. and Carriage Removal
Take the weight off the guard. Remove
mounting bolts. Remove the guard. 17. Remove the auxiliary manifold cover from
the carriage. See Figure 7-297 on
6. Disconnect and cap the left end of the page 7-259.
right side main lift hose at the tractor
bulkhead fittings. 18. Disconnect the wires of the over-the-mast
cable from the terminal strip, labeling as
7. If so equipped, disconnect the ambient needed for reconnection.
temperature sensor connector JPA and
19. On the standard reach carriage, remove
HTI connector JP13 on the tractor deck.
auxiliary manifold mounting screws to
8. Disconnect the mast switch connector permit access to the over-the-mast hose
JPS4 (near the lift pump) and the encoder fittings at the manifold.
connector JPS11. Feed harness through
tractor opening. NOTE: There may be shims between the
manifold and carriage.
9. Disconnect over-the-mast cable connector
JPS3 on the tractor deck.
10. Disconnect and plug hydraulic hoses A1
and A2 at the main manifold, labeling as
7-258 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7440 (Complete Disassembly)
32. Remove top mounting hardware from each
of the free lift cylinders. Lift each free lift
cylinder off the mounting pin at the
bottom and past the mounting pin at the
bottom top.
33. Remove carriage stops at the top of the
inner telescopic.
34. Remove the forks.
35. Rig lifting straps around the carriage.
Using a hoist, carefully lift the carriage out
of the inner telescopic and lower the
carriage to the floor.
Main Lift Chain Removal
7DSC_942A.JPG
Figure 7-297. Auxiliary Manifold Access
36. Rig a lifting strap of one hoist around the
lower crosstie of the main frame (the one
20. Disconnect and plug/cap the where the overhead guard attaches).
over-the-mast hoses and fittings at the 37. Rig a lifting strap of another hoist around
auxiliary manifold. Label as needed to the top crossties of both inner and outer
assure correct reconnection. telescopics. Using the hoist, raise the
21. Jack carriage up about 3 in. (7.5 cm) to telescopics about 10 in. (25 cm).
provide slack in the free lift chains. 38. Remove master links from the upper
Remove master links on free lift chains. (adjustable) chain anchors. See
Feed free lift chains through pulleys and Figure 7-298.
drape over front of carriage.
22. Remove or loosen hose/cable retaining
Master
clamps on back of carriage.
Link
23. Remove or loosen the upper clamp from
left free lift cylinder.
24. Remove hose/cable ties from the free lift
cylinders.
25. Separate and block the telescopics to
provide slack in the OTM lift hose.
26. Remove the OTM hose/cable retainers
Chain
from the bottom of the inner telescopic. Anchor
27. Disconnect and cap/plug the main lift
hose at the left side free lift cylinder.
7R1051602_C2A.CGM
28. Remove the OTM hose/cable retainers Figure 7-298. Main Lift Chain Upper Chain Anchor
from the mast crosstie and left main lift
cylinder. 39. It will be easier to remove the lift chain if
you separate telescopics first.
29. Remove the OTM hoses and cable from the
mast.
30. Feed hoses and cable through free lift Separation of Telescopics
cylinder pulleys. 40. Using the hoists, carefully lower the mast
31. Remove connecting hose from free lift to a horizontal position on jack stands.
cylinders.
1026304B, 15 July 2007 7-259
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7440 (Complete Disassembly) Mast, Chain, Hose, Cable
41. Loosen the L-bracket bolts holding the 44. Remove anti-rattle pads and shims from
main lift cylinders to the telescopic. bottom of outer telescopic. See
42. Remove the top mounting bolt, washer, Figure 7-301.
and sleeve holding the main lift cylinder to
the outer telescopic. See Figure 7-299.
Shim
Mounting Bolt
Washer
Sleeve
Outer Anti-Rattle Pad Cover
Telescopic
7R1020561_A4.CGM
Figure 7-301. Outer Telescopic Lower Bearing and
Anti-Rattle Pads
71020561_A2.CGM
Figure 7-299. Main Lift Cylinder Mounting Hardware
45. Remove anti-rattle pads and shims from
bottom of inner telescopic. See
43. Remove main lift chain sheaves from top of
outer telescopic. See Figure 7-300. Figure 7-302.
46. Using a suitable hoist, pull the inner
telescopic halfway out of the outer
Bearing Sheave telescopic. Keep tension on the main lift
chains while pulling the inner telescopic.
47. Remove the main lift chains at the lower
chain anchor. See Figure 7-302.
Master
Link
Snap Ring
Chain
Anchor
Shim
Stud
Bearing
71051602_C9.CGMs
Figure 7-300. Main LIft Chain Sheave
Anti-Rattle Pad
71051602_C8.CGM
Figure 7-302. Main LIft Chain Lower Chain Anchor and
Inner Telescopic Lower Roller Bearing
7-260 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7440 (Complete Disassembly)
48. Remove the upper roller bearings and
shims from the top of the outer telescopic.
See Figure 7-303. Bolt
Stud
Bearing
Stud Shim Bearing
Retaining Screw
Shim
and Washer
71051602_C9.CGM
Figure 7-303. Outer Telescopic Upper Bearing
49. Remove the lower roller bearings and
shims from the bottom of the inner
telescopic. See Figure 7-302.
50. Using a suitable hoist, remove the inner
telescopic from the outer telescopic.
51. Using a suitable hoist, pull the outer Stop Block
telescopic halfway out of the main frame.
71051602_C6.CGM
52. Disconnect the height encoder belt at the Figure 7-304. Main Frame Upper Bearing
top of the outer telescopic. See “Height
Encoder Belt” on page 7-216. 56. Pull the telescopic until the lower stop
access cutouts align with the stop blocks
53. Remove the height encoder from the main
mounted to the main frame. Remove the
frame.
stop blocks on the main frame. See
54. Reconnect the encoder belt at the Figure 7-304.
telescopic.
57. Remove the lower roller bearings and
55. Remove the upper roller bearings and shims from the outer telescopic. See
shims from the main frame. See Figure 7-301.
Figure 7-304. 58. Using a suitable hoist, remove the outer
telescopic from the main frame.
1026304B, 15 July 2007 7-261
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7440 (Complete Assembly) Mast, Chain, Hose, Cable
Mast, Model 7440 prevent the bearing from walking on the
stud shaft. See Figure 7-291.
(Complete Assembly)
Assembling and Shimming
Outer Telescopic to Main Frame
Lower Bearings of Outer Telescopic
1. Begin the assembly with the main frame
positioned horizontally on jack stands.
2. Attach both ends of the height encoder
belt to the mast.
3. Attach the lower roller bearing to one side
of the outer telescopic. Make sure the flat
spot on the bearing outer stud is correctly
7R1022231_A.CGM
positioned against the mast. This is Figure 7-305. Inner Race
important because the correct bearing
alignment is canted with respect to the
10. Using the hoist, slide the outer telescopic
channel. See Figure 7-301.
the entire length of the main frame,
4. Using a suitable hoist, insert the outer checking for binding. The tightest spots
telescopic into the main frame as far as will generally be at the crossties. Add or
the crosstie. remove shims as necessary to maintain a
5. Attach the lower roller bearing to the other snug but free-running fit.
side of the outer telescopic. 11. Align mast stop cutouts on the outer
6. Using a pry bar, move the outer telescopic telescopic with the stop locations on the
and bearing to one side. mainframe. Install mast stops on the main
frame,
7. Use spare shims as a gauge to determine
the amount of shims required to cause the
roller bearing to contact the main frame. Upper Bearings of Main Frame
8. Remove both lower bearings. Install one 12. With the outer telescopic inserted halfway
half of the total shim thickness required to into the main frame, attach the upper
each roller bearing. Reinstall the bearings. roller bearing to one side of the main
Apply thread-locking compound frame. Make sure the flat spot on the
(P/N 990-536) to the bearing mounting bearing outer stud is correctly positioned
bolt and torque to 260 ft. lb. (352 Nm). against the mast. See Figure 7-304.
9. If the inner race of the bearing does not 13. Attach but do not tighten the upper roller
protrude past the end of the bearing stud bearing to the other side of the main
when the bearing is fully seated, bend the frame.
flat washer to contact the bearing to
14. Use spare shims as a gauge to determine
the amount of shims required to cause the
roller bearing to contact the outer
telescopic.
15. Remove both upper bearings. Install one
half of the total shim thickness required to
each roller bearing. Reinstall the bearings.
Apply thread-locking compound
7-262 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7440 (Complete Assembly)
(P/N 990-536) to the bearing mounting prevent the bearing from walking on the
bolt and torque to 260 ft. lb. (352 Nm). stud shaft. See Figure 7-305.
16. If the inner race of the bearing does not 26. Using the hoist, slide the inner telescopic
protrude past the end of the bearing stud the entire length of the outer tele, checking
when the bearing is fully seated, bend the for binding. Add or remove shims as
flat washer to contact the bearing to necessary to maintain a snug but
prevent the bearing from walking on the free-running fit.
stud shaft. See Figure 7-305. 27. When the lower mast bearing shimming is
17. Using the hoist, slide the outer telescopic complete, attach the main lift chains to the
the entire length of the main frame, lower chain anchors. Keep tension on the
checking for binding. Add or remove shims chains as the inner telescopic is inserted
as necessary to maintain a snug but into the outer telescopic.
free-running fit.
18. When the upper mast bearing shimming is Upper Bearings of Outer Telescopic
complete, reinstall the height encoder.
28. With the inner telescopic inserted halfway
into the main frame, attach the upper
Assembling and Shimming roller bearing to one side of the outer tele.
Inner Telescopic to Outer Make sure the flat spot on the bearing
Telescopic outer stud is correctly positioned against
the mast. See Figure 7-303.
Lower Bearings of Inner Telescopic 29. Attach but do not tighten the upper roller
bearing to the other side of the outer
19. Attach the lower roller bearing to one side telescopic.
of the inner telescopic. Make sure the flat 30. Use spare shims as a gauge to determine
spot on the bearing outer stud is correctly the amount of shims required to cause the
positioned against the mast. See roller bearing to contact the inner
Figure 7-302. telescopic.
20. Using a suitable hoist, insert the inner 31. Remove both upper bearings. Install one
telescopic into the outer telescopic as far half of the total shim thickness required to
as the crosstie. each roller bearing. Reinstall the bearings.
21. Attach the lower roller bearing to the other Apply thread-locking compound
side of the inner telescopic. (P/N 990-536) to the bearing mounting
22. Using a pry bar, move the inner telescopic bolt and torque to 260 ft. lb. (352 Nm).
and bearing to one side. 32. If the inner race of the bearing does not
23. Use spare shims as a gauge to determine protrude past the end of the bearing stud
the amount of shims required to cause the when the bearing is fully seated, bend the
roller bearing to contact the outer tele. flat washer to contact the bearing to
prevent the bearing from walking on the
24. Remove both lower bearings. Install one stud shaft. See Figure 7-305.
half of the total shim thickness required to
each roller bearing. Reinstall the bearings. 33. Using the hoist, slide the inner telescopic
Apply thread-locking compound the entire length of the outer telescopic,
(P/N 990-536) to the bearing mounting checking for binding. Add or remove shims
bolt and torque to 260 ft. lb. (352 Nm). as necessary to maintain a snug but
free-running fit.
25. If the inner race of the bearing does not
protrude past the end of the bearing stud
when the bearing is fully seated, bend the Main Lift Chain Installation
flat washer to contact the bearing to
34. Install anti-rattle pads and shims at
bottom of inner and outer telescopics.
1026304B, 15 July 2007 7-263
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7440 (Complete Assembly) Mast, Chain, Hose, Cable
Shim so pads are snug against mast. See 48. Remove the bearings being shimmed from
Figure 7-301 and Figure 7-302. the carriage. Install one half of the total
35. Install the main lift chain sheaves to the shim thickness required to each roller
top of the outer telescopic. See bearing.
Figure 7-300. 49. Using the hoist, reinsert the carriage into
36. Install a new sleeve and collar, washer, the inner telescopic. Check for tight areas
and mounting bolt through the telescopic while moving the carriage to the bottom of
crosstie and into the cylinder housing of the inner telescopic.
each main lift cylinder. Apply 50. Remove the carriage from the inner
thread-locking compound (P/N 1013829) telescopic far enough to expose the
to the threads of the bolt and leave a 0.12 bearings being shimmed.
inch (3 mm) gap between the bolt head 51. Remove the bearings being shimmed from
and washer. (See Figure 7-299.) the carriage.
37. Rig lifting straps around the upper
NOTE: The carriage may have to be removed
crossties of all three mast sections.
several times to obtain the correct fit.
38. Using a suitable hoist, raise the mast to a
vertical position. 52. Install the center set of roller bearings,
without shims, in the carriage.
39. Rig a lifting strap of one hoist around the
lower crosstie of the main frame (the one 53. Repeat steps 45 through 51 for the center
where the overhead guard attaches). set of bearings.
40. Lower the telescopics into the main frame 54. Install the upper set of roller bearings,
approx. 3 in. (7.5 cm) from the floor. without shims, in the carriage.
41. Insert chain anchor bolts into chain 55. Repeat steps 45 through 51 for the upper
anchor blocks. Lower the telescopics set of bearings.
completely. Tighten the chain anchor nuts
until the inner telescopic is 3/8 in. off of Carriage, Free Lift Cylinder, and
the outer telescopic at the upper crossties. Hose/Cable Installation
56. Drape the free lift chains forward over the
Shimming Carriage to Inner carriage back rest. Rig lifting straps
Telescopic around the carriage. Using a hoist,
42. Drape the free lift chains forward over the carefully lift the carriage and insert it into
carriage back rest. Rig lifting straps the inner telescopic and lower the carriage
around the carriage. to about 3 in. (7.5 cm) above the floor.
43. Install the lower set of roller bearings, 57. Attach the manifold block at the bottom of
without shims, in the carriage. the mast between the main and free lift
cylinders. Apply thread-locking compound
44. Using a hoist, carefully lift the carriage (P/N 990-536) to bolt threads and torque
and insert it into the inner telescopic until to 15 ft. lb. (21 Nm).
the bearings just enter the telescopic.
58. Connect the tee tubing for the main lift
45. Using a pry bar, move the carriage cylinders.
bearings to one side.
46. Use spare shim(s) as a gauge to determine
the amount of shims required to remove
side play.
47. Remove the carriage from the inner
telescopic far enough to expose the
bearings being shimmed.
7-264 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7440 (Complete Assembly)
59. Route cable and hoses around upper 63. Reference Figure 7-307 for the following
pulleys. steps, which route the hoses/cable.
71051959_B9.CGM
Figure 7-306. Over-the-Mast Hose/Cable Pulleys
60. Install carriage stops at top of inner
telescopic. Apply thread-locking
compound (P/N 990-536) to mounting
bolts and torque to 35 ft. lb. (47.5 Nm).
61. Lift each free lift cylinder into place over
the mounting pin at the bottom and the
mounting pin at the top.
62. Attach the lift hose to the free lift cylinder.
71051959_B2.CGM
Figure 7-307. Over-the-Mast Hose and Cable Installation
1026304B, 15 July 2007 7-265
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7440 (Complete Assembly) Mast, Chain, Hose, Cable
64. Connect hose to free lift cylinders. See 66. Position the hoses and cable into their
Figure 7-308. clamps at the back of the carriage and
tighten. See Figure 7-309.
Standard Carriage
71067160_C1.CGM
Figure 7-308. Free Lift Cylinder Hose Connection
65. Attach the OTM hoses to the reach
manifold and the OTM cable to the
carriage terminal strip.
Deep-Reach ® Carriage
71051959_B13.cgm 1051959_B14.CGM
Figure 7-309. Carriage Hose Routing
7-266 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7440 (Complete Assembly)
67. Feed OTM hoses and cable through free lift 82. Set the tension on the cable spring by
cylinder pulleys. sliding the cable grip to produce a spring
68. Position hoses in the retaining clamp at length of 1.75 ± 0.12 inch (44.5 ± 3.0 mm).
the top of the left free lift cylinder. See 83. Feed cable and hoses through remaining
Figure 7-310 on page 7-268. Remove all retainers. Remove all slack and tighten.
slack. 84. Feed the free lift chains over free lift
69. Find the correct L5 value from Table 7-24 pulleys, from forks side to tractor side.
on page 7-268. Measure and mark hoses Install master links to attach the free lift
above the clamp, using the L5 value. L5 chains to the chain anchor blocks.
equals the length the hoses are to be
stretched over the free lift cylinder.
70. Reconnect the battery connector and turn
the key switch ON.
71. Place block under carriage and lower
carriage to relieve tension on hoses.
72. Pull down on the hoses until marks are
flush with top of retainers.
73. Set the tension on the cable spring at the
top of the right free lift cylinder by sliding
the cable grip to produce a spring length of
1.75 ± 0.12 inch (44.5 ± 3.0 mm).
74. Route hoses and cable down free lift
cylinders. Remove slack. Fasten hoses and
cable to cylinders with cable ties.
75. Fasten the cable to the free lift cylinder
connecting tube and position cable into
retainers at the bottom of the inner
telescopic.
76. Position hoses into the retainers at the
bottom of the inner telescopic. Remove all
slack and tighten the retainers.
77. Route and feed the hoses and cable
through the pulley assembly at the top of
the telescopic.
78. Feed the hoses and cable through the
retainer at the main frame crosstie. See
Figure 7-310 on page 7-268. Remove all
slack.
79. Find the correct L4 values from Table 7-24
on page 7-268. Measure and mark hoses
above the retainer.
80. Block between the telescopics to provide
slack in the hoses.
81. Pull down on the hoses until marks are
flush with top of retainers.
1026304B, 15 July 2007 7-267
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7440 (Complete Assembly) Mast, Chain, Hose, Cable
L4
L5
71051959_B2.cgm 1051959_B3.CGM
Figure 7-310. Over-the-Mast Hose/Cable Retainer Locations (Model 7440)
Table 7-24. Over-the-Mast Hose stretching values (Model 7440)
L4 (Lift and Aux Hoses) L5 (Aux Hoses)
OACH in. mm OACH in. mm
142 to 147 2.75 69.9 142 to 158 1.50 38.1
148 to 154 3.00 76.2
155 to 163 3.25 82.6 159 to 184 1.75 44.5
164 to 171 3.50 88.9
172 to 180 3.75 95.3
181 to 184 4.00 101.6
7-268 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Mast, Chain, Hose, Cable Mast, Model 7440 (Complete Assembly)
threads. Install mounting bolts and torque
to 130 ft. lb. (174 Nm).
Mating Tractor to Mast
100. Install the mast guard.
85. Position the tractor about 10 in. (25 cm) 101. Using a suitable battery moving device,
from the mast. Place blocks under the install the battery. Install battery gates.
tractor near the mast to match the bolt
hole height in tractor and mast. 102. Attach front covers and top cover.
86. With the mast secured by a hoist, use a lift 103. Make sure all hoist straps and blocks are
truck to mate the tractor to the mast. removed.
87. Apply thread-locking primer 104. Reconnect the battery connector and turn
(P/N 990-666) to mast mounting bolt the key switch ON.
threads and hole threads. Permit to dry for 105. Bleed the hydraulic system. See
several minutes. “Hydraulic System Bleeding” on
88. Apply thread-locking compound page 7-134.
(P/N 990-544) to threads of mast 106. Test all lift truck functions.
mounting bolts. 107. Apply thread-locking compound and
89. From the battery compartment thread tighten main lift cylinder L-bracket
eight mounting bolts and washers through mounting bolts to 55 ft. lb. (74.5 Nm).
bottom of the tractor frame into the mast. 108. Using a work basket and lift truck, grease
Thread four mounting bolts and washers the channels of all sections of the mast.
through the top of the tractor frame into
the mast. Torque to 165 ft. lb. (224
Nm)bolts.
90. Connect the main lift hose fitting at the left
side of the tractor.
91. Install the battery connector bracket.
92. Connect auxiliary hoses A1 and A2 at the
main manifold, observing labels.
93. Connect over-the-mast cable connector
JPS3 on the tractor deck. See
Figure 7-233.
94. Feed the mast switch harness into the
tractor, across the top of the deck to the
right side near the lift pump. Connect
connector JPS4.
95. Connect the ambient temperature sensor
cable connector JPA on the tractor deck.
96. Connect HTI encoder to JP13 and JPS11.
97. Connect the right side main lift hose to the
fitting on the tractor bulkhead.
98. Secure a hoist strap around the overhead
guard or position a lift truck with pallet
under the overhead guard. Lift the guard
into position at the lower crosstie of the
main frame.
99. Apply thread-locking compound
(P/N 990-536) to the mounting bolt
1026304B, 15 July 2007 7-269
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Mast, Model 7440 (Complete Assembly) Mast, Chain, Hose, Cable
7-270 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Software Configuration
Software Configuration
Section 7. Component Procedures
Overview PC Connection to Lift Truck
The program allows you to update software and
configure options of the lift truck.
Vehicle
Manager
• Flash memory program
• Blank primary memory
• Set factory defaults
• Configure options
Requirements
FlashWare can be installed on an
IBM-compatible PC. The PC communicates with
the lift truck software through a 9-pin serial
cable.
Use surge protector (P/N 154-010-801)
to protect your PC from possible
77404_004.TIF
electrostatic discharge or voltage surge. Figure 7-311. Vehicle Manager location
1. Turn the lift truck key switch OFF.
Installation to PC
2. Connect the surge protector to the COM 1
If you are a customer service technician, obtain or COM 2 port of your computer.
FlashWare from your Raymond dealer.
If you are a Raymond dealer technician, obtain
FlashWare from the iNet software download Use surge protector (P/N 154-010-801)
site. to protect your PC from possible
electrostatic discharge or voltage surge.
To install FlashWare on the PC, double-click the
installation file and follow the instructions on 3. Connect a standard 9-pin serial cable to
the screen. the surge protector.
4. Remove the right side cover of the lift
truck.
5. Connect the cable to connector JC9 on the
Vehicle Manager. See Figure 6-2 on
page 6-116.
6. Turn the key switch ON.
1026304B, 15 July 2007 7-271
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Software Configuration
Matching Software Versions FlashWare Items
Model 7400 requires matching sets of Vehicle The following items are available for Model
Manager (VM) and Display Manager (DM) 7400/7420/7440 FlashWare. Items in italics
software. Matching VM and DM versions may or may require a passkey code from an authorized
not have the same version number. Raymond dealer.
• Electronic Key
To make sure you install matching software,
• Sideshift
follow these steps:
• Second Mast Speed Limit
1. Download and install the latest FlashWare
application package from the iNet to your • Unnested Speed Switch
PC. • Travel Alarm
2. Using the FlashWare application, load to • OACH
the PC the latest Software Model Table, if
• Extended Height
one was provided in the package.
• Deadman Lockout
3. Open the Software Model Table: Click on
Help and select “View Software Model • Lift Limit with Bypass
Number Table” from the dropdown menu. • Secondary Control Handle
4. Compare the software versions listed in • Embedded Statistics (VM Ver 2.2+)
the table with the versions in the truck. To • Bump Detector
display software versions in the truck, see
• Height Indicator
“Version” under “Program Mode Menus” on
page 6-9. • Height-Tilt Indicator
5. Load to FlashWare and install software to • High Performance Traction
the truck as needed to make sure a • Ambient Temperature Sensor
matching set of VM/DM software is
• Security Start Switch
installed.
• Reverse Steering
• Electric Steer Type
• High Speed Travel Speed Limit Switch
(VM Ver 2.1+)
• Ext Access Enable (VM Ver 2.5+)
• OCSS
• Vantage Point (VM Ver 2.6+)
• Vertical Hold (VM Ver 4.3+)
• Weight-Height Limit Display (VM Ver 3.7+)
• Traction Motor (Danaher or Sauer
Danfoss) (VM Ver 3.7+)
7-272 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Options
Options
Section 7. Component Procedures
1026304B, 15 July 2007 7-273
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Options Component Procedures Summary Options
Options Component
Procedures Summary
Table 7-25. Options Component Procedures Summary
Procedure/ Thread-Locking
Component Photo or Compound/ Helpful Hints
Drawing Torque Values
Operator Procedures:
Compartment page 7-275 See Procedure
Sensor System
Vantage Point Procedures:
See Procedure
page 7-294
7-274 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Options Operator Compartment Sensor System
Operator Compartment • Kit P/N 1054736/001 is used for Model
7400 Series DA, EA (side stance, DC lift).
Sensor System • Kit P/N 1054736/002 is used for Model
7400 Series FA (side stance, AC lift).
This section provides installation and
maintenance instructions for the Raymond Component Identification
Operator Compartment Sensor Systems (OCSS)
designed for Model 7400 Reach-Fork ® lift truck Refer to Table 7-26, “Part Numbers by Tractor
applications. Series,” on page 7-275 and Table 7-27, “Kit
Component photos,” on page 7-277 for item
There are four different kits available: numbers [Item X] referenced in the installation
• Kit P/N 1054735/001 is used for Model procedure.
7400 Series AA, BA (fore-aft stance, DC
lift). Table 2 includes all parts contained in all four
kits. Some parts will not be included in all kits.
• Kit P/N 1054735/002 is used for Model
See Table 1 for a list of parts by kit number.
7400 Series CA (fore-aft stance, AC lift).
Table 7-26. Part Numbers by Tractor Series
Note: (Item No. refers to Table 7-27, “Kit Component photos,” on page 7-277)
Series AA/BA Series CA Series DA/EA Series FA
Item
Component Fore-Aft Fore-Aft Side Stance Side Stance
No.
DC Lift AC Lift DC Lift AC Lift
Hardware Kit Part Number 1054735/001 1054735/002 1054736/001 1054736/002
Cable Tie (Qty 15) 9 611-029 611-029 611-029 611-029
Cable Tie (Qty 5) 9 611-028 611-028 611-028 611-028
Cable Tie Anchor, 10 611-044 611-044 611-044 611-044
Adhesive-Backed (Qty 6)
Capture Plate, Harness 31 1043472 1043472 1049088 1049088
Circuit Card, CAN I/O 25 1031429/003 1031429/003 1031429/003 1031429/003
Expander Module
Counterweight 4 N/A N/A 1053563 1053563
Cover, Sensor, Left-Hand 21, 1041601 1041601 1048702 1048702
22
Cover, Sensor, Right-Hand 23, 1041602 1041602 1048703 1048703
24
Drill Template, Left-Hand 1 N/A N/A 1055507 1055507
Drill Template, Right-Hand 2 N/A N/A 1055508 1055508
Fastener, Reclosable, 26 811-861/006 811-861/006 811-861/006 811-861/006
Mushroom Cap
Fastener, Reclosable, 27 811-861/016 811-861/016 811-861/016 811-861/016
Mushroom Cap
Gasket (Qty 4) 20 1037771 1037771 1037771 1037771
1026304B, 15 July 2007 7-275
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Operator Compartment Sensor System Options
Table 7-26. Part Numbers by Tractor Series
Note: (Item No. refers to Table 7-27, “Kit Component photos,” on page 7-277)
Series AA/BA Series CA Series DA/EA Series FA
Item
Component Fore-Aft Fore-Aft Side Stance Side Stance
No.
DC Lift AC Lift DC Lift AC Lift
Harness, Field Upgrade 29 1053217/001 1053217/002 1053217/003 1053217/004
JT1/JD1/JX1
Harness, Sensor to Module 30 1053362/002 1053362/002 1053362/001 1053362/001
JCS1/JCS2/JCS3/JX2
Housing, Sensor, Left-Hand 5, 6 1056330 1056330 1056373 1056373
Housing, Sensor, 7, 8 1056371 1056371 1056372 1056372
Right-Hand
Nut (Qty 2) 19 N/A N/A 5-015-007 5-015-007
Operator Manual Insert 32 1055571A or 1055571A or 1055571A or 1055571A or
Sheet or Manual 1028087B 1028087B 1028087B 1028087B
Screw (Qty 2) 14 N/A N/A 5-003-013 5-003-013
Screw, Sensor Housing 15 N/A N/A 5-001-024 5-001-024
(Qty 4)
Screw, Sensor Cover (Qty 6) 16 5-004-014 5-004-014 5-004-014 5-004-014
Sensors with Harness, 11 1053471/001 1053471/001 1053471/003 1053471/003
Left-Hand
Sensors with Harness, 11 1053471/002 1053471/002 1053471/004 1053471/004
Right-Hand
Shim-Spacer 12 N/A N/A 1048962 1048962
(Qty 2)
Shim-Spacer 13 N/A N/A 1048961 1048961
(Qty 3)
Stud (Qty 2) 3 N/A N/A 1032297 1032297
Tool, Welding Positioning 28 1041598 1041598 N/A N/A
Washer, Flat 17 N/A N/A 5-018-008 5-018-008
(Qty 6)
Washer, Flat 19 5-018-009 5-018-009 5-018-009 5-018-009
(Qty 2)
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Options Operator Compartment Sensor System
Table 7-27. Kit Component photos
Note: For applications of each item, refer to Table 7-26, “Part Numbers by Tractor Series,” on page 7-275.
Item 1: P/N 1055507 Item 2: P/N 1055508 Item 3: P/N 1032297 Item 4: P/N 1053563
Left Drill Template Right Drill Template Stud (Qty 2) Counterweight
Item 5: P/N 1056330 Item 6: P/N 1056373 Item 7: P/N 1056371 Item 8: P/N 1056372
Housing, Sensor, Housing, Sensor, Housing, Sensor, Housing, Sensor,
Left-Hand, Fore-Aft Left-Hand, Side Stance Right-Hand, Fore-Aft Right-Hand, Side Stance
Item 9: P/Ns 611-028, Item 10: 611-044 Item 11: P/N 1053471/ Item 12: P/N 1048692
611-029 Cable Tie Anchor, Sensors with Harness Shim Spacer (Qty 2)
Cable Tie (Qty 5 and 15) Adhesive-Backed (Qty 6)
1026304B, 15 July 2007 7-277
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Operator Compartment Sensor System Options
Table 7-27. Kit Component photos
Note: For applications of each item, refer to Table 7-26, “Part Numbers by Tractor Series,” on page 7-275.
Item 13: P/N 1048961 Item 14: P/N 5-003-013 Item 15: 5-001-024 Item 16: P/N 5-004-014
Shim Spacer (Qty 3) Screw, Buttonhead Screw, Hex Head Cap Screw, Socket Flat Head
Socket (Qty 2) (Sensor Housing) (Qty 4) (Housing Cover) (Qty 6)
Item 17: P/N 5-018-008 Item 18: P/N 5-015-007 Item 19: 5-018-009 Item 20: P/N 1037771
Washer, Flat Nut Washer, Flat Gasket (Qty 4)
(Sensor Housing) (Qty 6) (Sensor Housing) (Qty 2) (Qty 8)
Item 21: P/N 1041601 Item 22:1048702 Item 23: 1041602 Item 24: P/N 1048703
Cover, Sensor, Left-Hand, Cover, Sensor, Left-Hand, Cover, Sensor, Cover, Sensor,
Fore-Aft Side Stance Right-Hand, Fore-Aft Right-Hand, Side Stance
7-278 1026304B, 15 July 2007
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Options Operator Compartment Sensor System
Table 7-27. Kit Component photos
Note: For applications of each item, refer to Table 7-26, “Part Numbers by Tractor Series,” on page 7-275.
Item 25: P/N Item 26: P/N Item 27: P/N Item 28: P/N 1041598
1031429/003 811-861/006 811-861/016 Tool, Welding Positioning
CAN I/O Expander Fastener, Reclosable, Fastener, Reclosable,
Module Mushroom Cap Mushroom Cap
Lift Truck Operation
Lift Truck Operation
Operator Compartment
Sensor System (Optional)
This truck can be equipped with an optional
Operator Compartment Sensor System.
The system consists of light sensors
spanning the entry to the operator
compartment. The system functions as
follows:
• When the key switch is turned ON at
start up, the truck will not travel if
either light sensor is blocked or
interrupted while requesting travel. To
reset the travel function, the operator
must remove the object blocking the
sensor and return the control handle to
neutral.
• While traveling, the truck will decelerate
to a stop if either light sensor is blocked
or interrupted. Once the sensor has
been blocked or interrupted, the truck
will slow to a stop even if the object
blocking the sensor is removed. If the
beam remains blocked, the truck will
then have limited travel speed by moving
the control handle through neutral. To
resume full travel once the truck comes
to a stop, the operator must remove the
object blocking the sensor and return
the control handle to neutral.
• When the sensor is blocked or
interrupted, an alarm will sound and a
message will be displayed on the
Operator Display.
Publication 1055571A
Item 29: P/N 1053217/ Item 30: P/N 1053362 Item 31: P/N 1043472 Item 32: P/N 1028087B
Harness, JT1/JD1/JX1 Harness, Sensor to Capture Plate, Harness or 1055571A
Module Operator Manual or
Operator Manual Insert
Sheet
Tools Required • Thread-locking compound P/N 1013829
and P/N 990-544
You need the following tools to install the kit: • Degreaser/surface cleaner
• Lift truck jack • Diagonal cutters for trimming cable ties
• Jack stands or solid blocks • Laptop computer with FlashWare, and
• Center punch OCSS software downloaded from iNet
• Hammer
• Drill
Installation on Series
• Drill bits: 1/4, 5/8, and 3/4 in.
AA/BA/CA (Fore-Aft Stance)
• Cutting fluid for lubricating while drilling
Painting Housings
• Deburring tool or file
• Welding equipment (Series AA/BA/CA If the housings are to be painted a different
Fore-Aft only) color, paint them after welding but before
sensor installation to prevent contaminating the
• Assorted open- and box-end wrenches
sensors.
• Assorted hex-head wrenches (standard
and metric)
1026304B, 15 July 2007 7-279
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Operator Compartment Sensor System Options
Position and Jack Up Truck 2. Using the positioning tool, position the
sensor housings on top of the
1. Turn the drive wheel 90 degrees, to permit counterweight. The housings fit to the
maximum access between the drive tire curvature of the tractor frame. Press the
and rear wall of the tractor frame. housings firmly against the frame.
2. Turn the key switch OFF and disconnect 3. Through each housing, center-punch the
the battery connector. tractor frame for the 3/4 in. passage holes.
See Figure 7-313.
Sensor Housings
Use extreme care when the lift truck is
jacked up. Never block the lift truck
between the telescopic and the floor.
Use a suitable hoist to stabilize the mast.
Keep hands and feet clear while jacking
the lift truck. After the lift truck is
jacked, place solid blocks or jack stands
beneath it to support it. Do not rely on
the jack alone to support the lift truck.
Welding
3. Jack up and block the tractor. Once the Positioning Tool
truck is securely resting on blocks, remove
the jack so it does not block access for the
counterweight, housing, or capture plate. Center-Punch Points
See Figure 7-312.
Jack Here No Jack Area 3/4 in. Passage Holes
7TOYRCH_T.EPS
Figure 7-312. Correct Jacking Location
4. Do not remove the counterweight.
Drill Sensor Harness Passage Holes
1. Using the housing cover screws [Item 16], Figure 7-313. Passage Hole Locations
71054735_03.CGM 1054735_04.CGM
mount the welding positioning tool [Item
28] to both left- and right-hand sensor 4. Remove the housings and positioning tool.
housings [Items 5 and 7].
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Options Operator Compartment Sensor System
5. Drill 1/4 in. pilot holes through the tractor 2. Using the flexible mushroom cap
frame for the 3/4 in. passage holes. This reclosable fastener material [Items 26 and
step could require several bits because of 27], attach the CAN I/O Expander Module
the hardness of the tractor frame steel. [Item 25] to the Operator Display bracket
as shown in Figure 7-315.
Do not damage components in the
motor compartment or electronics
compartment when drilling the holes
through the frame.
6. Enlarge the pilot hole in each housing to
3/4 inch.
7. Deburr the holes.
Weld the Sensor Housings
1. Position the sensor housings carefully on
top of the counterweight.
2. Tack weld the sensor housings in place.
3. Remove the housing cover screws and
remove the welding positioning tool.
4. Weld a 0.25 inch bead along the top and
outboard edge of each sensor housing. See
Figure 7-314.
CAN I/O
Expander Module
Welding
71054735_05.CGM
Figure 7-314. Welding Locations
5. If the housings are to be painted a
different color, paint them after welding
but before sensor installation to prevent 71054735_01.CGM 1054735_08.CGM
Figure 7-315. CAN I/O Expander Module Location
contaminating the sensors.
(Fore-Aft)
Install Components 3. If the factory-installed main electrical
harness has a JX1 connector near the
1. Remove top covers and open the motor
CAN I/O Expander Module, connect it to
compartment door.
the module. Skip to step 7.
1026304B, 15 July 2007 7-281
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Operator Compartment Sensor System Options
NOTE: JX1 connectors were included in e. Reconnect connector JPT1 at the TPA.
factory-installed main electrical
harnesses beginning with Series AA/BA
truck serial number 05306 and Series
CA truck serial number 05275.
4. Connect the control harness JX1 [Item 29]
to the CAN I/O Expander Module.
5. Connect the control harness [Item 29] to
the Operator Display.
a. At the Operator Display, disconnect
connector JPD1.
b. Insert the socket for wire JD1-1 into the
back of pin number 1 location in the
Molex connector. Push the wire in until
7_DSC0159.JPG
the socket clicks in the connector. Figure 7-316. AMP Superseal Connectors,
unlocking wedge lock
c. Reconnect connector JPD1 at the
Operator Display.
7. Connect the main sensor harness JX2
6. Connect the control harness [Item 29] to [Item 30] to the CAN I/O Expander
the Traction Power Amplifier (TPA). Module.
a. At the TPA, disconnect connector JPT1. 8. Route the right-side harness branch as
b. On connector JT1, unlock the red shown in Figure 7-317 over and around
wedge lock by prying gently between the Vehicle Manager to the inside of the
the seal and wedge lock tabs. The red tractor wall near the right-side entrance of
wedge lock should slide forward about the operator compartment. Attach with
3/16 inch. See Figure 7-316. cable ties [Item 9] and adhesive-backed
cable tie anchors [Item 10] where shown
c. Insert each of the three control harness with arrows in Figure 7-317.
wires into the correct pin location in the
connector, either pins 8, 15, and 23
(Series CA) or 7, 14, and 22 (Series
AA/BA): From the back side of the
connector, push the wire straight
through the wire seal into the socket
until it clicks. Pull back gently to be
sure the contact is locked in place. Pin
numbers are stamped on the ends of
the connector shell. Reference
schematic Figure A-6 on page A-22.
d. With all wires in place, push the wedge
lock back until it clicks and locks.
71054735_08.CGM
Figure 7-317. Right-Side Harness Installation
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Options Operator Compartment Sensor System
9. Route the left-side harness branch as
shown in Figure 7-318 around the lift
motor, then down into the motor
compartment. Attach with cable ties [Item
9] and adhesive-backed cable tie anchors
[Item 10] to the back wall of the motor
compartment.
71054735_07.CGM
Figure 7-318. Left-Side Harness Installation
10. Remove the deadman pedal assembly.
This is necessary in order to route the
left-side sensor harness.
1026304B, 15 July 2007 7-283
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Operator Compartment Sensor System Options
11. With the truck jacked up, remove two
drive unit mounting nuts and washers as
shown in Figure 7-319.
Drive Unit
Mounting Bolt
Harness
Capture Plate
Washer
Nut
71054735_06.CGM
Figure 7-319. Mounting Capture Plate under Drive Unit
12. Mount the harness capture plate [Item pockets of the housing. The wires are
31], using the drive unit bolts, washers, different length so they only fit one way.
and nuts. Add washers [Item 19] if not 18. Attach the right-hand sensor harness
present. Apply thread-locking compound [Item 11] to the back of the tractor wall
(P/N 990-544) to the mounting bolts and with cable tie [Item 9] and
torque to 130 ft. lb. (176 Nm). adhesive-backed cable tie anchor [Item
13. Attach a feed wire to the connector end of 10], as shown in Figure 7-317.
the left-side sensor harness [Item 11]. 19. Connect the sensor harness to the main
14. Feed the left-side sensor harness through harness at connectors JPCS2 and JPCS3.
the passage hole in the sensor housing 20. Feed sensors and wires through the
and tractor frame until you can reach it in passage holes in the tractor and right-side
the area of the deadman pedal. housing.
15. Route and connect the left-side sensor 21. Route the sensor wires carefully in the
harness to the main harness at connectors channels of the housing and the sensors
JPCS1 and JPCS4. Secure the harnesses and gaskets in the pockets of the housing.
with cable ties and adhesive-backed cable The wires are different length so they only
tie anchors. fit one way.
16. Reinstall the deadman pedal assembly. 22. On each side, attach the sensor cover
17. Route the sensor wires carefully in the [Items 21 and 23] with three socket
channels of the housing and the sensors flathead screws [Item 16]. Use
[Item 30] and gaskets [Item 20] in the
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Options Operator Compartment Sensor System
thread-locking compound (P/N 990-536)
on screw threads.
Gasket
Sensor
Gasket
Sensor
Sensor Cover
71054735_02.CGM
Figure 7-320. Sensor Installation
Install Software and Prepare for Testing and System Setup
Testing
Go to “Testing and System Setup” on
1. Download the appropriate software from page 7-292.
the iNet.
2. Install software using FlashWare.
Reference “Firmware Configuration” at the
end of “Component Procedures” in the
Model 7400 Maintenance Manual P/N
1026304. Follow the instructions in the
online FlashWare help.
3. Install covers and close the motor
compartment door.
4. Lower the lift truck to the floor and remove
the jack and blocking.
1026304B, 15 July 2007 7-285
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Operator Compartment Sensor System Options
Installation on Series DA/EA/FA counterweight, housing, or capture plate.
See Figure 7-321.
(Side Stance)
Painting Housings
If the housings are to be painted a different
color, paint them before installation to prevent
contaminating the sensors.
Remove Counterweight
1. Turn the drive wheel 90 degrees, to permit
maximum access between the drive tire
and rear wall of the tractor frame.
2. Turn the key switch OFF and disconnect
the battery connector.
Jack Here No Jack Area
7TOYRCH_T.EPS
Figure 7-321. Correct Jacking Location
Use extreme care when the lift truck is 4. Remove the counterweight.
jacked up. Never block the lift truck
between the telescopic and the floor.
Drill Sensor Housing Mounting and
Use a suitable hoist to stabilize the mast.
Keep hands and feet clear while jacking Passage Holes
the lift truck. After the lift truck is 1. Tape drill templates in place. See
jacked, place solid blocks or jack stands Figure 7-322.
beneath it to support it. Do not rely on
2. Using a center punch, mark locations for
the jack alone to support the lift truck.
new holes on the tractor frame.
3. Jack up and block the tractor. Once the 3. Remove the templates.
truck is securely resting on blocks, remove 4. Drill 1/4 in. pilot holes through the tractor
the jack so it does not block access for the frame for the 5/8 in. mounting holes and
3/4 in. passage holes. This step could
require several bits because of the
hardness of the tractor frame steel.
Do not damage components in the
motor compartment or electronics
compartment when drilling the holes
through the frame.
5. Enlarge the two mounting holes for each
housing to 5/8 inch.
6. Enlarge the passage hole in each housing
to 3/4 inch.
7. Deburr the holes.
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Options Operator Compartment Sensor System
Drilling Template Drilling Template
3/4 in. passage hole
5/8 in. mounting hole
3/4 in. passage hole
5/8 in. mounting hole
5/8 in. mounting hole
71053736_1B, 1C.CGM
Figure 7-322. Drilling Sensor Mounting and Passage Holes
Install Counterweight
1. Apply thread-locking compound
(P/N 990-669) to the short threaded ends
of the counterweight mounting studs [Item
3] and thread them into the back of the
new counterweight [Item 4]. Use jam nuts
temporarily to make tightening the studs
easier. Torque to 55 ft. lb. (72 Nm).
Remove jam nuts.
2. Apply thread-locking compound
(P/N 990-669) to the long threaded ends of
the counterweight mounting studs.
3. Install the counterweight on the tractor.
4. Install, but do not tighten, counterweight
washers [Item 17] and nuts [Item 18].
Slide the counterweight sideways to obtain
correct contact. It is essential that the
counterweight be in contact with the frame
as indicated in Figure 7-323. If it is not,
1026304B, 15 July 2007 7-287
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Operator Compartment Sensor System Options
the counterweight is more vulnerable to
fracture if impacted.
Tractor Frame
Counterweight
Counterweight must be in contact
with frame at these points.
71054736_1D.CGM
Figure 7-323. Counterweight Mounting (Side Stance, Overhead View)
5. Install shims [Items 12 and 13] as needed to threads of button head socket screws
at counterweight keyway to eliminate any [Item 14], install in ends of shims and
gap. The shims are different thicknesses to tighten to 9 ft. lb. (12 Nm). See
permit many combinations. Apply Figure 7-324.
thread-locking compound (P/N 1013829)
Drive Unit
Mounting Bolt
Washer
Harness Capture Plate Nut
Counterweight
Button Head Socket Screws
Shims
71054736_B1.CGM
Figure 7-324. Counterweight Shims and Harness Capture Plate
6. Torque counterweight mounting nuts to 55 ft. lb. (72 Nm).
7-288 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Options Operator Compartment Sensor System
Install Components 2. Install the right-hand sensor housing
[Item 8], using two M12 bolts [Item 15] and
1. Apply thread-locking compound washers [Item 17]. Torque to 55 ft. lb.
(P/N 990-669) to the threads of the M12 (72 Nm). (You will install the left-hand
mounting bolts [Item 15]. sensor housing in step 19.)
Mounting Bolts
Sensor Housing
71054736_1F.CGM
Figure 7-325. Sensor Housing Mounting
3. Remove top covers and open the motor
compartment door. CAN I/O
4. Using the flexible mushroom cap Expander
reclosable fastener material [Items 26 and Module
27], attach the CAN I/O Expander Module
[Item 25] to the inside of the tractor wall
between the steer amplifier and the
relay/control fuse card as shown in
Figure 7-326.
7
Figure 7-326. CAN I/O Expander Module Location
(Side Stance)
1026304B, 15 July 2007 7-289
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Operator Compartment Sensor System Options
5. If the factory-installed main electrical e. Reconnect connector JPT1 at the TPA.
harness has a JX1 connector near the
CAN I/O Expander Module, connect it to
the module. Skip to step 9.
NOTE: JX1 connectors were included in
factory-installed main electrical
harnesses beginning with Series DA/EA
truck serial number 05316 and Series
FA truck serial number 05279.
6. Connect the control harness JX1 [Item 29]
to the CAN I/O Expander Module.
7. Connect the control harness [Item 29] to
the Operator Display.
a. At the Operator Display, disconnect 7_DSC0159.JPG
connector JPD1. Figure 7-327. AMP Superseal Connector,
Unlocking Wedge Lock
b. Insert the socket for wire JD1-1 into the
back of pin number 1 location in the 9. Connect the main sensor harness JX2
Molex connector. Push the wire in until [Item 30] to the CAN I/O Expander
the socket clicks in the connector. Module.
c. Reconnect connector JPD1 at the 10. Route the right-side harness branch as
Operator Display. shown in Figure 7-328 to the inside of the
8. Connect the control harness [Item 29] to tractor wall near the right-side entrance of
the Traction Power Amplifier (TPA). the operator compartment. Attach with
cable ties [Item 9] and adhesive-backed
a. At the TPA, disconnect connector JPT1.
cable tie anchors [Item 10] as shown.
b. On connector JT1, unlock the red
wedge lock by prying gently between
the seal and wedge lock tabs. The red
wedge lock should slide forward about
3/16 inch. See Figure 7-327.
c. Insert each of the three control harness
wires into the correct pin location in the
connector, either pins 8, 15, and 23
(Series FA) or 7, 14, and 22 (Series Housing
DA/EA): From the back side of the Mounting Bolt
connector, push the wire straight
through the wire seal into the socket Passage hole
until it clicks. Pull back gently to be
sure the contact is locked in place. Pin
numbers are stamped on the ends of
the connector shell. Reference
schematic Figure A-6 on page A-22.
d. With all wires in place, push the wedge
lock back until it clicks and locks.
71054736_1G.CGM
Figure 7-328. Right-Side Harness Installation
(viewed from inside tractor)
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Options Operator Compartment Sensor System
11. Route the left-side harness branch as housing before mounting the left-side
shown in Figure 7-329 in front of the lift housing.
motor, then down into the motor 18. With the left-side sensor harness routed,
compartment. Attach with cable ties [Item mount the left-side sensor housing [Item
9] and adhesive-backed cable tie anchors 6] to the tractor: Apply thread-locking
[Item 10] to the back wall of the motor compound (P/N 990-669) to two M12 bolts
compartment. [Item 15]. Install left-side sensor housing
with M12 bolts [Item 15] and washers
[Item 17]. Torque to 55 ft. lb. (72 Nm).
19. Route the sensor wires carefully in the
channels in the housing and the sensors
and gaskets in the pockets in the housing.
The wires are different length so they only
fit one way. See Figure 7-330.
20. Attach right-hand sensor harness to the
back of the tractor wall with cable tie [Item
9] and adhesive-backed cable tie anchor
[Item 10], as shown in Figure 7-328.
21. Connect sensor harness to main harness
at connectors JPCS2 and JPCS3.
22. Feed sensors and wires through the
passage holes in the tractor and housing.
23. Route the sensor wires carefully in the
channels in the housing and the sensors
[Item 30] and gaskets [Item 20] in the
71054736_1A.CGM
pockets in the housing. The wires are
Figure 7-329. Left-Side Harness Installation different length so they only fit one way.
See Figure 7-330.
12. Remove the deadman pedal assembly.
24. On each side, attach the sensor cover
This is necessary in order to route the
[Items 22 and 24] with three socket
left-side sensor harness.
flathead screws [Item 16]. Use
13. With the truck jacked up, remove two thread-locking compound (P/N 1013829)
drive unit mounting nuts and washers as on screw threads.
shown in Figure 7-324.
14. Mount the harness capture plate [Item
31], using the drive unit bolts, washers,
and nuts. Add washers [Item 19] if not
present. Apply thread-locking compound
(P/N 990-544) to the mounting bolts and
torque to 130 ft. lb. (176 Nm).
15. Reinstall the deadman pedal assembly.
16. Connect the left-side sensor harness to the
main harness at connectors JPCS1 and
JPCS4 in the motor compartment.
17. Because the passage holes in the tractor
wall and left-side sensor housing do not
directly align, you must feed the sensor
harness through the passage hole in the
1026304B, 15 July 2007 7-291
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Operator Compartment Sensor System Options
Mounting Bolts
Sensor Housing
Gasket
Sensor
Cover
Plate
71054736_1F.CGM
Figure 7-330. Sensor Mounting
Install Software 1. Connect the battery connector.
2. Block the upper sensor beam (with a piece
1. Download the appropriate software from
of masking tape).
the iNet.
3. Turn the key switch ON.
2. Install software using FlashWare.
Reference “Software Configuration” on 4. Depress the deadman pedal. An alarm
page 7-271. Follow the instructions in the tone should sound and the Operator
online FlashWare help. Display should scroll the message
“Entrance Beam Blocked.”
3. Install covers and close motor
compartment door. 5. With the sensor still blocked and the
deadman pedal depressed, move the
4. Lower the lift truck to the floor and remove
control handle to request travel. The truck
jack and blocking.
should not travel.
Testing and System Setup 6. Unblock the sensor. Return the control
handle to neutral, then move control
handle to request travel. The truck should
Go to “Testing and System Setup” on
travel at requested speed, up to full
page 7-292.
configured speed.
7. While traveling greater than 1.0 mph but
Testing and System Setup less than full speed, block the sensor
beam. The truck should plug to a stop, an
To test correct operation of the OCSS, do the alarm tone should sound, and the
following steps, in an open area, in the order Operator Display should scroll the
and exactly as directed. message “Entrance Beam Blocked.”
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Options Operator Compartment Sensor System
8. With the sensor still blocked and the
deadman pedal depressed, move the
control handle to neutral, then move the
control handle to request travel. The truck
should travel to a maximum of 1.0 mph.
9. Stop the truck and return the control
handle to neutral. Unblock the sensor
beam. With the deadman pedal depressed,
move the control handle to request travel.
The truck should now travel at requested
speed, up to full configured speed.
10. Stop the truck and turn the key switch
OFF. Block the lower beam (with a piece of
masking tape). Repeat steps 3 through 9
for the lower beam.
1026304B, 15 July 2007 7-293
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Vantage Point Options
Vantage Point 1. You are completing installation of a
Vantage Point ™ System ordered with a newly
built Model 7400, 7420, or 7440 lift truck.
This document contains instructions for field
2. You are adding the Vantage Point ™ System to
installation, set-up, troubleshooting, and
a Model 7400, 7420, or 7440 lift truck
maintenance of a Vantage Point ™ System on a
previously ordered and built without a
Model 7400, 7420, or 7440 lift truck.
Vantage Point ™ System.
The Vantage Point ™ System provides additional
visual assistance to operators when performing Parts and Component
pallet storage and retrieval tasks at greater lift Identification
heights.
Table 7-28 lists parts and parts kit
You can use this document in the following requirements for the various lift trucks.
situations:
Table 7-28. Parts Requirements
Mast
Hardware and Over-the-
Description Camera Bracket Switch1
Instructions Kit Mast Cable
Cable
Model 7400 Standard Carriage 939-VPT/SYS 1057638 N/A N/A
factory-ordered with Model
7400/7420/7440 Reach-Fork ®
Model 7400 Standard Carriage 939-VPT/SYS 1057638 1062321/ N/A
factory-ordered without Model
7400/7420/7440 Reach-Fork ®
Model 7400 Deep-Reach ® Carriage 939-VPT/SYS 1057641 N/A N/A
factory-ordered with Model
7400/7420/7440 Reach-Fork ®
Model 7400 Deep-Reach Carriage 939-VPT/SYS 1057641 1062321/ N/A
factory-ordered without Model
7400/7420/7440 Reach-Fork ®
Refer to Table 7-29, “Kit Components,
Vantage-Point ™ System,” on page 7-295 for
item numbers [Item X] referenced in the
installation procedure.
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Table 7-29. Kit Components, Vantage-Point ™ System
Item 1: P/N 1055451 Item 2: P/N Item 3: Item 4: P/N
Camera 1053218/002 P/N 1039653/001 1042259/001
Cable: Camera JVS8 to Monitor, Power Converter, Cable: Power Converter to
OTM PVS4 Monitor Cable TS1 (74xx)
Item 5: P/Ns 1047822, Item 6: P/N 1034721 Item 7: P/N 611-029 Item 8: P/N 611-088
1039652 Cable Wrap Cable Tie Cable Tie Anchor:
Clamp and Hardware Adhesive-Backed (Qty 7)
Item 9: P/N 5-011-002 Item 10: P/N 5-011-009 Item 11: Item 12: P/N 1V3-593
Thread-Forming Screw, Thread-Forming Screw, P/N 1-074-087/005 Cable Clamp
M4x12 M8x25 Cushioned Cable Clamp
Item 13: P/N 1049814 Item 14: Item 15: Item 16:
Model 74xx only: P/N 828-013-533/117 P/N 828-013-533/134 P/N 1004232/043
Replacement Clamp Bolts Wire, Model 74xx only, Wire, Jumper Wire,
5/16 x 18 x 3.5 in. Flat JPVT1 to JPC18-8 Not Used on Model 74xx Not Used on Model 74xx
Socket Head
1026304B, 15 July 2007 7-295
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Vantage Point Options
Tools Required
You need the following tools to install the kit:
• Approved work platform
• Hardwood blocks for blocking mast
• Assorted open- and box-end wrenches
• Assorted hex-head wrenches
• Screwdrivers
• Degreaser/surface cleaner
• Diagonal cutters for trimming cable ties
• Laptop computer with iNet access for
software download
If the lift truck does not have predrilled holes in
the carriage bottom plate for the camera
bracket, you will also need:
• Center punch
• Recommended: magnetic-base drill press
• Drill
• Drill bits: L and pilot sizes
• Cutting fluid for lubricating while drilling
• Deburring tool or file
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System Block Diagram
Power
Power
Converter
Converter:
Item
Item33 OVERHEAD GUARD
Over-the-Mast
Connector Monitor: Cable
JPVS1 Item 3 (If replaced,
see Table 7-28,
Connector
“Parts
JPVS2
Requirements,”
Cable: on Main Lift
Item 4 page 7-294.) Pulley
Cable:
Item 3
Free Lift
TRACTOR Pulley
MAST
Terminal
Strip TS1
Connector
JPVT1
Connector
Wire: JVS4
Item 14
Aux
Manifold
Area
CARRIAGE
Connector
PVS4
Vehicle
Manager Cable:
Item 2
Connector
JPVS8
Connector Connector Connector
JPC18-8 JVS5 PVS3
Camera:
Item 1
7400 System Block Diagram
Figure 7-331. Model 7400 Vantage-Point™ System Block Diagram
1026304B, 15 July 2007 7-297
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Vantage Point Options
Installation Drill the Carriage Plate Holes
NOTE: New lift trucks ordered with the Vantage
Preparation Point ™ System will have holes pre-drilled
in the carriage plate. Lift trucks in the
1. Lift trucks below serial number 03069
field may or may not have holes
require modification as described in
pre-drilled. If you need to drill the
Raymond Service Bulletin RCH-05-018.
carriage plate holes, use the following
These modifications affect the routing and
procedure.
tensioning of the over-the-mast hoses and
cable. 1. Position the fork carriage at a convenient
2. Remove the mast guard. working height. It will be more convenient
to drill holes from the underside of the
3. Remove the top cover (Series AA/BA/CA) fixed carriage plate. Extend the reach
or display top cover (Series DA/EA/FA). carriage. Block the carriage or secure the
4. Remove the left front cover. carriage with an overhead hoist. Turn the
key switch OFF and disconnect the battery
connector.
2. Mark drilling locations on the bottom of
the bottom plate of the fixed carriage. Pay
attention to proper orientation. See
Figure 7-332 and Figure 7-333.
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Model 7400 Standard Reach Model 7400 Deep-Reach ®
Camera Bracket Camera
Camera Camera Bracket
1058514_6.CGM 1055735_6.cgm
Figure 7-332. Model 7400 Camera Location on Fork Carriage
3. With a center punch, mark the location of
two holes on the bottom plate. See
Figure 7-333 on page 7-300.
4. Drill two L-size holes through the plate. A
magnetic drill press will make this task
easier. Deburr the holes on both sides.
1026304B, 15 July 2007 7-299
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Vantage Point Options
Model 7400 Standard Reach Truck
0.24 in.
TRACTOR SIDE
5.34 in.
2.74 in. 0.290 +0.006 -0.002 in.
“L” size hole VIEW IS LOOKING UP
FROM UNDERNEATH
PLATE
6.50 in.
12.97 in.
FORKS SIDE
3.24 in.
18.31 in.
Model 7400 Deep-Reach ® Truck
0.26 in.
5.82 in.
TRACTOR SIDE
2.87 in.
VIEW IS LOOKING UP
FROM UNDERNEATH
6.50 in. PLATE
0.290 +0.006 -0.002 in.
2.99 in. “L” size hole
FORKS SIDE
0.64 in.
18.32 in.
1020329.CGM 1006909.CGM
Figure 7-333. Model 7400 Camera Mounting Hole Location
Install Camera, Bracket, and Cable the two self-threading screws. Do not
exceed 40 ft. lb. torque.
1. Attach the camera [Item 1] to the camera
cable [Item 2] at connector JPVS8. NOTE: The camera bracket is correctly
positioned at a five degree angle towards
2. Apply thread-locking compound
the left side.
(P/N 1013829) to the threads of the two
M8x25 self-threading screws [Item 10]. 3. Clean cable clamp mounting locations on
Install the camera bracket (see Table 7-28, carriage with alcohol or other solvent and
“Parts Requirements,” on page 7-294) with permit to dry. Apply self-adhesive cable
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Options Vantage Point
clamps [Item 12] to carriage as shown in 4. Apply thread-locking compound
Figure 7-334. (P/N 1013829) to the screw threads of the
two M6 button-head socket screws
provided with the camera. Attach the
Model 7400 Standard Reach Truck
camera [Item 1] to the camera bracket,
(Viewed from Tractor) using the two screws.
5. Attach the camera cable [Item 2] to the
bracket with an insulated cable clamp
[Item 11], using the M4x12 form-threading
screw [Item 9].
6. Attach cable wrap [Item 6] over the camera
cable from camera to clamp. Trim any
4
excess length.
7. Feed camera cable through self-adhesive
cable clamps to the area near the auxiliary
manifold. See Figure 7-334.
Replacing the Over-the-Mast
Electrical Cable
Cable Clamp
Locations NOTE: This procedure is not needed if the
Model 7400/7420/7440 Reach-Fork ®
was ordered with a newly built truck. In
this case the correct over-the-mast
electrical cable will have been installed
Model 7400 Deep-Reach ® Truck at the factory.
(Viewed from Carriage) The camera wires are contained within the
replacement over-the-mast electrical cable
[P/N 1062321].
Cable Clamp
Locations
When working on an elevated mast,
make sure to block the mast and
carriage to prevent unrequested
movement.
1. Use an approved work platform to access
locations on the mast. For more
information on approved work platforms,
see the Model 7400 Operator Manual.
2. Lift trucks below serial number 03069
require modification as described in
Raymond Service Bulletin RCH-05-018.
These modifications affect the routing and
tensioning of the over-the-mast hoses and
cable.
71058514_4C.CGM 1055735_6.CGM
3. Mark the hydraulic hoses at all four
Figure 7-334. Model 7400 Camera Cable Clamp hose/cable retainer blocks to help in
Mounting Locations
1026304B, 15 July 2007 7-301
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Vantage Point Options
setting correct tension during reassembly. 5. Feed the old cable from the tractor deck
See Figure 7-335. out through the opening in the tractor
bulkhead.
Upper Free Lift 6. The replacement over-the-mast electrical
Cylinder cable is used in both Model 7400 and EASi
Hose/Cable lift trucks. For Model 7400, on the carriage
Retainer end of the cable (connector JVS4) where
there are two cable grips, remove and
discard the grip with the loop facing the
tractor. The remaining cable grips on the
Main Lift cable will face in opposite directions.
Cylinder 7. Make sure to observe correct routing and
Hose/Cable position when installing new electrical
Retainer cable. Make sure hoses and cable do not
cross each other.
8. Reconnect the battery connector and turn the
key switch ON. Carefully elevate and block
mast between inner and outer telescopics
high enough to access the hose/cable
retainer and guide bracket at the back of
the carriage. Turn the key switch OFF and
disconnect the battery connector.
9. Feed the new cable [P/N 1062321], (the
end with the female camera connector)
over the main lift pulley (from the tractor
side toward the forks side).
10. Feed the cable down around the clamp at
Carriage
Hose/Cable
the bottom of the free lift cylinder, then up
Retainer through the free lift pulley (from tractor
side toward the forks side).
11. Feed the cable down around the
Inner “U”-shaped hose bracket at the back of the
Telescopic carriage and up to the aux manifold. See
Hose/Cable
Figure 7-336 on page 7-303.
Retainer
Lower Free Lift
Cylinder
Hose/Cable
Retainer
71018766_C03.CGM
Figure 7-335. Model 7400 Hose/Cable Retainer Block
Locations
4. Perform steps 1 through 6 and 8 through
24 of the Over-the-Mast Hose and Cable
Removal procedure. See “Hose and Cable,
Over-the-Mast” on page 7-220. Leave
hydraulic hoses in place.
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NOTE: The spring and cable grip location will 12. Connect the solenoid wires to TS2.
be determined later in step 21. Connect camera cable and over-the-mast
cable at connector JPVS4. Reinstall the
aux manifold cover.
Model 7400 Standard Reach Truck
13. When installing cable retainer blocks,
remove slack from the electrical cable
without putting it under tension. Position
hydraulic hoses using witness marks
made previously.
14. Install and tighten the hose/cable retainer
block above the “U”-shaped guide bracket.
Make sure the electrical cable is positioned
4 to the right of the two hydraulic hoses.
15. If the electrical cable is not held firmly in
place by the retainer block, add a cable tie
immediately above the retainer block as a
strain relief to the terminal strip.
16. Route the cable through the mast hose
retention strap at the bottom of the free lift
cylinder and cable guide at the bottom of
the inner telescopic. Make sure electrical
cable is positioned to the left of the two
hydraulic hoses. Tighten the strap. See
Figure 7-337.
Model 7400 Deep-Reach ® Truck
Mast Hose
Retention
Strap
71058514_4B.CGM
Figure 7-337. Model 7400 Over-the-Mast Cable Routing,
bottom of free lift cylinder and inner tele
(hydraulic hoses not shown)
17. Install and tighten the hose/cable retainer
block next to the bottom of the free lift
cylinder.
71058514_4C.CGM 1055735_4,CGM
Figure 7-336. Model 7400 Carriage Hose/Cable Retainer 18. Install and tighten the hose/cable retainer
and Bracket block at the top of the free lift cylinder.
1026304B, 15 July 2007 7-303
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Vantage Point Options
19. Install and tighten the hose/cable retainer close to the support member of the
block on the main lift cylinder. The tension overhead guard. See Figure 7-338.
spring (P/N 830-052) should have an
extended length of 1.75 ±0.12 inches over
the coils. Tighten a cable tie at the top of
the cable grip.
20. Reconnect the battery connector and turn the
key switch ON. Remove blocking from the
telescopics. Turn the key switch OFF and
disconnect the battery connector.
21. At the “U”-shaped hose/cable bracket,
loosen the carriage hose and cable retainer
bracket. Pull enough slack cable, install
the tension spring, and locate the cable
Saddle Clamp
grip to set a 0.75 inch gap between the
cable and the bracket. Attach a cable tie to
secure the cable grip in place. See
Figure 7-336 on page 7-303. 7DSCF1572M.JPG
Figure 7-338. Mounting Display Monitor to
22. Perform steps 31 through 34 of the Overhead Guard
Over-the-Mast Hose and Cable Installation
procedure. See “Hose and Cable,
3. If they are not already attached, attach the
Over-the-Mast”on page 7-224.
video and power cables to the monitor by
23. Install mast guard and covers. inserting the connector. Carefully position
and install the cable strain relief cover
Installing the Display Monitor with two screws. See Figure 7-339.
1. If it is not already attached to the display
monitor, attach the power converter
module to the back of the monitor with two
screws.
2. Install the display monitor mount
assembly [Item 5] to the crosstie on the
overhead guard bracket weldment, using
two 5/16 x 18 x 3.5 in. flat socket head
bolts and nuts. (Replace the silver-colored
bolts with the longer black bolts [Item 13].)
Angle the saddle clamps so the bolts are
78311_04.EPS
Figure 7-339. Video and Power Cable Attachment to
Monitor
4. Attach the monitor assembly [Item 3] to
the mounting clamp [Item 5].
5. Attach the power cable [Item 4] to the
power converter module [Item 3] at
connector JPVS1.
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6. Route the power cable and video cable
from the monitor along the crosstie and
down the main frame upright and into the
tractor. Attach with cable ties and
adhesive-backed cable tie anchors [Items 7
and 8]. See Figure 7-340 for suggested
approximate cable tie locations.
= Cable Tie Location
71058514_3.CGM 1058514_2.CGM
Figure 7-340. Model 7400 Cable Tie Locations
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Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Vantage Point Options
7. You can connect the Vantage Point ™ System Install Software and Prepare for
to lift truck power in one of two ways: Use Testing
the Keyed Aux Power Option to cause the
Vantage Point ™ System to be powered up 1. Download the appropriate software (VM
only when the key switch is turned ON. version 2.6 or higher) from the iNet.
Use the Battery Aux Power Option to 2. Install software using FlashWare.
cause the Vantage Point ™ System to be Reference “Software Configuration” on
powered up even with the key switch page 7-271. Follow the instructions in the
turned OFF. In either case, the connection online FlashWare help.
points are at Aux Power terminal strip
3. Reinstall the mast guard.
TS1.
4. Reinstall the covers previously removed.
a. Connect the power cable to aux power
terminal strip TS1, red wire to positive 5. Go to “Testing and System Setup”.
and white wire to negative. See
Figure 7-341. Testing and System Setup
b. If the lift truck is not equipped with a
JVT-1 harness connector, route the 1. Reconnect the battery connector. If the
wire [Item 14] from the power cable power is connected via keyed aux power,
[Item 4] to connector JPC18-8 at the turn the key switch ON. You should
Vehicle Manager. observe the following. See Figure 7-342 on
page 7-308.
c. Connect spade connector JPVT1.
a. Display button LEDs light up
momentarily in the order 1, 2, 3, 4, 5,
8.
PVS3 b. Camera selection LEDs light up
momentarily in the order 1, 2, 3.
JVS5 c. All display LEDs light up momentarily
together.
d. The camera image displays briefly, then
blanks.
e. With the carriage in the free lift zone,
Terminal CAM1, Button 3 and Button 8 LEDs are
Strip TS1 lit.
2. Verify camera triggering.
a. Lower the fork carriage completely.
Elevate the fork carriage within the free
Power Cable lift zone. The monitor display should be
Wire to JPVT1 blank.
71061798.CGM
Figure 7-341. Model 7400, Tractor Deck Connections b. Elevate the fork carriage past free lift.
CAM1 and Button 3 LEDs extinguish,
8. Connect the video cable from the display CAM2 and Button 2 LEDs light up, and
monitor (JVS5) to the over-the-mast cable the camera image appears.
(PVS3). 3. Check the video image orientation.
9. If necessary, coil excess cable carefully in a. If the image is inverted (upside-down),
the tractor deck and secure lightly with a see “Inverted Image (Buttons 1 and 2)”
cable tie. on page 7-310.
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b. If the image is mirrored (left for right), The standard Raymond defaults for the
see “Mirror Image (Buttons 1 and 3)” on Vantage-Point ™ display are:
page 7-310.
c. If there is a horizontal black bar
running through the picture, see Table 7-1. Raymond Vantage-Point ™ System Display
“Monitor Frequency (Button 4)” on Defaults
page 7-310.
Feature Default Status
4. Set brightness control.
a. Turn automatic brightness off (press Powersave Mode Disabled
Button 2 until LED extinguishes). See
Power ON/OFF Disabled
“Automatic Brightness (Button 2)” on
page 7-309. Monitor Standby Disabled
b. Set brightness, contrast, and color Manual Camera Select Disabled
intensity for average workplace lighting
conditions. See “Brightness (Buttons 5, Automatic Brightness ON
6, and 7)” and “Contrast (Buttons 4, 6, Reference Marker ON
and 7)” and “Color Intensity
(saturation) (Buttons 4, 5, 6, and 7)” on Frequency 60 Hz
page 7-309.
Keypad Lock Locked
c. Turn automatic brightness on (press
Button 2 until LED lights up). Check Invert Image Normal View
monitor brightness under various Mirror Image Normal View
lighting levels in the workplace.
5. Enable the level indicator.
a. Level the forks; check with a level.
b. Turn the reference marker on. See
“Reference Marker (Buttons 2, 3, 6, and
7)” on page 7-309.
c. Adjust the green line to intersect the
fork tips.
6. Lock the keypad. See “Keypad Lock
(Buttons 1 and 5)” on page 7-310.
1026304B, 15 July 2007 7-307
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Vantage Point Options
Adjusting the Monitor
Button 1: Button 3: Button 5: Button 7:
Camera Monitor Brightness Increase / Up
Selection Standby
Objects in C3
monitor are
C2
closer than
they appear C1
Objects in C3
monitor are
C2
closer than
they appear C1
Button 2: Button 4: Button 6: Button 8:
Automatic Contrast Decrease/ Down Display
Brightness ON/OFF
8311_01.EPS 8311_03.EPS
Figure 7-342. Vantage-Point System Display and Buttons
Powersave Mode Enable (Buttons 4, 5) Monitor Standby (Button 3)
Powersave mode enables the Power The default setting of the monitor standby
ON/OFF Button 8. The Raymond default function is disabled. The monitor standby
is Powersave disabled. To toggle Powersave function can be toggled enabled or
mode between enabled and disabled, disabled. To toggle between enabled and
unlock the keypad. Press buttons 4 and 5 disabled, unlock the keypad. Then press
at the same time and hold for 60 seconds. and hold Button 3 for 40 seconds.
With Powersave enabled, use Button 3 to When the function is disabled:
blank the display monitor, or use Button 8
to blank the display monitor and also turn During free lift, display monitor is in
off power to the camera. standby mode, with Button 3 and
CAM 1 LEDs lighted and camera image
You cannot enable Powersave Mode while blanked.
in manual camera selection mode.
Above free lift transition, display
Power ON/OFF (Button 8) monitor toggles ON, with Button 3 and
In the Raymond application, with CAM1 LEDs extinguished, CAM 2 LED
Powersave disabled, this button is locked lighted, and camera image on the
ON and cannot be toggled OFF, even with screen.
the keypad unlocked. When the function is enabled, display
With Powersave enabled, press Button 8 to monitor can be toggled ON or OFF in the
toggle the monitor display and camera ON free lift zone, but cannot be turned OFF
and OFF. above free lift transition.
NOTE: If the keypad is unlocked, the monitor
standby function enabled, then the
keypad locked, the monitor standby
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function will be locked enabled, allowing Contrast (Buttons 4, 6, and 7)
the operator to see the camera image With the keypad either locked or unlocked,
even in the free lift zone. This is not and an image is displayed, to adjust the
permitted for customer operation, as the picture contrast, press Button 4 to select
operator should not use the camera the Contrast function for Buttons 6 and 7.
system for driving. Press and hold Button 6 to decrease
contrast, or Button 7 to increase contrast.
NOTE: The reference marker with standby
Each of the three camera views is set
enabled is set separately from standby
separately.
disabled.
NOTE: You can adjust contrast even with
Manual Camera Select Enable Automatic Brightness turned ON, but
(Buttons 1 and 4) the change is best seen with Automatic
Manual camera selection is set disabled by Brightness turned OFF.
default. To toggle manual camera selection
between enabled and disabled state, press Brightness (Buttons 5, 6, and 7)
and hold Buttons 1 and 4 for 40 seconds. With the keypad either locked or unlocked,
and an image is displayed, to adjust the
Camera Selection (Button 1) picture brightness, press Button 5 to
The display unit can handle up to three select the Brightness function for Buttons
cameras. If only one camera is used, the 6 and 7. Press and hold Button 6 to
display can show up to three different decrease brightness, or Button 7 to
views. Those views could be, for example, increase brightness. Each of the three
normal, normal with reference line, and camera views is set separately.
mirror view.
NOTE: You can adjust brightness even with
To manually select a camera view, unlock Automatic Brightness turned ON.
the keypad and press button 1. The
camera view changes, the selected camera Color Intensity (saturation)
LED lights up, and Button 1 LED lights up (Buttons 4, 5, 6, and 7)
to show that the camera view has been With the keypad either locked or unlocked,
selected manually. To return to the default and an image is displayed, to adjust the
view, press and hold Button 1 for 2 color intensity or saturation, press
seconds. The video image changes and the Buttons 4 and 5 at the same time to select
Button 1 LED is extinguished. the Color Intensity function for Buttons 6
and 7. Press and hold Button 6 to reduce
Automatic Brightness (Button 2) saturation, or Button 7 to increase
Button 2 toggles automatic brightness ON saturation. Each of the three camera views
or OFF. With automatic brightness set ON, is set separately.
Button 2 LED lights up and the system
adjusts the monitor brightness NOTE: You can adjust saturation even with
automatically as the ambient light in the Automatic Brightness turned ON.
work place changes. For most
applications, this is the desired setting. Reference Marker (Buttons 2, 3, 6, and 7)
The display can show a green horizontal
To toggle automatic brightness ON or OFF, line across the screen. The operator can
unlock the keypad and press Button 2. use this line as a reference marker to
With the keypad locked, Button 2 is show, for example, when forks are level, or
disabled and automatic brightness is when forks are in position relative to a
locked either ON or OFF, depending on the rack cross beam. With the keypad locked,
status of the function when the keypad the reference marker cannot be toggled or
was locked. adjusted. To toggle the reference marker
ON and OFF, unlock the keypad. With an
image displayed, press Buttons 2 and 3 at
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Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Vantage Point Options
the same time for ten seconds to select the Keypad Lock (Buttons 1 and 5)
Reference Marker function for Buttons 6 To lock or unlock the keypad, press and
and 7. To adjust the vertical position of the hold Buttons 1 and 5 for 15 seconds.
marker on the screen, press and hold When the keypad is locked, the monitor is
Button 6 to move it lower, or Button 7 to on, but no keypad button functions
move it higher. (except unlock, brightness, contrast, and
color intensity) are active.
NOTE: Each of the three camera views is set
separately.
Restore Factory Settings (Button 5)
To restore Raymond default settings, press
Inverted Image (Buttons 1 and 2)
Button 5 during the start-up process for
If the camera were mounted upside-down,
the display.
the image would be inverted. With the
keypad locked, this function cannot be
toggled. To correct an inverted image, Component Procedures
unlock the keypad. Press Buttons 1 and 2
at the same time and hold for thirty-five Cleaning the Camera and Monitor
seconds.
Display
NOTE: Each of the three camera views is set
separately. Camera
Mirror Image (Buttons 1 and 3) Although the camera is sealed, do not pressure
The display can show the picture in mirror wash. Use a soft cloth dampened with water to
image (left and right reversed). With the clean the camera lens. Do not use chemical or
keypad locked, this function cannot be abrasive cleaners.
toggled. To toggle between normal and
mirror image, unlock the keypad. Press Monitor Display
Buttons 1 and 3 at the same time and hold
for five seconds. Mirror Image would be The monitor display is not sealed. Do not
useful if the monitor is mounted where it pressure wash or immerse the display. Use only
can be seen by the operator driving a soft cloth dampened with water to clean the
tractor-first. monitor display. Do not use chemical or
abrasive cleaners.
NOTE: Each of the three camera views is set
separately.
Replacing Display (without Replacing
Monitor Frequency (Button 4) Cables)
The monitor can function at either 50 or
60 Hz. For North American operation, it Removal
should be set to 60 Hz. With the keypad 1. Turn the key switch OFF and disconnect
locked, this function cannot be toggled. To the battery connector.
toggle between 50 and 60 Hz, unlock the
keypad. Press and hold Button 4 for 15 2. Remove the display from the mounting
seconds. bracket at the swivel ball.
NOTE: Each of the three camera views is set
separately.
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3. Disconnect the power cable from the DC Troubleshooting
converter module. See Figure 7-343.
NOTE: See “Vantage Point” on page 5-34.
Output to Display Input from Truck DC
Power
Camera Cable
71039653.CGM
Figure 7-343. Display, DC Converter, and Camera Cable
(Back View)
4. On the back of the display, remove two
screws securing the cable strain relief
cover.
5. Disconnect the cable connector from the
display.
6. Remove two socket head cap screws
holding the DC converter module to the
display.
7. Remove two socket head cap screws
securing the mounting ball to the display.
Replacement
1. Attach the display to the mounting ball
with two socket head cap screws.
2. Attach the DC converter to the display
with two socket head cap screws.
3. Plug the power and camera cable
connector into the display.
4. Carefully attach the cable strain relief
cover to the display with two screws.
5. Connect the power cable from the lift truck
to the input of the DC converter.
6. Mount the camera swivel ball to the
mounting bracket and position as desired.
1026304B, 15 July 2007 7-311
Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Vantage Point Options
7-312 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Section 8. Theory of Operation
NOTE: Schematics have changed and will vary
slightly from those shown in this section.
Do not use the schematics in this section
to troubleshoot the truck.
Use the master schematics in the
Appendix for troubleshooting.
1026304B, 15 July 2007 8-1
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
8-2 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Traction System Functional Operation
Traction System
Functional Operation
Battery Connected
When the battery is connected, the truck has
B+ and B– supplied to the following points:
1. B+ to JPF4-3 and 4-4 through FU7 and to
the normally open tips of K1 relay and
JPF4-15.
2. B+ to JPF4-1 and 4-2 through FU5 to the
normally open tips of K2, K3, K4 and the
key switch S1. The K4 coil. JPF4-1 and
JPF4-2 also supply the VM with Battery
Sense In at JPC24-24. It is protected by a
thermistor for overcurrent conditions
cause by shorts in the wiring. This is used
by the VM to make sure that battery
voltage is within the requirements for the
lift and traction amps prior to powering
them up.
3. B+ to the normally open tips of the Steer,
Traction and Lift contactors.
4. B– is supplied to all points labeled B–, B–F,
any sensor connection with a (–) negative
label and DGND.
1026304B, 15 July 2007 8-3
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Traction System Functional Operation
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR BLACK -4 -5 -4
T VEL SENSOR+
PANEL TME T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
TP2 TP3 TP5 T VEL PHASE B
JPT3
RED -2 -8 -16
FU1 FU3 FU2 T TEMP+
(150A) (500A) (350A) TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 MOTOR TEMPERATURE TA
-2 1 1 1 X TPC Y JPS1-8 -2 TPC
-3 STR LPC TPC CONTACTOR
2 2
-4 2 U
U
B-
V
TM V
W
1 W
B+ +
1 TR
LR 2 MOTOR VELOCITY
2 RED JPL2-1 JPL1-3
L VEL SENSOR+
BLACK -4 -4
LR-2 TR-2 LME L VEL SENSOR-
WHITE -3 -5
L VEL PHASE A
BLUE -2 -6
L VEL PHASE B
RED JPL3-2 -16
STR
L TEMP+
Y X LMT
RED/BLK -1 -17
L TEMP-
X LPC Y JPS1-9
MOTOR TEMPERATURE LPC
LA
-2
CONTACTOR
B-
U
U
V
LM V
JPS1-5 JPS1-6 JPS1-7 JPS1-10 JPS1-11
W
W +
B+
JP
B-
TP4 STR-2
MS-A1
A1 +
MS SA
A2 -
MS-A2
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
T˚ K3 TS1-2
JPF1-1 JPS10-3
FU8 (15A/5A)
-2
1 2 JPF4-15 -5
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/
TS2-2
RELAY
CARD JPF2-8 JPS3-1
TS2-1 1 2 -3
REACH
B+ 1 SIDE
SHIFT
2 -4
1 2 -5
Buss+/- TILT
5v
4
B- -6
Input
8R828-011-224_D_C.EPS
Figure 8-1. Battery Plugged In (Series CA/FA)
8-4 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Traction System Functional Operation
VEHICLE
MANAGER
JPT1
-20
ID2 RED JPE1-1 JPC10-6
-21 +12V_EN1
IDGND WHT -3 JPC22-5
CHANNEL_A_1 JPC12-1 JPH1-1
-2 -12 +5VP +5VP
BLU
CHANNEL_B_1
STEER BLK -4 JPC18-5 +5VP
TILLER DGND
-3 -3
ENCODER RED JPE2-1 JPC10-7 P_THROTTLE VR1
+12V_EN2
WHT -3 JPC22-13
CHANNEL_A_2 DGND
BLU -2 -14 +5VP +5VP +
CHANNEL_B_2
0 S3
TA BLK -4 JPC18-6
DGND LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-1 -4 -4 0
REACH S4
B+K3
-7 -11 -11
DGND RETRACT -
-22 DGND
BUS_I+
BUS_I- -14 -5 -5
TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
JPL1 -8 -8 -
-15 SSHIFT_LEFT S8
BUS_I- DGND
DISPLAY -9 -9
-23 SSHIFT_RIGHT S9
BUS_I+ -12
-8 JPD3-1 B-1 -12
DGND +12VP DGND DGND
SOUNDER -13
-2 B-2
SOUNDER
HTR6
-7 -7
-22 -2 H_HTR
BUS_I+ BUS_I+ JPC14-5
-14 -3 JPD1-5
BUS_I- BUS_I- +12VP
-7 -4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
DGND JPC20-8 -2
-7 -4 +12VP
BUS_I- JPC22-7 -3
LA -8 -3
DGND
HGG_FAULT
HGG_CONTACTOR
JPC24-2 -4
-12 JPC10-3 -5
ID1 THERM_EN 4
-13
IDGND JPC24-13
+12VP JPAD-1
JPC10-8
AUX DEADMAN -2
JPC24-4
DGND -3
-1
B+K3
JPC18-11
STR_CONTACTOR JPC24-23 JPA-1
ROOM_TEMP
JPC6-6 -11 -2
DGND
+12VP
-5
CCW_PWM JPC18-18 SPL-6
-2 ALARM 4 4
CW_PWM
-3
STEER_CURRENT
-4
DGND JPC20-16
-1 L/L SOL2
NEUTRAL_PULSE 1 2
-15
(B+K2)B+L/L
JPC22-19
FU1_SENSE -18
JPC14-10 AUX1
DGND
-2 -17
DGND (B+K2)B+AUX1 SOL5T
-1
1 2
-8
-9 B-F -20
AUX2 SOL5B
1st SPEED 1 2
S12 LIMITING SWITCH JPS4-1 JPC20-1 -19
+12VP (B+K2)B+AUX2
NC -12
JPS4-3 COM DUMP SOL3
NO -2 JPC22-1 1
AC LIFT &
SPEED_LIMIT_1 2
-13
(B+K2)B+DUMP
JPC10-10
BUS_E+
-5 JPC20-4 JPY1-1 +
+12VP
ELECTRIC
BUS_E-
HRN JPC24-18 -2 0
-NEG PRESSURE PRESS
-6 -3 -
-IN H-1 JPC18-16 DGND
H HORN
STEER
-POS H-2
JPBR-2 JPS2-2 JPC20-5 JPDP-1
+12VP
DEADMAN
VR4
SENSOR
-1 -1 JPC20-14 JPC24-19 -3
BRAKE BRAKE DEADMAN
FAN-T -7 -2
JPB1-1 + JPB1-2 JPC18-17 DGND
- FAN
JPC20-2 JPS12-1
DEADMAN
FAN-FW +12VP
JPC22-8 -2
SWITCH
JPB2-1 JPB2-2 ON DEADMAN
+ - NC
S2
JPC18-7 -3 JPDS-COM JPDS-NO
FAN-FW2 DGND
JPB4-1 JPB4-2
+ -
FAN-DU
JPB3-1 JPB3-2
+ -
-10 JPC20-7 JPE4-1 RED
SOL1 L/H +12VP
2 1 JPC22-9 -3
JPC14-6 CHANNELA_4 WHT STEER
RELAY_ENABLE MOTOR
JPC22-21 -10 -2 BLU ENCODER
EPO_SENSE CHANNELB_4
JPC10-9 -4 BLK
DGND
JPC14-12
ROTATION
B+KEY JPC20-9 JPST-1 +
SWITCH
+12VP
END OF
STEER
JPC22-22 -2 0 S11
STEER_LIMIT
-11 -3 -
DGND
-7
B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
FLASHWARE
TXD JPC9-2
JPS3-2 -3
RXD
DGND -5
-3 JPC18-12
REACH_SOL
-4 -14
SIDESHIFT_SOL
COMMUNICATIONS
-5 -15 VBUS JPC2-1
TILT_SOL
D+ -2
USB
D- -3
DGND -4
-6 JPC22-18
NESTED_SWITCH
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-5
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Traction System Functional Operation
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR T VEL SENSOR+
BLACK
PANEL TME
-4 -5 -4
T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
T VEL PHASE B
2 JPT3
1 RED
TPC -2 -8 -16
STR T TEMP+
2 1 TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 FU2 MOTOR TEMPERATURE TA
-2 (350A) X TPC Y JPS1-8 -2 TPC
-3 TP5 CONTACTOR
-4 U
U
B-
1 V
TM V
TR STR W
FU1 W
(150A) Y X B+ +
TP2 FU3 2
(500A) Y X
LPC
2
LPC
1
SPL-2
JPS1-5 JPS1-6 JPS1-7 JPS1-10 -9 JPS1-11
A1 +
A2
A1 +
LM
MS
A2 -
S1 -
JP
B-
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
K3 TS1-2
JPF1-1 T˚
JPS10-3
FU8 (15A/5A)
-2
-5
1 2 JPF4-15
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/ TS2
RELAY -2
CARD JPF2-8 JPS3-1
TS2-1
1 2 -3
REACH
1 2 -4
SIDE
SHIFT
1 2 -5
TILT
B+
Buss+/- 4
-6
5v
B-
Input
8R828-011-224_D_C.EPS
Figure 8-2. Battery Plugged In (Series AA/BA/DA/EA)
8-6 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Traction System Functional Operation
VEHICLE
MANAGER
BW1 JPC22-15
JPT1 BRUSH_WEAR_1
ID2 -20
-21
IDGND
LM_A1 JPC12-1 JPH1-1
+5VP +5VP
BW2 -16
BRUSH_WEAR_2 +5VP
-3 -3
P_THROTTLE VR1
LM_A2 DGND
+5VP +5VP +
(ON LM) 0 S3
TA LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-23 -4 -4 0
REACH S4
BUS_I+
-15 -11 -11
BUS_I- RETRACT -
-8 DGND
DGND
-1 -5 -5
B+K3 TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
-8 -8 -
SSHIFT_LEFT S8
DGND
DISPLAY -9 -9
SSHIFT_RIGHT S9
-12
JPD3-1 B-1 -12
+12VP DGND DGND
SOUNDER
-2 B-2 -13
SOUNDER
HTR6
-7 -7
-2 H_HTR
BUS_I+ JPC14-5
-3 JPD1-5
BUS_I- +12VP
-4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
-7 -4 JPC20-8 -2
BUS_I- +12VP
JPC22-7 -3
-8 -3 HGG_FAULT
DGND JPC24-2 -4
HGG_CONTACTOR
JPC10-3 -5
THERM_EN 4
JPC24-13
+12VP JPAD-1
JPC18-11 JPC10-8
STR_CONTACTOR AUX DEADMAN -2
-9 JPC24-4
LIFT_CONTACTOR DGND -3
T˚ JPZ-1 JPC24-22
LIFT_MOT_TEMP
(ON LM) JPC24-23 JPA-1
-2 -10 ROOM_TEMP
DGND
-11 -2
DGND
JPC22-20
FU3_SENSE
-19 JPC18-18 SPL-6
FU1_SENSE ALARM 4 4
JPC14-10
DGND
-2
DGND
-1 JPC20-16
L/L SOL2
-8
1 2
-9 B-F -15
(B+K2)B+L/L
1st SPEED JPS4-1 JPC20-1
S12 +12VP AUX1 -18
LIMITING SWITCH
NC
JPS4-3 COM -17
NO -2 JPC22-1 (B+K2)B+AUX1 SOL5T
SPEED_LIMIT_1 1 2
JPC10-10
BUS_E+ -20
AUX2 SOL5B
-5
BUS_E- 1 2
HRN -19
(B+K2)B+AUX2
-NEG
-12
-IN H-1 JPC18-16 AUXDUMP SOL8
H HORN
1 2
-POS H-2 -13
(B+K2)B+AUXDUMP
JPBR-2 JPS2-2
PRESSURE
+12VP
JPC20-4
JPC24-18
JPY1-1
-2
+
0
PRESS
DC LIFT &
-1 -1 JPC20-14
HYDRAULIC
BRAKE BRAKE -6 -3 -
DGND
JPB1-1
FAN-T
+ -
JPB1-2 JPC18-17
FAN +12VP
JPC20-5 JPDP-1
STEERING
DEADMAN
VR4
SENSOR
JPC24-19 -3
FAN-FW DEADMAN
JPB2-1 JPB2-2
+ - -7 -2
DGND
FAN-LM JPC20-2 JPS12-1
JPB5-2
DEADMAN
JPB5-1 +12VP
+ - JPC22-8 -2
SWITCH
ON_DEADMAN
NC
FAN-FW2 S2
JPB4-1 JPB4-2 JPDS-COM
+ - -1 DGND JPC18-7 -3 JPDS-NO
SOL4 2nd_STAGE
2 1
FAN-DU
JPB3-1 JPB3-2
+ - -10
SOL1 L/H
2 1
JPC14-6
RELAY_ENABLE
JPC22-21
EPO_SENSE
JPC14-12
B+KEY
-7 B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
JPS3-2
-3 JPC18-12 TXD JPC9-2
REACH_SOL
FLASHWEAR
RXD -3
-4 -14
SIDESHIFT_SOL DGND -5
-5 -15
TILT_SOL
COMMUNICATIONS
VBUS JPC2-1
D+ -2
USB
-6 D- -3
JPC22-18
NESTED_SWITCH -4
DGND
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-7
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Traction System Functional Operation
Key Turned ON • Reach, Tilt, Sideshift, Aux 1, Aux 2,
L/L, L/H, and Dump solenoids, Nested
When the key is turned ON, B+ is supplied to Switch, Horn and FAN- T, FW, FW2 and
the following points: DU are all supplied by B+K2.
1. Through the EPO switch to the coils of K1, • Connections for optional devices at
K2 and K3. JPF2-9 by B+K1.
2. To JPC14-12 at the VM as B+ Key. This, • B+ is supplied to the VM by B+K4 to be
internal to the VM, activates the power used internally.
supply circuits that supply all 12V and 5V
5. With all microprocessors powered up,
outputs from the VM and activates the
SelfTest continues:
microprocessor in the VM. The power
supplies will maintain a steady output as • The VM checks to make sure its power
long as battery voltage remains above 17V. supplies are within range.
With the power supplies activated, 12V is • The VM checks the BUS to make sure
supplied to the display, activating its communications are functioning with
internal circuitry. The display also all other devices, Display, LA and TA.
contains a microprocessor and requires
• The amplifiers check the Pre-charge
firmware updates any time the VM is
circuit voltages to make sure they are
updated.
in range. If not, a message is sent over
3. The processor in the VM looks at Battery the BUS to the VM and a code is
Sense In (JPC24-24) and verifies it is displayed.
within the required parameters for the
• The VM asks the TA and LA for the
amps, 28 to 45V. If it is, there is an output
status of the TPC and LPC contactors to
from the processor to JPC14-6 taking the
make sure they are open. This is only
relay coils for K1, K2, K3 and K4 to B–
checked during SelfTest on trucks with
internal to the VM. The VM also uses this
traction or lift amplifiers. On trucks
input to calculate BSOC and compares it
with DC lift systems, the VM checks the
to the last battery voltage in its memory.
LPC. This is done continuously after the
The VM then determines if the display
truck has passed SelfTest and the VM
requires updating.
has not commanded it to be closed.
4. The tips of K1, K2, K3 and 4 close,
• The VM looks at the Steer Contactor to
supplying B+ to:
verify it is open. This is done only
• The lift and traction amps pre-charge during SelfTest.
circuits (TA+ and LA+) from B+K3.
• The VM commands the LA and TA over
B+K3 at JPT1-1 and JPL1-1 are also
the BUS to close the LPC and TPC. The
used by the amplifiers to power their
VM activates the circuitry to close the
internal circuitry that includes power
STR contactor. All are checked to make
supplies. The power supplies provide
sure power is supplied through the
12V to the motor velocity and
contactor tips to the motors circuits.
temperature sensors. When K3 is open,
The LA and TA report the state of the
it supplies a path for the capacitors in
LPC and TPC over the BUS. They are
the amplifiers pre-charge circuits to
monitored via the (+) connections on
discharge to B–. Both pre-charge
the amplifiers. When the contactor
circuits have a thermistor in them (on
closes, the amplifiers see a higher
the Fuse Relay Card) to protect from
voltage than seen from the pre-charge
overcurrent damage if there is an open
circuit. The VM monitors the STR
in the motor power circuitry or
contactor via JPC22-19.
contactors.
• The VM verifies the EPO switch is
closed.
8-8 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Traction System Functional Operation
• The software and configured After SelfTest is complete, the LPC and TPC
parameters are checked in the LA, TA, contactors remain energized for approx.
display and VM to make sure they are 30 seconds. If no function requests are made by
within limits and correct. the operator, they open. On trucks with a DC
• The amplifiers check to make sure lift system, the TPC remains closed for approx.
there are no shorts in the power 30 seconds and the LPC contactor opens
circuits. immediately after circuits are tested. The STR
contactor opens on both trucks as soon as the
• The VM checks to make sure the circuits are tested. The VM also monitors the
Deadman Switch is open and the temperature inputs from the TA and LA.
Deadman Sensor is in the released Anytime one of the readings goes above 113°F,
state. the VM turns on fans T, FW, FW2 and DU.
• The VM checks to make sure the Steer
Request Encoder is connected.
• The VM checks to make sure the lift
and throttle pots are within 0.2V of the
learned neutral position and are not
outside the allowable minimum and
maximum voltages. They are
continuously monitored and messages
will be displayed if activated prior to
closing the Deadman Switch.
• The TA is commanded to activate the
drive motor to make sure current is
seen and there are no speed velocity
sensor inputs. This is to make sure the
power circuits are functional and the
brake is applying resistance to the drive
motor.
• The VM checks the state of the control
handle switches to make sure they are
in the open position. They are
continuously monitored and messages
will be displayed if activated prior to
closing the Deadman Switch.
• The VM checks the information from
the TA and LA to make sure the
temperature sensor readings are within
range and determines if speed limiting
is required.
• The VM checks pressure transducer
readings to make sure they are within
range.
• The VM checks to make sure the
Ambient Temperature Sensor is within
the acceptable range.
• The VM checks its memory for all
previously logged faults that have not
been cleared.
1026304B, 15 July 2007 8-9
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Traction System Functional Operation
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR BLACK -4 -5 -4
T VEL SENSOR+
PANEL TME T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
TP2 TP3 TP5 T VEL PHASE B
JPT3
RED -2 -8 -16
FU1 FU3 FU2 T TEMP+
(150A) (500A) (350A) TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 MOTOR TEMPERATURE TA
-2 1 1 1 X TPC Y JPS1-8 -2 TPC
-3 STR LPC TPC CONTACTOR
2 2
-4 2 U
U
B-
V
TM V
W
1 W
B+ +
1 TR
LR 2 MOTOR VELOCITY
2 RED JPL2-1 JPL1-3
L VEL SENSOR+
BLACK -4 -4
LR-2 TR-2 LME L VEL SENSOR-
WHITE -3 -5
L VEL PHASE A
BLUE -2 -6
L VEL PHASE B
RED JPL3-2 -16
STR
L TEMP+
Y X LMT
RED/BLK -1 -17
L TEMP-
X LPC Y JPS1-9
MOTOR TEMPERATURE LPC
LA
-2
CONTACTOR
B-
U
U
V
LM V
JPS1-5 JPS1-6 JPS1-7 JPS1-10 JPS1-11
W
W +
B+
JP
B-
TP4 STR-2
MS-A1
A1 +
MS SA
A2 -
MS-A2
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
T˚ K3 TS1-2
JPF1-1 JPS10-3
FU8 (15A/5A)
-2
1 2 JPF4-15 -5
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/
TS2-2
RELAY
CARD JPF2-8 JPS3-1
TS2-1 1 2 -3
REACH
B+ 1 SIDE
SHIFT
2 -4
1 2 -5
Buss+/- TILT
5v
4
B- -6
Input
8R828-011-224_D_C.EPS
Figure 8-3. Key Turned ON (Series CA/FA)
8-10 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Traction System Functional Operation
VEHICLE
MANAGER
JPT1
-20
ID2 RED JPE1-1 JPC10-6
-21 +12V_EN1
IDGND WHT -3 JPC22-5
CHANNEL_A_1 JPC12-1 JPH1-1
-2 -12 +5VP +5VP
BLU
CHANNEL_B_1
STEER BLK -4 JPC18-5 +5VP
TILLER DGND
-3 -3
ENCODER RED JPE2-1 JPC10-7 P_THROTTLE VR1
+12V_EN2
WHT -3 JPC22-13
CHANNEL_A_2 DGND
BLU -2 -14 +5VP +5VP +
CHANNEL_B_2
0 S3
TA BLK -4 JPC18-6
DGND LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-1 -4 -4 0
REACH S4
B+K3
-7 -11 -11
DGND RETRACT -
-22 DGND
BUS_I+
BUS_I- -14 -5 -5
TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
JPL1 -8 -8 -
-15 SSHIFT_LEFT S8
BUS_I- DGND
DISPLAY -9 -9
-23 SSHIFT_RIGHT S9
BUS_I+ -12
-8 JPD3-1 B-1 -12
DGND +12VP DGND DGND
SOUNDER -13
-2 B-2
SOUNDER
HTR6
-7 -7
-22 -2 H_HTR
BUS_I+ BUS_I+ JPC14-5
-14 -3 JPD1-5
BUS_I- BUS_I- +12VP
-7 -4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
DGND JPC20-8 -2
-7 -4 +12VP
BUS_I- JPC22-7 -3
LA -8 -3
DGND
HGG_FAULT
HGG_CONTACTOR
JPC24-2 -4
-12 JPC10-3 -5
ID1 THERM_EN 4
-13
IDGND JPC24-13
+12VP JPAD-1
JPC10-8
AUX DEADMAN -2
JPC24-4
DGND -3
-1
B+K3
JPC18-11
STR_CONTACTOR JPC24-23 JPA-1
ROOM_TEMP
JPC6-6 -11 -2
DGND
+12VP
-5
CCW_PWM JPC18-18 SPL-6
-2 ALARM 4 4
CW_PWM
-3
STEER_CURRENT
-4
DGND JPC20-16
-1 L/L SOL2
NEUTRAL_PULSE 1 2
-15
(B+K2)B+L/L
JPC22-19
FU1_SENSE -18
JPC14-10 AUX1
DGND
-2 -17
DGND (B+K2)B+AUX1 SOL5T
-1
1 2
-8
-9 B-F -20
AUX2 SOL5B
1st SPEED 1 2
S12 LIMITING SWITCH JPS4-1 JPC20-1 -19
+12VP (B+K2)B+AUX2
NC -12
JPS4-3 COM DUMP SOL3
NO -2 JPC22-1 1
AC LIFT &
SPEED_LIMIT_1 2
-13
(B+K2)B+DUMP
JPC10-10
BUS_E+
-5 JPC20-4 JPY1-1 +
+12VP
ELECTRIC
BUS_E-
HRN JPC24-18 -2 0
-NEG PRESSURE PRESS
-6 -3 -
-IN H-1 JPC18-16 DGND
H HORN
STEER
-POS H-2
JPBR-2 JPS2-2 JPC20-5 JPDP-1
+12VP
DEADMAN
VR4
SENSOR
-1 -1 JPC20-14 JPC24-19 -3
BRAKE BRAKE DEADMAN
FAN-T -7 -2
JPB1-1 + JPB1-2 JPC18-17 DGND
- FAN
JPC20-2 JPS12-1
DEADMAN
FAN-FW +12VP
JPC22-8 -2
SWITCH
JPB2-1 JPB2-2 ON DEADMAN
+ - NC
S2
JPC18-7 -3 JPDS-COM JPDS-NO
FAN-FW2 DGND
JPB4-1 JPB4-2
+ -
FAN-DU
JPB3-1 JPB3-2
+ -
-10 JPC20-7 JPE4-1 RED
SOL1 L/H +12VP
2 1 JPC22-9 -3
JPC14-6 CHANNELA_4 WHT STEER
RELAY_ENABLE MOTOR
JPC22-21 -10 -2 BLU ENCODER
EPO_SENSE CHANNELB_4
JPC10-9 -4 BLK
DGND
JPC14-12
ROTATION
B+KEY JPC20-9 JPST-1 +
SWITCH
+12VP
END OF
STEER
JPC22-22 -2 0 S11
STEER_LIMIT
-11 -3 -
DGND
-7
B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
FLASHWARE
TXD JPC9-2
JPS3-2 -3
RXD
DGND -5
-3 JPC18-12
REACH_SOL
-4 -14
SIDESHIFT_SOL
COMMUNICATIONS
-5 -15 VBUS JPC2-1
TILT_SOL
D+ -2
USB
D- -3
DGND -4
-6 JPC22-18
NESTED_SWITCH
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-11
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Traction System Functional Operation
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR T VEL SENSOR+
BLACK
PANEL TME
-4 -5 -4
T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
T VEL PHASE B
2 JPT3
1 RED
TPC -2 -8 -16
STR T TEMP+
2 1 TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 FU2 MOTOR TEMPERATURE TA
-2 (350A) X TPC Y JPS1-8 -2 TPC
-3 TP5 CONTACTOR
-4 U
U
B-
1 V
TM V
TR STR W
FU1 W
(150A) Y X B+ +
TP2 FU3 2
(500A) Y X
LPC
2
LPC
1
SPL-2
JPS1-5 JPS1-6 JPS1-7 JPS1-10 -9 JPS1-11
A1 +
A2
A1 +
LM
MS
A2 -
S1 -
JP
B-
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
K3 TS1-2
JPF1-1 T˚
JPS10-3
FU8 (15A/5A)
-2
-5
1 2 JPF4-15
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/ TS2
RELAY -2
CARD JPF2-8 JPS3-1
TS2-1
1 2 -3
REACH
1 2 -4
SIDE
SHIFT
1 2 -5
TILT
B+
Buss+/- 4
-6
5v
B-
Input
8R828-011-224_D_C.EPS
Figure 8-4. Key Turned ON (Series AA/BA/DA/EA)
8-12 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Traction System Functional Operation
VEHICLE
MANAGER
BW1 JPC22-15
JPT1 BRUSH_WEAR_1
ID2 -20
-21
IDGND
LM_A1 JPC12-1 JPH1-1
+5VP +5VP
BW2 -16
BRUSH_WEAR_2 +5VP
-3 -3
P_THROTTLE VR1
LM_A2 DGND
+5VP +5VP +
(ON LM) 0 S3
TA LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-23 -4 -4 0
REACH S4
BUS_I+
-15 -11 -11
BUS_I- RETRACT -
-8 DGND
DGND
-1 -5 -5
B+K3 TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
-8 -8 -
SSHIFT_LEFT S8
DGND
DISPLAY -9 -9
SSHIFT_RIGHT S9
-12
JPD3-1 B-1 -12
+12VP DGND DGND
SOUNDER
-2 B-2 -13
SOUNDER
HTR6
-7 -7
-2 H_HTR
BUS_I+ JPC14-5
-3 JPD1-5
BUS_I- +12VP
-4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
-7 -4 JPC20-8 -2
BUS_I- +12VP
JPC22-7 -3
-8 -3 HGG_FAULT
DGND JPC24-2 -4
HGG_CONTACTOR
JPC10-3 -5
THERM_EN 4
JPC24-13
+12VP JPAD-1
JPC18-11 JPC10-8
STR_CONTACTOR AUX DEADMAN -2
-9 JPC24-4
LIFT_CONTACTOR DGND -3
T˚ JPZ-1 JPC24-22
LIFT_MOT_TEMP
(ON LM) JPC24-23 JPA-1
-2 -10 ROOM_TEMP
DGND
-11 -2
DGND
JPC22-20
FU3_SENSE
-19 JPC18-18 SPL-6
FU1_SENSE ALARM 4 4
JPC14-10
DGND
-2
DGND
-1 JPC20-16
L/L SOL2
-8
1 2
-9 B-F -15
(B+K2)B+L/L
1st SPEED JPS4-1 JPC20-1
S12 +12VP AUX1 -18
LIMITING SWITCH
NC
JPS4-3 COM -17
NO -2 JPC22-1 (B+K2)B+AUX1 SOL5T
SPEED_LIMIT_1 1 2
JPC10-10
BUS_E+ -20
AUX2 SOL5B
-5
BUS_E- 1 2
HRN -19
(B+K2)B+AUX2
-NEG
-12
-IN H-1 JPC18-16 AUXDUMP SOL8
H HORN
1 2
-POS H-2 -13
(B+K2)B+AUXDUMP
JPBR-2 JPS2-2
PRESSURE
+12VP
JPC20-4
JPC24-18
JPY1-1
-2
+
0
PRESS
DC LIFT &
-1 -1 JPC20-14
HYDRAULIC
BRAKE BRAKE -6 -3 -
DGND
JPB1-1
FAN-T
+ -
JPB1-2 JPC18-17
FAN +12VP
JPC20-5 JPDP-1
STEERING
DEADMAN
VR4
SENSOR
JPC24-19 -3
FAN-FW DEADMAN
JPB2-1 JPB2-2
+ - -7 -2
DGND
FAN-LM JPC20-2 JPS12-1
JPB5-2
DEADMAN
JPB5-1 +12VP
+ - JPC22-8 -2
SWITCH
ON_DEADMAN
NC
FAN-FW2 S2
JPB4-1 JPB4-2 JPDS-COM
+ - -1 DGND JPC18-7 -3 JPDS-NO
SOL4 2nd_STAGE
2 1
FAN-DU
JPB3-1 JPB3-2
+ - -10
SOL1 L/H
2 1
JPC14-6
RELAY_ENABLE
JPC22-21
EPO_SENSE
JPC14-12
B+KEY
-7 B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
JPS3-2
-3 JPC18-12 TXD JPC9-2
REACH_SOL
FLASHWEAR
RXD -3
-4 -14
SIDESHIFT_SOL DGND -5
-5 -15
TILT_SOL
COMMUNICATIONS
VBUS JPC2-1
D+ -2
USB
-6 D- -3
JPC22-18
NESTED_SWITCH -4
DGND
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-13
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Traction System Functional Operation
Deadman Pedal Depressed
When the Deadman Pedal is depressed, S2 is
closed, supplying the VM with B– through
JPC22-8, ON DEADMAN. This activates
circuitry that informs the VM the switch is
closed. At the same time, the pedal moves the
DEADMAN SENSOR, which is a potentiometer
connected to the pedal. The VM sees the input
from the sensor increase from the neutral
voltage. If a change is not seen from both
inputs, an error will be displayed. The input
from the DEADMAN SENSOR is used by the VM
to determine plugging strength of the drive
motor. The further the deadman pedal is
released, the more aggressive the plugging
command. The brake does not get applied until
the truck is at a complete stop and S2 is
opened.
With the S2 switch closed, the VM tells the LA
and TA it is closed and commands the LPC, TPC
and STR contactors to be closed on trucks with
an AC lift system. Trucks with a DC lift system
will not close the LPC until there is a lift request
seen by the VM. The VM will now react to any
request from control pots or switches for
lift/lower, travel and aux functions. When S2 is
opened again, the LPC and TPC will remain
energized for 30 seconds with no functions
commanded and then open. The STR contactor
will remain energized for 3 seconds and then
open. S2 will then have to be closed again for
the contactors to be energized.
With the deadman switch closed, the TA will
continuously monitor the input from the
Traction Velocity Sensor. If no travel request is
seen from the control handle and inputs are
seen from the sensor, the TA will power the
drive motor as required to keep the truck in the
same position. This prevents unwanted
movement when on uneven surfaces, dock
plates or ramps, or if placing a pallet in the rack
system.
8-14 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Traction System Functional Operation
1026304B, 15 July 2007 8-15
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Traction System Functional Operation
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR BLACK -4 -5 -4
T VEL SENSOR+
PANEL TME T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
TP2 TP3 TP5 T VEL PHASE B
JPT3
RED -2 -8 -16
FU1 FU3 FU2 T TEMP+
(150A) (500A) (350A) TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 MOTOR TEMPERATURE TA
-2 1 1 1 X TPC Y JPS1-8 -2 TPC
-3 STR LPC TPC CONTACTOR
2 2
-4 2 U
U
B-
V
TM V
W
1 W
B+ +
1 TR
LR 2 MOTOR VELOCITY
2 RED JPL2-1 JPL1-3
L VEL SENSOR+
BLACK -4 -4
LR-2 TR-2 LME L VEL SENSOR-
WHITE -3 -5
L VEL PHASE A
BLUE -2 -6
L VEL PHASE B
RED JPL3-2 -16
STR
L TEMP+
Y X LMT
RED/BLK -1 -17
L TEMP-
X LPC Y JPS1-9
MOTOR TEMPERATURE LPC
LA
-2
CONTACTOR
B-
U
U
V
LM V
JPS1-5 JPS1-6 JPS1-7 JPS1-10 JPS1-11
W
W +
B+
JP
B-
TP4 STR-2
MS-A1
A1 +
MS SA
A2 -
MS-A2
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
T˚ K3 TS1-2
JPF1-1 JPS10-3
FU8 (15A/5A)
-2
1 2 JPF4-15 -5
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/
TS2-2
RELAY
CARD JPF2-8 JPS3-1
TS2-1 1 2 -3
REACH
B+ 1 SIDE
SHIFT
2 -4
1 2 -5
Buss+/- TILT
5v
4
B- -6
Input
8R828-011-224_D_C.EPS
Figure 8-5. Deadman Depressed (Series CA/FA)
8-16 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Traction System Functional Operation
VEHICLE
MANAGER
JPT1
-20
ID2 RED JPE1-1 JPC10-6
-21 +12V_EN1
IDGND WHT -3 JPC22-5
CHANNEL_A_1 JPC12-1 JPH1-1
-2 -12 +5VP +5VP
BLU
CHANNEL_B_1
STEER BLK -4 JPC18-5 +5VP
TILLER DGND
-3 -3
ENCODER RED JPE2-1 JPC10-7 P_THROTTLE VR1
+12V_EN2
WHT -3 JPC22-13
CHANNEL_A_2 DGND
BLU -2 -14 +5VP +5VP +
CHANNEL_B_2
0 S3
TA BLK -4 JPC18-6
DGND LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-1 -4 -4 0
REACH S4
B+K3
-7 -11 -11
DGND RETRACT -
-22 DGND
BUS_I+
BUS_I- -14 -5 -5
TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
JPL1 -8 -8 -
-15 SSHIFT_LEFT S8
BUS_I- DGND
DISPLAY -9 -9
-23 SSHIFT_RIGHT S9
BUS_I+ -12
-8 JPD3-1 B-1 -12
DGND +12VP DGND DGND
SOUNDER -13
-2 B-2
SOUNDER
HTR6
-7 -7
-22 -2 H_HTR
BUS_I+ BUS_I+ JPC14-5
-14 -3 JPD1-5
BUS_I- BUS_I- +12VP
-7 -4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
DGND JPC20-8 -2
-7 -4 +12VP
BUS_I- JPC22-7 -3
LA -8 -3
DGND
HGG_FAULT
HGG_CONTACTOR
JPC24-2 -4
-12 JPC10-3 -5
ID1 THERM_EN 4
-13
IDGND JPC24-13
+12VP JPAD-1
JPC10-8
AUX DEADMAN -2
JPC24-4
DGND -3
-1
B+K3
JPC18-11
STR_CONTACTOR JPC24-23 JPA-1
ROOM_TEMP
JPC6-6 -11 -2
DGND
+12VP
-5
CCW_PWM JPC18-18 SPL-6
-2 ALARM 4 4
CW_PWM
-3
STEER_CURRENT
-4
DGND JPC20-16
-1 L/L SOL2
NEUTRAL_PULSE 1 2
-15
(B+K2)B+L/L
JPC22-19
FU1_SENSE -18
JPC14-10 AUX1
DGND
-2 -17
DGND (B+K2)B+AUX1 SOL5T
-1
1 2
-8
-9 B-F -20
AUX2 SOL5B
1st SPEED 1 2
S12 LIMITING SWITCH JPS4-1 JPC20-1 -19
+12VP (B+K2)B+AUX2
NC -12
JPS4-3 COM DUMP SOL3
NO -2 JPC22-1 1
AC LIFT &
SPEED_LIMIT_1 2
-13
(B+K2)B+DUMP
JPC10-10
BUS_E+
-5 JPC20-4 JPY1-1 +
+12VP
ELECTRIC
BUS_E-
HRN JPC24-18 -2 0
-NEG PRESSURE PRESS
-6 -3 -
-IN H-1 JPC18-16 DGND
H HORN
STEER
-POS H-2
JPBR-2 JPS2-2 JPC20-5 JPDP-1
+12VP
DEADMAN
VR4
SENSOR
-1 -1 JPC20-14 JPC24-19 -3
BRAKE BRAKE DEADMAN
FAN-T -7 -2
JPB1-1 + JPB1-2 JPC18-17 DGND
- FAN
JPC20-2 JPS12-1
DEADMAN
FAN-FW +12VP
JPC22-8 -2
SWITCH
JPB2-1 JPB2-2 ON DEADMAN
+ - NC
S2
JPC18-7 -3 JPDS-COM JPDS-NO
FAN-FW2 DGND
JPB4-1 JPB4-2
+ -
FAN-DU
JPB3-1 JPB3-2
+ -
-10 JPC20-7 JPE4-1 RED
SOL1 L/H +12VP
2 1 JPC22-9 -3
JPC14-6 CHANNELA_4 WHT STEER
RELAY_ENABLE MOTOR
JPC22-21 -10 -2 BLU ENCODER
EPO_SENSE CHANNELB_4
JPC10-9 -4 BLK
DGND
JPC14-12
ROTATION
B+KEY JPC20-9 JPST-1 +
SWITCH
+12VP
END OF
STEER
JPC22-22 -2 0 S11
STEER_LIMIT
-11 -3 -
DGND
-7
B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
FLASHWARE
TXD JPC9-2
JPS3-2 -3
RXD
DGND -5
-3 JPC18-12
REACH_SOL
-4 -14
SIDESHIFT_SOL
COMMUNICATIONS
-5 -15 VBUS JPC2-1
TILT_SOL
D+ -2
USB
D- -3
DGND -4
-6 JPC22-18
NESTED_SWITCH
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-17
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Traction System Functional Operation
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR T VEL SENSOR+
BLACK
PANEL TME
-4 -5 -4
T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
T VEL PHASE B
2 JPT3
1 RED
TPC -2 -8 -16
STR T TEMP+
2 1 TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 FU2 MOTOR TEMPERATURE TA
-2 (350A) X TPC Y JPS1-8 -2 TPC
-3 TP5 CONTACTOR
-4 U
U
B-
1 V
TM V
TR STR W
FU1 W
(150A) Y X B+ +
TP2 FU3 2
(500A) Y X
LPC
2
LPC
1
SPL-2
JPS1-5 JPS1-6 JPS1-7 JPS1-10 -9 JPS1-11
A1 +
A2
A1 +
LM
MS
A2 -
S1 -
JP
B-
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
K3 TS1-2
JPF1-1 T˚
JPS10-3
FU8 (15A/5A)
-2
-5
1 2 JPF4-15
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/ TS2
RELAY -2
CARD JPF2-8 JPS3-1
TS2-1
1 2 -3
REACH
1 2 -4
SIDE
SHIFT
1 2 -5
TILT
B+
Buss+/- 4
-6
5v
B-
Input
8R828-011-224_D_C.EPS
Figure 8-6. Deadman Depressed (Series AA/BA/DA/EA)
8-18 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Traction System Functional Operation
VEHICLE
MANAGER
BW1 JPC22-15
JPT1 BRUSH_WEAR_1
ID2 -20
-21
IDGND
LM_A1 JPC12-1 JPH1-1
+5VP +5VP
BW2 -16
BRUSH_WEAR_2 +5VP
-3 -3
P_THROTTLE VR1
LM_A2 DGND
+5VP +5VP +
(ON LM) 0 S3
TA LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-23 -4 -4 0
REACH S4
BUS_I+
-15 -11 -11
BUS_I- RETRACT -
-8 DGND
DGND
-1 -5 -5
B+K3 TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
-8 -8 -
SSHIFT_LEFT S8
DGND
DISPLAY -9 -9
SSHIFT_RIGHT S9
-12
JPD3-1 B-1 -12
+12VP DGND DGND
SOUNDER
-2 B-2 -13
SOUNDER
HTR6
-7 -7
-2 H_HTR
BUS_I+ JPC14-5
-3 JPD1-5
BUS_I- +12VP
-4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
-7 -4 JPC20-8 -2
BUS_I- +12VP
JPC22-7 -3
-8 -3 HGG_FAULT
DGND JPC24-2 -4
HGG_CONTACTOR
JPC10-3 -5
THERM_EN 4
JPC24-13
+12VP JPAD-1
JPC18-11 JPC10-8
STR_CONTACTOR AUX DEADMAN -2
-9 JPC24-4
LIFT_CONTACTOR DGND -3
T˚ JPZ-1 JPC24-22
LIFT_MOT_TEMP
(ON LM) JPC24-23 JPA-1
-2 -10 ROOM_TEMP
DGND
-11 -2
DGND
JPC22-20
FU3_SENSE
-19 JPC18-18 SPL-6
FU1_SENSE ALARM 4 4
JPC14-10
DGND
-2
DGND
-1 JPC20-16
L/L SOL2
-8
1 2
-9 B-F -15
(B+K2)B+L/L
1st SPEED JPS4-1 JPC20-1
S12 +12VP AUX1 -18
LIMITING SWITCH
NC
JPS4-3 COM -17
NO -2 JPC22-1 (B+K2)B+AUX1 SOL5T
SPEED_LIMIT_1 1 2
JPC10-10
BUS_E+ -20
AUX2 SOL5B
-5
BUS_E- 1 2
HRN -19
(B+K2)B+AUX2
-NEG
-12
-IN H-1 JPC18-16 AUXDUMP SOL8
H HORN
1 2
-POS H-2 -13
(B+K2)B+AUXDUMP
JPBR-2 JPS2-2
PRESSURE
+12VP
JPC20-4
JPC24-18
JPY1-1
-2
+
0
PRESS
DC LIFT &
-1 -1 JPC20-14
HYDRAULIC
BRAKE BRAKE -6 -3 -
DGND
JPB1-1
FAN-T
+ -
JPB1-2 JPC18-17
FAN +12VP
JPC20-5 JPDP-1
STEERING
DEADMAN
VR4
SENSOR
JPC24-19 -3
FAN-FW DEADMAN
JPB2-1 JPB2-2
+ - -7 -2
DGND
FAN-LM JPC20-2 JPS12-1
JPB5-2
DEADMAN
JPB5-1 +12VP
+ - JPC22-8 -2
SWITCH
ON_DEADMAN
NC
FAN-FW2 S2
JPB4-1 JPB4-2 JPDS-COM
+ - -1 DGND JPC18-7 -3 JPDS-NO
SOL4 2nd_STAGE
2 1
FAN-DU
JPB3-1 JPB3-2
+ - -10
SOL1 L/H
2 1
JPC14-6
RELAY_ENABLE
JPC22-21
EPO_SENSE
JPC14-12
B+KEY
-7 B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
JPS3-2
-3 JPC18-12 TXD JPC9-2
REACH_SOL
FLASHWEAR
RXD -3
-4 -14
SIDESHIFT_SOL DGND -5
-5 -15
TILT_SOL
COMMUNICATIONS
VBUS JPC2-1
D+ -2
USB
-6 D- -3
JPC22-18
NESTED_SWITCH -4
DGND
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-19
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Traction System Functional Operation
Electric Steering waves, the Steer Amplifier determines the speed
of rotation requested and sends the appropriate
NOTE: This information is based on a truck voltage to the steer motor. Direction of steer
that is not programmed for Reverse motor/drive unit rotation is controlled by the
Steering. If programmed for Reverse side of the steer motor which has positive
Steering, the VM will reverse the CW voltage applied to it, MS-A1 or MS-A2. The VM
and CCW commands to the Steer then monitors the inputs from the Steer Motor
Amplifier. It will also know to look for Encoder to determine the direction and speed
feedback from the Steer Motor Encoder the motor is turning and compares it to the
in the opposite direction. request. The VM also monitors the Steer Motor
On trucks with electric steering, when the VM current from the Steer Amplifier on JPC6-3,
closes the STR contactor, the VM begins to Steer_Current. Current limit for the steer motor
monitor the inputs from the Steer Amplifier, is approx. 100 amps and is controlled by the
Steer Tiller Encoder and the Steer Motor Steer Amplifier. The VM uses this input when
Encoder. The VM is looking for a current draw checking the steering system for shorts or
on the 12V lines that power the two steer tiller opens in the power circuit. The VM is also
encoder channels. With no steer requests from watching the input from a switch, END OF
the Steer Tiller Encoder, the VM is looking for STEER ROTATION SWITCH, mounted next to
an input from the Steer Amplifier on JPC6-1, the drive unit. This is a proximity switch that is
Neutral_Pulse. This feedback from the Steer turned ON and OFF by a metal ring mounted to
Amplifier informs the VM that the Amplifier is he drive unit. As the drive unit nears the end of
connected and powered up. The Neutral_Pulse its rotation the metal ring is no longer under
is created by the VM sending a very low steering the proximity switch and the switch will open
command over the CCW and CW wires to the prior to hitting the drive unit’s mechanical stop.
Steer Amplifier. These commands are alternated When this input to the VM goes low at
back and forth between CCW and CW. This JPC22-22, Steer_Limit, the VM will no longer
creates a toggling high/low input on the send out a steer command in that direction. It
Neutral_Pulse line that changes about 10 times will only send out commands when there is a
a second. When a steer command is present, request in the opposite direction from the
this input does not toggle as fast and the VM operator. This prevents the steering system
will ignore it. When the operator turns the from being held in current limit.
steering wheel, a set of square wave voltages
(chopped DC voltage) is sent to the VM on
Channels A1, B1, A2 and B2. The VM looks at
the square waves as sets. A1 and B1 are one set
and A2 and B2 are another set. Based on which
channel of the set is seen first, A or B, the VM
determines the direction the operator has
requested the drive unit to turn. The VM
determines the requested speed by the amount
of time between the square waves. Less off time
between them means a faster rotation has been
requested. Two sets are used so the VM can
compare them and verify the encoder is
functioning correctly. Once this information
has been processed, the VM sends out a
chopped DC voltage to the Steer Amplifier over
CCW_PWM or CW_PWM. CCW_PWM is a
request for the drive unit to be turned in the
Counterclockwise direction and CW_PWM is a
command to turn in the Clockwise direction.
Based on the off time between the square
8-20 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Traction System Functional Operation
Travel Request
Primary Control Handle
With the deadman switch closed, the VM
constantly sends an RPM request that causes
the Traction Amplifier to maintain the speed
requested by the operator. With the control
handle in neutral, the request is always at
0 RPM. When the VM sees a change in the
learned neutral voltage from the primary
control handle travel pot (VR1) at JPC12-3, it
first checks for any inputs that activate a speed
limit condition. If none are seen, it calculates
the direction and percent of full speed
requested based on the learned values. A
message is sent to the Traction Amplifier (TA)
over the BUS as a command to travel in the
appropriate direction at the RPM to obtain the
requested speed. The TA then determines the
proper sequence to energize the motor leads (U,
V and W) to move the truck in the proper
direction. The TA also determines the required
amount of DC voltage to be sent through the
motor leads based on the acceleration
parameters programmed and the requested
RPM. The TA then monitors the feedback from
the Motor Velocity sensor inside the drive motor
to adjust the voltage to the motor to maintain
the requested RPM and direction. Any
conditions that prevent the TA from
maintaining these requests will be sent over the
BUS to the VM and the VM will tell the Display
over the BUS to display a message informing
the operator. The VM will also take care of
invoking any system shut down or limitations
based on the information from the TA.
Secondary Control Handle
Travel requests from the Secondary Control
Handle are processed in the same way as the
Primary Control Handle. The only difference is
that forks-first travel speed is limited by the
VM.
1026304B, 15 July 2007 8-21
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Traction System Functional Operation
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR T VEL SENSOR+
BLACK
PANEL TME
-4 -5 -4
T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
T VEL PHASE B
2 JPT3
1 RED
TPC -2 -8 -16
STR T TEMP+
2 1 TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 FU2 MOTOR TEMPERATURE TA
-2 (350A) X TPC Y JPS1-8 -2 TPC
-3 TP5 CONTACTOR
-4 U
U
B-
1 V
TM V
TR STR W
FU1 W
(150A) Y X B+ +
TP2 FU3 2
(500A) Y X
LPC
2
LPC
1
SPL-2
JPS1-5 JPS1-6 JPS1-7 JPS1-10 -9 JPS1-11
A1 +
A2
A1 +
LM
MS
A2 -
S1 -
JP
B-
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
K3 TS1-2
JPF1-1 T˚
JPS10-3
FU8 (15A/5A)
-2
-5
1 2 JPF4-15
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/ TS2
RELAY -2
CARD JPF2-8 JPS3-1
TS2-1
1 2 -3
REACH
1 2 -4
SIDE
SHIFT
1 2 -5
TILT
B+
Buss+/- 4
-6
5v
B-
Input
8R828-011-224_D_C.EPS
Figure 8-7. Travel Request (Series AA/BA/DA/EA)
8-22 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Traction System Functional Operation
VEHICLE
MANAGER
BW1 JPC22-15
JPT1 BRUSH_WEAR_1
ID2 -20
-21
IDGND
LM_A1 JPC12-1 JPH1-1
+5VP +5VP
BW2 -16
BRUSH_WEAR_2 +5VP
-3 -3
P_THROTTLE VR1
LM_A2 DGND
+5VP +5VP +
(ON LM) 0 S3
TA LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-23 -4 -4 0
REACH S4
BUS_I+
-15 -11 -11
BUS_I- RETRACT -
-8 DGND
DGND
-1 -5 -5
B+K3 TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
-8 -8 -
SSHIFT_LEFT S8
DGND
DISPLAY -9 -9
SSHIFT_RIGHT S9
-12
JPD3-1 B-1 -12
+12VP DGND DGND
SOUNDER
-2 B-2 -13
SOUNDER
HTR6
-7 -7
-2 H_HTR
BUS_I+ JPC14-5
-3 JPD1-5
BUS_I- +12VP
-4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
-7 -4 JPC20-8 -2
BUS_I- +12VP
JPC22-7 -3
-8 -3 HGG_FAULT
DGND JPC24-2 -4
HGG_CONTACTOR
JPC10-3 -5
THERM_EN 4
JPC24-13
+12VP JPAD-1
JPC18-11 JPC10-8
STR_CONTACTOR AUX DEADMAN -2
-9 JPC24-4
LIFT_CONTACTOR DGND -3
T˚ JPZ-1 JPC24-22
LIFT_MOT_TEMP
(ON LM) JPC24-23 JPA-1
-2 -10 ROOM_TEMP
DGND
-11 -2
DGND
JPC22-20
FU3_SENSE
-19 JPC18-18 SPL-6
FU1_SENSE ALARM 4 4
JPC14-10
DGND
-2
DGND
-1 JPC20-16
L/L SOL2
-8
1 2
-9 B-F -15
(B+K2)B+L/L
1st SPEED JPS4-1 JPC20-1
S12 +12VP AUX1 -18
LIMITING SWITCH
NC
JPS4-3 COM -17
NO -2 JPC22-1 (B+K2)B+AUX1 SOL5T
SPEED_LIMIT_1 1 2
JPC10-10
BUS_E+ -20
AUX2 SOL5B
-5
BUS_E- 1 2
HRN -19
(B+K2)B+AUX2
-NEG
-12
-IN H-1 JPC18-16 AUXDUMP SOL8
H HORN
1 2
-POS H-2 -13
(B+K2)B+AUXDUMP
JPBR-2 JPS2-2
PRESSURE
+12VP
JPC20-4
JPC24-18
JPY1-1
-2
+
0
PRESS
DC LIFT &
-1 -1 JPC20-14
HYDRAULIC
BRAKE BRAKE -6 -3 -
DGND
JPB1-1
FAN-T
+ -
JPB1-2 JPC18-17
FAN +12VP
JPC20-5 JPDP-1
STEERING
DEADMAN
VR4
SENSOR
JPC24-19 -3
FAN-FW DEADMAN
JPB2-1 JPB2-2
+ - -7 -2
DGND
FAN-LM JPC20-2 JPS12-1
JPB5-2
DEADMAN
JPB5-1 +12VP
+ - JPC22-8 -2
SWITCH
ON_DEADMAN
NC
FAN-FW2 S2
JPB4-1 JPB4-2 JPDS-COM
+ - -1 DGND JPC18-7 -3 JPDS-NO
SOL4 2nd_STAGE
2 1
FAN-DU
JPB3-1 JPB3-2
+ - -10
SOL1 L/H
2 1
JPC14-6
RELAY_ENABLE
JPC22-21
EPO_SENSE
JPC14-12
B+KEY
-7 B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
JPS3-2
-3 JPC18-12 TXD JPC9-2
REACH_SOL
FLASHWEAR
RXD -3
-4 -14
SIDESHIFT_SOL DGND -5
-5 -15
TILT_SOL
COMMUNICATIONS
VBUS JPC2-1
D+ -2
USB
-6 D- -3
JPC22-18
NESTED_SWITCH -4
DGND
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-23
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Traction System Functional Operation
Cold Storage
On trucks with the Cold Storage option, the VM
looks at the Ambient Temperature Sensor
mounted on the overhead guard. If the
temperature indicates the truck is parked
inside the freezer, the VM does not turn off the
Relay Enable circuit when the key switch is
opened. When the key is turned OFF, K1, K2
and K3 all open because they are powered off
the key switch. The K4 coil and tips receive
power directly from the battery through FU5.
When the tips are closed, K4 supplies B+ to
internal circuitry of the VM. This is only used
on trucks equipped with the optional Cold
Storage package. Knowing the truck is still in
the freezer, the VM uses the input from the K4
tips to keep its circuitry powered up. This is
done so the VM can keep the circuitry activated
for the control handle heater. The display is
shut down and no other functions can be
operated until the key is turned back ON and
the truck is powered up.
8-24 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
Hydraulic System carriage. When they reach the limit of their
travel, the main lift cylinders extend, elevating
Functional Operation the telescopics.
(AC Lift Motor) Reach/Retract Cylinder
The reach/retract cylinder is a double-acting
hydraulic cylinder used for extending and
Series CA and FA retracting the forks from the mast.
Lift/Aux System Sideshift Cylinder
NOTE: The schematics in this chapter are The sideshift cylinder is a double-acting
intended for general understanding of hydraulic cylinder used to shift the load left and
theory of operation and do not reflect right with respect to the mast.
the latest developments in circuitry.
Tilt Cylinder
Do not use these schematics to
troubleshoot or repair the lift truck. The tilt cylinder is a double-acting hydraulic
cylinder used to tilt the forks up and down.
Always use the schematics in the
Appendix for troubleshooting and Load Holding Valve (SOL1)
repair.
The load holding valve is a normally closed
NOTE: On electrical schematics, only circuits solenoid valve used to hold the carriage in an
related directly with the hydraulic elevated position. It incorporates an override to
functions are addressed. allow lowering the carriage manually.
System Components Proportional Lower Valve (SOL2)
The proportional lower valve is a pressure
Main Lift/Aux Pump (P1)
compensated flow control solenoid valve used to
Pump P1 is a positive displacement gear pump lower the carriage. As the voltage to the valve
that rotates clockwise from the shaft end. P1 is increases, the flow through the valve increases,
used for all lift and aux functions. regardless of the pressure.
Main Lift System Proportional Relief (SOL3/Dump)
The main lift system consists of four single SOL3 is a proportional solenoid used as a
acting hydraulic cylinders. Hydraulic fluid flows system relief. In addition, SOL3 is used to divert
from the main manifold through a tee-fitting in hydraulic fluid from P1 back to the reservoir
the tractor, through fittings in the left and right after a lift is stopped and the pump is still
front of the tractor bulkhead. The right side spinning. It also acts as a valve to port excess
hose feeds the right side main lift cylinder. The hydraulic fluid back to the reservoir from the
left side divides again at a tee-fitting, supplying auxiliary functions.
both the left side main lift cylinder and the free
lift cylinders. At the bottom of the free lift 2d Pump (SOL 4)
cylinders, another tee-fitting divides the flow
Series BA/EA trucks have a dual lift pump. The
between left and right free lift cylinders. A flow
2d Pump solenoid, normally directs hydraulic
limiter is installed at one of the free lift and one
fluid from the 2d pump P2 back through the
or both of the main lift cylinders.
filter to the reservoir. When energized, the
When the operator requests lift, the entire lift solenoid blocks the return flow, forcing the
system is pressurized. Since the carriage additional hydraulic fluid from P2 to the lift
weighs less than the carriage plus telescopic, cylinders, providing high speed lift.
the free lift cylinders extend first, elevating the
1026304B, 15 July 2007 8-25
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
SOL5B/SOL5T Lift Motor
SOL5 is a directional solenoid valve providing The lift motor is a brushless, three-phase
directional control to the reach, tilt, and internally delta connected variable-speed AC
sideshift functions. De-energized, flow is motor.
blocked to the aux functions and directed to the
reservoir. When SOL5B is energized, flow is Lift Motor Speed Sensor
directed to port A2 for tilt up, sideshift right, or
The lift motor speed sensor is a two-channel
retract. When SOL5T is energized, flow is
bearing mounted encoder in the lift motor. Its
directed to port A1 for tilt down, sideshift left, or
purpose is to tell the lift power amplifier the
reach.
motor speed for motor speed regulation during
lift and auxiliary functions.
Reach/Retract Solenoid (R/R SOL)
R/R SOL is a normally closed solenoid valve Lift Motor Temperature Sensor
used to block (de-energized) or allow (energized)
The lift motor temperature sensor is mounted
fluid flow to and from the reach cylinders.
internally in the lift motor. Its purpose is to tell
the lift power amplifier the motor temperature.
Sideshift Solenoid (S/S SOL)
An external temperature sensor kit is available
S/S SOL is a normally closed solenoid valve to replace an inoperable internal temperature
used to block (de-energized) or allow (energized) sensor.
fluid flow to and from the sideshift cylinder.
Clogged Filter Switch (S19)
Tilt Solenoid (TILT SOL)
The switch is a normally open switch used to
TILT SOL is a normally closed solenoid valve inform the VM when the filter needs to be
used to block (de-energized) or allow (energized) changed. When pressure in the return line
fluid flow to and from the tilt cylinder. becomes high, the switch closes, completing the
circuit between JPC22-3 and JPF3-12. This
Flow Limiter Valve causes a message to be displayed on the
operator display.
Flow limiter valves are used to limit the
maximum lower speed of the forks. A check
Load Shuttle (LS-1)
valve forces restricted flow through the valve
during lower, but allows free flow during lift. The load shuttles are 2-input, pressure
activated, 2-position valves. In each shuttle, the
Aux Relief Valve (REL2) higher of the input pressures passes through
the valve at the pressure out port. The output
REL2 is a relief valve used to protect auxiliary
port provides flow used to operate pressure-
system components against excessive pressure.
activated devices such as piloted relief or
It is factory-adjusted to 2000 psi (13790 kPa). A
metering valves. The load shuttles provide
manual adjustment knob can be turned
pressure feedback to the pilot line of the PODS
clockwise to increase the relief pressure, or
valve to allow it to position itself for proper
counterclockwise to decrease the relief
auxiliary and lift function operation.
pressure.
Priority On Demand Spool (PODS)
Hydraulic Filter
This is a pilot operated spring return valve
The hydraulic system has one (7400) or two
which divides flow between the lift and auxiliary
(7420/7440) filters in the main manifold. Their
functions as requested. It also provides a path
purpose is to filter impurities from the
to the reservoir for excess hydraulic fluid from
hydraulic system. They filter all hydraulic fluid
P1.
on the return to the reservoir. There is no
internal bypass.
8-26 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
Theory of Lift/Aux Functions unrestricted section of the flow limiter to
the lift cylinders.
Lift 8. Hydraulic fluid from pump P2 is returned
to tank through de-energized aux select
Refer to Figures 8-8 and 8-9. solenoid SOL4 and the hydraulic fluid
1. Lift speed varies directly with lift motor filter.
rpm. The voltage supplied to the lift motor 9. When the lift knob is returned to neutral,
is proportional to the amount of lift the lift motor is ramped down. SOL3 is
request from VR2 (faster lift = higher opened to relieve any pressure spikes in
motor voltage). Maximum lift speed for a the system.
given weight load is governed by software.
Weight is calculated from inputs to the VM
from the pressure transducer. Weight of
the empty carriage and telescopic is
calculated during Learn Mode.
2. Prior to requesting a lift, all valves are in
the de-energized state.
3. When VR2 is moved to request lift, a
voltage is sent to the VM at JPC12-2. The
VM sees a voltage different from the
“learned” neutral voltage, and sends a
request to the lift power amplifier via
BUS+/BUS– (JPC14-11 and JPC14-4
through the operator display to JPL1-22
and JPL1-14).
4. The lift power amplifier internally supplies
B- to the lift contactor coil (LPC) at JPL1-2,
which closes the normally open contactor
tips.
5. The lift contactor is energized either by
depressing the deadman switch (S2), or
rotating the lift pot (VR2) out of neutral to
the lift position.
6. When the lift contactor coil is energized,
the contactor tips close, allowing B+ to be
supplied to the lift power amplifier, which
supplies voltage to the lift motor to make it
rotate.
The PODS valve (POD-1) receives pressure
at port 4, placing pressure on the pilot line
of the valve. This pressure moves the spool
in the valve to allow flow out port 2 down
to CV-1, the de-energized load holding
solenoid (SOL1), through the flow limiters
in the base of the lift cylinders and into the
lift cylinders, producing lift.
7. Fluid flows from the lift pump, load
holding solenoid SOL1, through the
1026304B, 15 July 2007 8-27
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR BLACK -4 -5 -4
T VEL SENSOR+
PANEL TME T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
TP2 TP3 TP5 T VEL PHASE B
JPT3
RED -2 -8 -16
FU1 FU3 FU2 T TEMP+
(150A) (500A) (350A) TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 MOTOR TEMPERATURE TA
-2 1 1 1 X TPC Y JPS1-8 -2 TPC
-3 STR LPC TPC CONTACTOR
2 2
-4 2 U
U
B-
V
TM V
W
1 W
B+ +
1 TR
LR 2 MOTOR VELOCITY
2 RED JPL2-1 JPL1-3
L VEL SENSOR+
BLACK -4 -4
LR-2 TR-2 LME L VEL SENSOR-
WHITE -3 -5
L VEL PHASE A
BLUE -2 -6
L VEL PHASE B
RED JPL3-2 -16
STR
L TEMP+
Y X LMT
RED/BLK -1 -17
L TEMP-
X LPC Y JPS1-9
MOTOR TEMPERATURE LPC
LA
-2
CONTACTOR
B-
U
U
V
LM V
JPS1-5 JPS1-6 JPS1-7 JPS1-10 JPS1-11
W
W +
B+
JP
B-
TP4 STR-2
MS-A1
A1 +
MS SA
A2 -
MS-A2
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
T˚ K3 TS1-2
JPF1-1 JPS10-3
FU8 (15A/5A)
-2
1 2 JPF4-15 -5
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/
TS2-2
RELAY
CARD JPF2-8 JPS3-1
TS2-1 1 2 -3
REACH
B+ 1 SIDE
SHIFT
2 -4
1 2 -5
Buss+/- TILT
5v
4
B- -6
Input
8R828-011-224_D_C.EPS
Figure 8-8. Lift - Electrical (Series CA/FA)
8-28 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
VEHICLE
MANAGER
JPT1
-20
ID2 RED JPE1-1 JPC10-6
-21 +12V_EN1
IDGND WHT -3 JPC22-5
CHANNEL_A_1 JPC12-1 JPH1-1
-2 -12 +5VP +5VP
BLU
CHANNEL_B_1
STEER BLK -4 JPC18-5 +5VP
TILLER DGND
-3 -3
ENCODER RED JPE2-1 JPC10-7 P_THROTTLE VR1
+12V_EN2
WHT -3 JPC22-13
CHANNEL_A_2 DGND
BLU -2 -14 +5VP +5VP +
CHANNEL_B_2
0 S3
TA BLK -4 JPC18-6
DGND LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-1 -4 -4 0
REACH S4
B+K3
-7 -11 -11
DGND RETRACT -
-22 DGND
BUS_I+
BUS_I- -14 -5 -5
TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
JPL1 -8 -8 -
-15 SSHIFT_LEFT S8
BUS_I- DGND
DISPLAY -9 -9
-23 SSHIFT_RIGHT S9
BUS_I+ -12
-8 JPD3-1 B-1 -12
DGND +12VP DGND DGND
SOUNDER -13
-2 B-2
SOUNDER
HTR6
-7 -7
-22 -2 H_HTR
BUS_I+ BUS_I+ JPC14-5
-14 -3 JPD1-5
BUS_I- BUS_I- +12VP
-7 -4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
DGND JPC20-8 -2
-7 -4 +12VP
BUS_I- JPC22-7 -3
LA -8 -3
DGND
HGG_FAULT
HGG_CONTACTOR
JPC24-2 -4
-12 JPC10-3 -5
ID1 THERM_EN 4
-13
IDGND JPC24-13
+12VP JPAD-1
JPC10-8
AUX DEADMAN -2
JPC24-4
DGND -3
-1
B+K3
JPC18-11
STR_CONTACTOR JPC24-23 JPA-1
ROOM_TEMP
JPC6-6 -11 -2
DGND
+12VP
-5
CCW_PWM JPC18-18 SPL-6
-2 ALARM 4 4
CW_PWM
-3
STEER_CURRENT
-4
DGND JPC20-16
-1 L/L SOL2
NEUTRAL_PULSE 1 2
-15
(B+K2)B+L/L
JPC22-19
FU1_SENSE -18
JPC14-10 AUX1
DGND
-2 -17
DGND (B+K2)B+AUX1 SOL5T
-1
1 2
-8
-9 B-F -20
AUX2 SOL5B
1st SPEED 1 2
S12 LIMITING SWITCH JPS4-1 JPC20-1 -19
+12VP (B+K2)B+AUX2
NC -12
JPS4-3 COM DUMP SOL3
NO -2 JPC22-1 1
AC LIFT &
SPEED_LIMIT_1 2
-13
(B+K2)B+DUMP
JPC10-10
BUS_E+
-5 JPC20-4 JPY1-1 +
+12VP
ELECTRIC
BUS_E-
HRN JPC24-18 -2 0
-NEG PRESSURE PRESS
-6 -3 -
-IN H-1 JPC18-16 DGND
H HORN
STEER
-POS H-2
JPBR-2 JPS2-2 JPC20-5 JPDP-1
+12VP
DEADMAN
VR4
SENSOR
-1 -1 JPC20-14 JPC24-19 -3
BRAKE BRAKE DEADMAN
FAN-T -7 -2
JPB1-1 + JPB1-2 JPC18-17 DGND
- FAN
JPC20-2 JPS12-1
DEADMAN
FAN-FW +12VP
JPC22-8 -2
SWITCH
JPB2-1 JPB2-2 ON DEADMAN
+ - NC
S2
JPC18-7 -3 JPDS-COM JPDS-NO
FAN-FW2 DGND
JPB4-1 JPB4-2
+ -
FAN-DU
JPB3-1 JPB3-2
+ -
-10 JPC20-7 JPE4-1 RED
SOL1 L/H +12VP
2 1 JPC22-9 -3
JPC14-6 CHANNELA_4 WHT STEER
RELAY_ENABLE MOTOR
JPC22-21 -10 -2 BLU ENCODER
EPO_SENSE CHANNELB_4
JPC10-9 -4 BLK
DGND
JPC14-12
ROTATION
B+KEY JPC20-9 JPST-1 +
SWITCH
+12VP
END OF
STEER
JPC22-22 -2 0 S11
STEER_LIMIT
-11 -3 -
DGND
-7
B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
FLASHWARE
TXD JPC9-2
JPS3-2 -3
RXD
DGND -5
-3 JPC18-12
REACH_SOL
-4 -14
SIDESHIFT_SOL
COMMUNICATIONS
-5 -15 VBUS JPC2-1
TILT_SOL
D+ -2
USB
D- -3
DGND -4
-6 JPC22-18
NESTED_SWITCH
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-29
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
G2 HTI
TACH 1
REL-2
M
SOL-5B
1 2
1 A1
4 3 2 LS-1
3
P1 2
P1
2 1 4
3 A2
POD-1
SOL-5T
G1
1
CV-1 1 CYL-1
2 2
SOL-1
1
SOL-3
1
CFS-1
SOL-2
TANK
FILTER
S-RET
CYL-P
PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-9. Lift - Hydraulic (Series CA/FA)
8-30 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
REACH
RC
3 4
A2
1 2
RR
REACH1 TILT
3 4 TC
1 2
TR
TILT
MAIN LIFT
FREE LIFT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-31
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
Lower
Refer to Figures 8-10 and 8-11.
1. Variable lowering is accomplished via the
proportional lower valve SOL2, a
two-position, normally closed pressure
compensated valve. Lowering speed is not
a function of weight on the forks. An
increasing voltage increases the flow
through the valve regardless of the
pressure in the system.
2. When VR2 is moved to request Lower, a
voltage is sent to the VM at JPC12-2. The
VM sees a voltage different from the
“learned” neutral voltage.
3. The VM energizes internal coil drivers for
SOL1 (load holding) at JPC18-10.
Proportional lower solenoid SOL2 opens
proportionally to the requested rate of
lower via a signal from the VM at
JPC20-16.
4. With load holding solenoid SOL1
energized, fluid flows out of the lift
cylinders through the regulated portion of
flow limiters (located in the base of the lift
cylinder), through load holding solenoid
SOL1, and then through energized
proportional lower solenoid SOL2. After
fluid exits these valves, it returns to tank
via the hydraulic fluid filter.
8-32 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
1026304B, 15 July 2007 8-33
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR BLACK -4 -5 -4
T VEL SENSOR+
PANEL TME T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
TP2 TP3 TP5 T VEL PHASE B
JPT3
RED -2 -8 -16
FU1 FU3 FU2 T TEMP+
(150A) (500A) (350A) TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 MOTOR TEMPERATURE TA
-2 1 1 1 X TPC Y JPS1-8 -2 TPC
-3 STR LPC TPC CONTACTOR
2 2
-4 2 U
U
B-
V
TM V
W
1 W
B+ +
1 TR
LR 2 MOTOR VELOCITY
2 RED JPL2-1 JPL1-3
L VEL SENSOR+
BLACK -4 -4
LR-2 TR-2 LME L VEL SENSOR-
WHITE -3 -5
L VEL PHASE A
BLUE -2 -6
L VEL PHASE B
RED JPL3-2 -16
STR
L TEMP+
Y X LMT
RED/BLK -1 -17
L TEMP-
X LPC Y JPS1-9
MOTOR TEMPERATURE LPC
LA
-2
CONTACTOR
B-
U
U
V
LM V
JPS1-5 JPS1-6 JPS1-7 JPS1-10 JPS1-11
W
W +
B+
JP
B-
TP4 STR-2
MS-A1
A1 +
MS SA
A2 -
MS-A2
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
T˚ K3 TS1-2
JPF1-1 JPS10-3
FU8 (15A/5A)
-2
1 2 JPF4-15 -5
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/
TS2-2
RELAY
CARD JPF2-8 JPS3-1
TS2-1 1 2 -3
REACH
B+ 1 SIDE
SHIFT
2 -4
1 2 -5
Buss+/- TILT
5v
4
B- -6
Input
8R828-011-224_D_C.EPS
Figure 8-10. Lower - Electrical (Series CA/FA)
8-34 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
VEHICLE
MANAGER
JPT1
-20
ID2 RED JPE1-1 JPC10-6
-21 +12V_EN1
IDGND WHT -3 JPC22-5
CHANNEL_A_1 JPC12-1 JPH1-1
-2 -12 +5VP +5VP
BLU
CHANNEL_B_1
STEER BLK -4 JPC18-5 +5VP
TILLER DGND
-3 -3
ENCODER RED JPE2-1 JPC10-7 P_THROTTLE VR1
+12V_EN2
WHT -3 JPC22-13
CHANNEL_A_2 DGND
BLU -2 -14 +5VP +5VP +
CHANNEL_B_2
0 S3
TA BLK -4 JPC18-6
DGND LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-1 -4 -4 0
REACH S4
B+K3
-7 -11 -11
DGND RETRACT -
-22 DGND
BUS_I+
BUS_I- -14 -5 -5
TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
JPL1 -8 -8 -
-15 SSHIFT_LEFT S8
BUS_I- DGND
DISPLAY -9 -9
-23 SSHIFT_RIGHT S9
BUS_I+ -12
-8 JPD3-1 B-1 -12
DGND +12VP DGND DGND
SOUNDER -13
-2 B-2
SOUNDER
HTR6
-7 -7
-22 -2 H_HTR
BUS_I+ BUS_I+ JPC14-5
-14 -3 JPD1-5
BUS_I- BUS_I- +12VP
-7 -4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
DGND JPC20-8 -2
-7 -4 +12VP
BUS_I- JPC22-7 -3
LA -8 -3
DGND
HGG_FAULT
HGG_CONTACTOR
JPC24-2 -4
-12 JPC10-3 -5
ID1 THERM_EN 4
-13
IDGND JPC24-13
+12VP JPAD-1
JPC10-8
AUX DEADMAN -2
JPC24-4
DGND -3
-1
B+K3
JPC18-11
STR_CONTACTOR JPC24-23 JPA-1
ROOM_TEMP
JPC6-6 -11 -2
DGND
+12VP
-5
CCW_PWM JPC18-18 SPL-6
-2 ALARM 4 4
CW_PWM
-3
STEER_CURRENT
-4
DGND JPC20-16
-1 L/L SOL2
NEUTRAL_PULSE 1 2
-15
(B+K2)B+L/L
JPC22-19
FU1_SENSE -18
JPC14-10 AUX1
DGND
-2 -17
DGND (B+K2)B+AUX1 SOL5T
-1
1 2
-8
-9 B-F -20
AUX2 SOL5B
1st SPEED 1 2
S12 LIMITING SWITCH JPS4-1 JPC20-1 -19
+12VP (B+K2)B+AUX2
NC -12
JPS4-3 COM DUMP SOL3
NO -2 JPC22-1 1
AC LIFT &
SPEED_LIMIT_1 2
-13
(B+K2)B+DUMP
JPC10-10
BUS_E+
-5 JPC20-4 JPY1-1 +
+12VP
ELECTRIC
BUS_E-
HRN JPC24-18 -2 0
-NEG PRESSURE PRESS
-6 -3 -
-IN H-1 JPC18-16 DGND
H HORN
STEER
-POS H-2
JPBR-2 JPS2-2 JPC20-5 JPDP-1
+12VP
DEADMAN
VR4
SENSOR
-1 -1 JPC20-14 JPC24-19 -3
BRAKE BRAKE DEADMAN
FAN-T -7 -2
JPB1-1 + JPB1-2 JPC18-17 DGND
- FAN
JPC20-2 JPS12-1
DEADMAN
FAN-FW +12VP
JPC22-8 -2
SWITCH
JPB2-1 JPB2-2 ON DEADMAN
+ - NC
S2
JPC18-7 -3 JPDS-COM JPDS-NO
FAN-FW2 DGND
JPB4-1 JPB4-2
+ -
FAN-DU
JPB3-1 JPB3-2
+ -
-10 JPC20-7 JPE4-1 RED
SOL1 L/H +12VP
2 1 JPC22-9 -3
JPC14-6 CHANNELA_4 WHT STEER
RELAY_ENABLE MOTOR
JPC22-21 -10 -2 BLU ENCODER
EPO_SENSE CHANNELB_4
JPC10-9 -4 BLK
DGND
JPC14-12
ROTATION
B+KEY JPC20-9 JPST-1 +
SWITCH
+12VP
END OF
STEER
JPC22-22 -2 0 S11
STEER_LIMIT
-11 -3 -
DGND
-7
B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
FLASHWARE
TXD JPC9-2
JPS3-2 -3
RXD
DGND -5
-3 JPC18-12
REACH_SOL
-4 -14
SIDESHIFT_SOL
COMMUNICATIONS
-5 -15 VBUS JPC2-1
TILT_SOL
D+ -2
USB
D- -3
DGND -4
-6 JPC22-18
NESTED_SWITCH
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-35
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
G2 HTI
TACH 1
REL-2
M
SOL-5B
1 2
1 A1
4 3 2 LS-1
3
P1 2
P1
2 1 4
3 A2
POD-1
SOL-5T
G1
1
CV-1 1 CYL-1
2 2
Legend: SOL-1
Pressure
1 Line
SOL-3 Return Line
Suction Line 1
Electrical
2
Control
Signal
CFS-1
SOL-2
TANK
FILTER
S-RET
CYL-P
PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-11. Lower - Hydraulic (Series CA/FA)
8-36 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
REACH
RC
3 4
A2
1 2
RR
REACH1 TILT
3 4 TC
1 2
TR
TILT
MAIN LIFT
FREE LIFT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-37
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
Auxiliary Functions which allows fluid flow to the requested
function.
Tilt NOTE: LS-1 (load shuttle) also supplies a pilot
Fork tilt allows the operator to raise or lower the pressure to REL2 to supply the auxiliary
tips of the forks. Standard fork tilt is 5° up and relief if pressure gets too high.
2° down. 6. Fluid flows through the energized TILT
In the following discussion, the forks are tilted SOL (mounted on the carriage) and then to
up. Refer to Figures 8-12 and 8-13. the tilt cylinder.
1. When the deadman pedal is depressed, the
VM sends a command over BUS+/BUS-
lines to the lift power amplifier to energize
the lift (LPC) contactor.
2. The lift power amplifier internally supplies
B- to the lift contactor coil (LPC) at JPL1-2,
which closes the normally open contactor
tips.
3. Switch S6 (tilt up switch) is depressed,
completing a circuit between JPC12-5 and
JPC12-12 at the VM.
4. The VM energizes the following solenoids
via internal coil drivers:
• SOL3 (Dump) at JPC20-12
• SOL5B at JPC20-20
• TILT SOL at JPC18-15
5. Pump P1 rotates at a speed predetermined
in software. Flow is ported to the PODS
valve at port 3 and out at port 4. Fluid
then flows through SOL-5B or SOL-5T,
depending on the direction of the function
requested. SOL5 is a proportional
solenoid, but the VM will send a fixed
voltage to it, regulating the speed of the
requested function. If more oil flows to
SOL5 than is needed for the function, back
pressure will be present at port 4, which is
also the pilot line for the PODS valve. This
will shift the spool of the PODS valve and
send the excess oil to SOL3 via port 2.
SOL3 is opened (energized) to allow the
excess oil to flow back to the filter and
reservoir. After leaving SOL5, the oil flows
to the load shuttle (LS-1). The load shuttle
ports oil back to the PODS valve (at port 1)
to help regulate the flow to the auxiliary
function. From LS-1, the fluid flows to the
tilt solenoid on the carriage. The tilt
solenoid is a normally closed solenoid
8-38 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
1026304B, 15 July 2007 8-39
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR BLACK -4 -5 -4
T VEL SENSOR+
PANEL TME T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
TP2 TP3 TP5 T VEL PHASE B
JPT3
RED -2 -8 -16
FU1 FU3 FU2 T TEMP+
(150A) (500A) (350A) TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 MOTOR TEMPERATURE TA
-2 1 1 1 X TPC Y JPS1-8 -2 TPC
-3 STR LPC TPC CONTACTOR
2 2
-4 2 U
U
B-
V
TM V
W
1 W
B+ +
1 TR
LR 2 MOTOR VELOCITY
2 RED JPL2-1 JPL1-3
L VEL SENSOR+
BLACK -4 -4
LR-2 TR-2 LME L VEL SENSOR-
WHITE -3 -5
L VEL PHASE A
BLUE -2 -6
L VEL PHASE B
RED JPL3-2 -16
STR
L TEMP+
Y X LMT
RED/BLK -1 -17
L TEMP-
X LPC Y JPS1-9
MOTOR TEMPERATURE LPC
LA
-2
CONTACTOR
B-
U
U
V
LM V
JPS1-5 JPS1-6 JPS1-7 JPS1-10 JPS1-11
W
W +
B+
JP
B-
TP4 STR-2
MS-A1
A1 +
MS SA
A2 -
MS-A2
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
T˚ K3 TS1-2
JPF1-1 JPS10-3
FU8 (15A/5A)
-2
1 2 JPF4-15 -5
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/
TS2-2
RELAY
CARD JPF2-8 JPS3-1
TS2-1 1 2 -3
REACH
B+ 1 SIDE
SHIFT
2 -4
Buss+/- 1 2 -5
TILT
5v
4
B- -6
Input
8R828-011-224_D_C.EPS
Figure 8-12. Tilt - Electrical (Series CA/FA)
8-40 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
VEHICLE
MANAGER
JPT1
-20
ID2 RED JPE1-1 JPC10-6
-21 +12V_EN1
IDGND WHT -3 JPC22-5
CHANNEL_A_1 JPC12-1 JPH1-1
-2 -12 +5VP +5VP
BLU
CHANNEL_B_1
STEER BLK -4 JPC18-5 +5VP
TILLER DGND
-3 -3
ENCODER RED JPE2-1 JPC10-7 P_THROTTLE VR1
+12V_EN2
WHT -3 JPC22-13
CHANNEL_A_2 DGND
BLU -2 -14 +5VP +5VP +
CHANNEL_B_2
0 S3
TA BLK -4 JPC18-6
DGND LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-1 -4 -4 0
REACH S4
B+K3
-7 -11 -11
DGND RETRACT -
-22 DGND
BUS_I+
BUS_I- -14 -5 -5
TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
JPL1 -8 -8 -
-15 SSHIFT_LEFT S8
BUS_I- DGND
DISPLAY -9 -9
-23 SSHIFT_RIGHT S9
BUS_I+ -12
-8 JPD3-1 B-1 -12
DGND +12VP DGND DGND
SOUNDER -13
-2 B-2
SOUNDER
HTR6
-7 -7
-22 -2 H_HTR
BUS_I+ BUS_I+ JPC14-5
-14 -3 JPD1-5
BUS_I- BUS_I- +12VP
-7 -4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
DGND JPC20-8 -2
-7 -4 +12VP
BUS_I- JPC22-7 -3
LA -8 -3
DGND
HGG_FAULT
HGG_CONTACTOR
JPC24-2 -4
-12 JPC10-3 -5
ID1 THERM_EN 4
-13
IDGND JPC24-13
+12VP JPAD-1
JPC10-8
AUX DEADMAN -2
JPC24-4
DGND -3
-1
B+K3
JPC18-11
STR_CONTACTOR JPC24-23 JPA-1
ROOM_TEMP
JPC6-6 -11 -2
DGND
+12VP
-5
CCW_PWM JPC18-18 SPL-6
-2 ALARM 4 4
CW_PWM
-3
STEER_CURRENT
-4
DGND JPC20-16
-1 L/L SOL2
NEUTRAL_PULSE 1 2
-15
(B+K2)B+L/L
JPC22-19
FU1_SENSE -18
JPC14-10 AUX1
DGND
-2 -17
DGND (B+K2)B+AUX1 SOL5T
-1
1 2
-8
-9 B-F -20
AUX2 SOL5B
1st SPEED 1 2
S12 LIMITING SWITCH JPS4-1 JPC20-1 -19
+12VP (B+K2)B+AUX2
NC -12
JPS4-3 COM DUMP SOL3
NO -2 JPC22-1 1
AC LIFT &
SPEED_LIMIT_1 2
-13
(B+K2)B+DUMP
JPC10-10
BUS_E+
-5 JPC20-4 JPY1-1 +
+12VP
ELECTRIC
BUS_E-
HRN JPC24-18 -2 0
-NEG PRESSURE PRESS
-6 -3 -
-IN H-1 JPC18-16 DGND
H HORN
STEER
-POS H-2
JPBR-2 JPS2-2 JPC20-5 JPDP-1
+12VP
DEADMAN
VR4
SENSOR
-1 -1 JPC20-14 JPC24-19 -3
BRAKE BRAKE DEADMAN
FAN-T -7 -2
JPB1-1 + JPB1-2 JPC18-17 DGND
- FAN
JPC20-2 JPS12-1
DEADMAN
FAN-FW +12VP
JPC22-8 -2
SWITCH
JPB2-1 JPB2-2 ON DEADMAN
+ - NC
S2
JPC18-7 -3 JPDS-COM JPDS-NO
FAN-FW2 DGND
JPB4-1 JPB4-2
+ -
FAN-DU
JPB3-1 JPB3-2
+ -
-10 JPC20-7 JPE4-1 RED
SOL1 L/H +12VP
2 1 JPC22-9 -3
JPC14-6 CHANNELA_4 WHT STEER
RELAY_ENABLE MOTOR
JPC22-21 -10 -2 BLU ENCODER
EPO_SENSE CHANNELB_4
JPC10-9 -4 BLK
DGND
JPC14-12
ROTATION
B+KEY JPC20-9 JPST-1 +
SWITCH
+12VP
END OF
STEER
JPC22-22 -2 0 S11
STEER_LIMIT
-11 -3 -
DGND
-7
B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
FLASHWARE
TXD JPC9-2
JPS3-2 -3
RXD
DGND -5
-3 JPC18-12
REACH_SOL
-4 -14
SIDESHIFT_SOL
COMMUNICATIONS
-5 -15 VBUS JPC2-1
TILT_SOL
D+ -2
USB
D- -3
DGND -4
-6 JPC22-18
NESTED_SWITCH
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-41
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
G2 HTI
TACH 1
REL-2
M
SOL-5B
1 2
1 A1
4 3 2 LS-1
3
P1 2
P1
2 1 4
3 A2
POD-1
SOL-5T
G1
1
CV-1 1 CYL-1
2 2
SOL-1
1
SOL-3
1
CFS-1
SOL-2
TANK
FILTER
S-RET
CYL-P
PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-13. Tilt - Hydraulic (Series CA/FA)
8-42 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
REACH
RC
3 4
A2
1 2
RR
REACH1 TILT
3 4 TC
1 2
TR
TILT
MAIN LIFT
FREE LIFT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-43
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
Reach reservoir. After leaving SOL5, the oil flows
to the load shuttle (LS-1). The load shuttle
Reach extends the forks away from the mast
ports oil back to the PODS valve (at port 1)
assembly. The reach/retract function can be
to help regulate the flow to the auxiliary
configured to have single speed reach/retract or
function. From LS-1, the fluid flows to the
two speed reach/retract. Single speed reach
reach solenoid on the carriage. The reach
moves at the speed of high-speed reach.
solenoid is a normally closed solenoid
In order to use two speed reach, depress S5 which allows fluid flow to the requested
after depressing S4. Doing this switches from function.
low speed to high-speed reach. Refer to Figures
NOTE: LS-1 (load shuttle) also supplies a pilot
8-14 and 8-15.
pressure to REL2 to supply the auxiliary
relief if pressure gets too high.
High-speed or single-speed reach
1. When the deadman pedal is depressed, the 7. Fluid flows through the energized REACH
VM sends a command over BUS+/BUS– SOL (mounted on the carriage) and then to
lines to the lift power amplifier to energize the reach cylinders.
the lift (LPC) contactor coil.
Low-Speed (of two-speed) Reach
2. The lift power amplifier internally supplies
B- to the lift contactor coil (LPC) at JPL1-2, Low-speed reach is activated by the reach
which closes the normally open contactor button (S4) only.
tips.
NOTE: To change the speed of the reach
3. When switch S4 (reach switch) is (High-speed versus Low-speed), the VM
depressed, a circuit is completed between adjusts the voltage to SOL5 to regulate
JPC12-4 and JPC12-12 at the VM. the valve for more or less flow.
4. On lift trucks with two speed reach, when
switch S5 (retract switch) is also depressed,
a circuit is completed between JPC12-11
and JPC12-12 at the VM.
5. The VM energizes the following solenoids
via internal coil drivers:
• SOL3 (Dump) at JPC20-12
• SOL5B at JPC20-20
• REACH SOL at JPC18-12
6. Pump P1 rotates at a speed predetermined
in software. Flow is ported to the PODS
valve at port 3 and out at port 4. Fluid
then flows through SOL-5B or SOL-5T,
depending on the direction of the function
requested. SOL5 is a proportional
solenoid, but the VM will send a fixed
voltage to it, regulating the speed of the
requested function. If more oil flows to
SOL5 than is needed for the function, back
pressure will be present at port 4, which is
also the pilot line for the PODS valve. This
will shift the spool of the PODS valve and
send the excess oil to SOL3 via port 2.
SOL3 is opened (energized) to allow the
excess oil to flow back to the filter and
8-44 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
1026304B, 15 July 2007 8-45
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR BLACK -4 -5 -4
T VEL SENSOR+
PANEL TME T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
TP2 TP3 TP5 T VEL PHASE B
JPT3
RED -2 -8 -16
FU1 FU3 FU2 T TEMP+
(150A) (500A) (350A) TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 MOTOR TEMPERATURE TA
-2 1 1 1 X TPC Y JPS1-8 -2 TPC
-3 STR LPC TPC CONTACTOR
2 2
-4 2 U
U
B-
V
TM V
W
1 W
B+ +
1 TR
LR 2 MOTOR VELOCITY
2 RED JPL2-1 JPL1-3
L VEL SENSOR+
BLACK -4 -4
LR-2 TR-2 LME L VEL SENSOR-
WHITE -3 -5
L VEL PHASE A
BLUE -2 -6
L VEL PHASE B
RED JPL3-2 -16
STR
L TEMP+
Y X LMT
RED/BLK -1 -17
L TEMP-
X LPC Y JPS1-9
MOTOR TEMPERATURE LPC
LA
-2
CONTACTOR
B-
U
U
V
LM V
JPS1-5 JPS1-6 JPS1-7 JPS1-10 JPS1-11
W
W +
B+
JP
B-
TP4 STR-2
MS-A1
A1 +
MS SA
A2 -
MS-A2
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
T˚ K3 TS1-2
JPF1-1 JPS10-3
FU8 (15A/5A)
-2
1 2 JPF4-15 -5
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/
TS2-2
RELAY
CARD JPF2-8 JPS3-1
TS2-1 1 2 -3
REACH
B+ 1 SIDE
SHIFT
2 -4
-5
Buss+/-
1 2
TILT
5v
4
B- -6
Input
8R828-011-224_D_C.EPS
Figure 8-14. Reach - Electrical (Series CA and FA)
8-46 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
VEHICLE
MANAGER
JPT1
-20
ID2 RED JPE1-1 JPC10-6
-21 +12V_EN1
IDGND WHT -3 JPC22-5
CHANNEL_A_1 JPC12-1 JPH1-1
-2 -12 +5VP +5VP
BLU
CHANNEL_B_1
STEER BLK -4 JPC18-5 +5VP
TILLER DGND
-3 -3
ENCODER RED JPE2-1 JPC10-7 P_THROTTLE VR1
+12V_EN2
WHT -3 JPC22-13
CHANNEL_A_2 DGND
BLU -2 -14 +5VP +5VP +
CHANNEL_B_2
0 S3
TA BLK -4 JPC18-6
DGND LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-1 -4 -4 0
REACH S4
B+K3
-7 -11 -11
DGND RETRACT -
-22 DGND
BUS_I+
BUS_I- -14 -5 -5
TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
JPL1 -8 -8 -
-15 SSHIFT_LEFT S8
BUS_I- DGND
DISPLAY -9 -9
-23 SSHIFT_RIGHT S9
BUS_I+ -12
-8 JPD3-1 B-1 -12
DGND +12VP DGND DGND
SOUNDER -13
-2 B-2
SOUNDER
HTR6
-7 -7
-22 -2 H_HTR
BUS_I+ BUS_I+ JPC14-5
-14 -3 JPD1-5
BUS_I- BUS_I- +12VP
-7 -4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
DGND JPC20-8 -2
-7 -4 +12VP
BUS_I- JPC22-7 -3
LA -8 -3
DGND
HGG_FAULT
HGG_CONTACTOR
JPC24-2 -4
-12 JPC10-3 -5
ID1 THERM_EN 4
-13
IDGND JPC24-13
+12VP JPAD-1
JPC10-8
AUX DEADMAN -2
JPC24-4
DGND -3
-1
B+K3
JPC18-11
STR_CONTACTOR JPC24-23 JPA-1
ROOM_TEMP
JPC6-6 -11 -2
DGND
+12VP
-5
CCW_PWM JPC18-18 SPL-6
-2 ALARM 4 4
CW_PWM
-3
STEER_CURRENT
-4
DGND JPC20-16
-1 L/L SOL2
NEUTRAL_PULSE 1 2
-15
(B+K2)B+L/L
JPC22-19
FU1_SENSE -18
JPC14-10 AUX1
DGND
-2 -17
DGND (B+K2)B+AUX1 SOL5T
-1
1 2
-8
-9 B-F -20
AUX2 SOL5B
1st SPEED 1 2
S12 LIMITING SWITCH JPS4-1 JPC20-1 -19
+12VP (B+K2)B+AUX2
NC -12
JPS4-3 COM DUMP SOL3
NO -2 JPC22-1 1
AC LIFT &
SPEED_LIMIT_1 2
-13
(B+K2)B+DUMP
JPC10-10
BUS_E+
-5 JPC20-4 JPY1-1 +
+12VP
ELECTRIC
BUS_E-
HRN JPC24-18 -2 0
-NEG PRESSURE PRESS
-6 -3 -
-IN H-1 JPC18-16 DGND
H HORN
STEER
-POS H-2
JPBR-2 JPS2-2 JPC20-5 JPDP-1
+12VP
DEADMAN
VR4
SENSOR
-1 -1 JPC20-14 JPC24-19 -3
BRAKE BRAKE DEADMAN
FAN-T -7 -2
JPB1-1 + JPB1-2 JPC18-17 DGND
- FAN
JPC20-2 JPS12-1
DEADMAN
FAN-FW +12VP
JPC22-8 -2
SWITCH
JPB2-1 JPB2-2 ON DEADMAN
+ - NC
S2
JPC18-7 -3 JPDS-COM JPDS-NO
FAN-FW2 DGND
JPB4-1 JPB4-2
+ -
FAN-DU
JPB3-1 JPB3-2
+ -
-10 JPC20-7 JPE4-1 RED
SOL1 L/H +12VP
2 1 JPC22-9 -3
JPC14-6 CHANNELA_4 WHT STEER
RELAY_ENABLE MOTOR
JPC22-21 -10 -2 BLU ENCODER
EPO_SENSE CHANNELB_4
JPC10-9 -4 BLK
DGND
JPC14-12
ROTATION
B+KEY JPC20-9 JPST-1 +
SWITCH
+12VP
END OF
STEER
JPC22-22 -2 0 S11
STEER_LIMIT
-11 -3 -
DGND
-7
B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
FLASHWARE
TXD JPC9-2
JPS3-2 -3
RXD
DGND -5
-3 JPC18-12
REACH_SOL
-4 -14
SIDESHIFT_SOL
COMMUNICATIONS
-5 -15 VBUS JPC2-1
TILT_SOL
D+ -2
USB
D- -3
DGND -4
-6 JPC22-18
NESTED_SWITCH
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-47
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
G2 HTI
TACH 1
REL-2
M
SOL-5B
1 2
1 A1
4 3 2 LS-1
3
P1 2
P1
2 1 4
3 A2
POD-1
SOL-5T
G1
1
CV-1 1 CYL-1
2 2
SOL-1
1
SOL-3
1
CFS-1
SOL-2
TANK
FILTER
S-RET
CYL-P
PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-15. Reach - Hydraulic (Series CA and FA)
8-48 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
REACH
RC
3 4
A2
1 2
RR
REACH1 TILT
3 4 TC
1 2
TR
TILT
MAIN LIFT
FREE LIFT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-49
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
Retract excess oil to flow back to the filter and
reservoir. After leaving SOL5, the oil flows
Retract returns the forks back to the mast
to the load shuttle (LS-1). The load shuttle
assembly after being extended by the reach
ports oil back to the PODS valve (at port 1)
function. The reach/retract function can be
to help regulate the flow to the auxiliary
configured to have single speed reach/retract or
function. From LS-1, the fluid flows to the
two speed reach/retract. Single speed retract
reach solenoid on the carriage. The reach
moves at the speed of high-speed retract.
solenoid is a normally closed solenoid
In order to use two speed retract, depress S5 which allows fluid flow to the requested
after depressing S4. Doing this switches from function.
low speed to high-speed reach. Refer to Figures
NOTE: LS-1 (load shuttle) also supplies a pilot
8-16 and 8-17.
pressure to REL2 to supply the auxiliary
relief if pressure gets too high.
High-speed or single-speed retract
1. When the deadman pedal is depressed, the Low-Speed (of two-speed) retract
VM sends a command over BUS+/BUS–
lines to the lift power amplifier to energize Low-speed retract is activated by the retract
the lift (LPC) contactor coil. button (S5) only.
2. The lift power amplifier internally supplies NOTE: To change the speed of the retract
B- to the lift contactor coil (LPC) at JPL1-2, (High-speed versus Low-speed), the VM
which closes the normally open contactor adjusts the voltage to SOL5 to regulate
tips. the valve for more or less flow.
3. When switch S5 (retract switch) is
depressed, a circuit is completed between
JPC12-11 and JPC12-12 at the VM.
4. On lift trucks with two speed retract, when
switch S4 (reach switch) is also depressed,
a circuit is completed between JPC12-4 and
JPC12-12 at the VM.
5. The VM energizes the following solenoids
via internal coil drivers:
• SOL3 (Dump) at JPC20-12
• SOL5T at JPC20-18
• REACH SOL at JPC18-12
6. Pump P1 rotates at a speed predetermined
in software. Flow is ported to the PODS
valve at port 3 and out at port 4. Fluid
then flows through SOL-5B or SOL-5T,
depending on the direction of the function
requested. SOL5 is a proportional
solenoid, but the VM will send a fixed
voltage to it, regulating the speed of the
requested function. If more oil flows to
SOL5 than is needed for the function, back
pressure will be present at port 4, which is
also the pilot line for the PODS valve. This
will shift the spool of the PODS valve and
send the excess oil to SOL3 via port 2.
SOL3 is opened (energized) to allow the
8-50 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
1026304B, 15 July 2007 8-51
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR BLACK -4 -5 -4
T VEL SENSOR+
PANEL TME T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
TP2 TP3 TP5 T VEL PHASE B
JPT3
RED -2 -8 -16
FU1 FU3 FU2 T TEMP+
(150A) (500A) (350A) TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 MOTOR TEMPERATURE TA
-2 1 1 1 X TPC Y JPS1-8 -2 TPC
-3 STR LPC TPC CONTACTOR
2 2
-4 2 U
U
B-
V
TM V
W
1 W
B+ +
1 TR
LR 2 MOTOR VELOCITY
2 RED JPL2-1 JPL1-3
L VEL SENSOR+
BLACK -4 -4
LR-2 TR-2 LME L VEL SENSOR-
WHITE -3 -5
L VEL PHASE A
BLUE -2 -6
L VEL PHASE B
RED JPL3-2 -16
STR
L TEMP+
Y X LMT
RED/BLK -1 -17
L TEMP-
X LPC Y JPS1-9
MOTOR TEMPERATURE LPC
LA
-2
CONTACTOR
B-
U
U
V
LM V
JPS1-5 JPS1-6 JPS1-7 JPS1-10 JPS1-11
W
W +
B+
JP
B-
TP4 STR-2
MS-A1
A1 +
MS SA
A2 -
MS-A2
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
T˚ K3 TS1-2
JPF1-1 JPS10-3
FU8 (15A/5A)
-2
1 2 JPF4-15 -5
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/
TS2-2
RELAY
CARD JPF2-8 JPS3-1
TS2-1 1 2 -3
REACH
B+ 1 SIDE
SHIFT
2 -4
1 2 -5
Buss+/- TILT
5v
4
B- -6
Input
8R828-011-224_D_C.EPS
Figure 8-16. Retract - Electrical (Series CA/FA)
8-52 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
VEHICLE
MANAGER
JPT1
-20
ID2 RED JPE1-1 JPC10-6
-21 +12V_EN1
IDGND WHT -3 JPC22-5
CHANNEL_A_1 JPC12-1 JPH1-1
-2 -12 +5VP +5VP
BLU
CHANNEL_B_1
STEER BLK -4 JPC18-5 +5VP
TILLER DGND
-3 -3
ENCODER RED JPE2-1 JPC10-7 P_THROTTLE VR1
+12V_EN2
WHT -3 JPC22-13
CHANNEL_A_2 DGND
BLU -2 -14 +5VP +5VP +
CHANNEL_B_2
0 S3
TA BLK -4 JPC18-6
DGND LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-1 -4 -4 0
REACH S4
B+K3
-7 -11 -11
DGND RETRACT -
-22 DGND
BUS_I+
BUS_I- -14 -5 -5
TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
JPL1 -8 -8 -
-15 SSHIFT_LEFT S8
BUS_I- DGND
DISPLAY -9 -9
-23 SSHIFT_RIGHT S9
BUS_I+ -12
-8 JPD3-1 B-1 -12
DGND +12VP DGND DGND
SOUNDER -13
-2 B-2
SOUNDER
HTR6
-7 -7
-22 -2 H_HTR
BUS_I+ BUS_I+ JPC14-5
-14 -3 JPD1-5
BUS_I- BUS_I- +12VP
-7 -4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
DGND JPC20-8 -2
-7 -4 +12VP
BUS_I- JPC22-7 -3
LA -8 -3
DGND
HGG_FAULT
HGG_CONTACTOR
JPC24-2 -4
-12 JPC10-3 -5
ID1 THERM_EN 4
-13
IDGND JPC24-13
+12VP JPAD-1
JPC10-8
AUX DEADMAN -2
JPC24-4
DGND -3
-1
B+K3
JPC18-11
STR_CONTACTOR JPC24-23 JPA-1
ROOM_TEMP
JPC6-6 -11 -2
DGND
+12VP
-5
CCW_PWM JPC18-18 SPL-6
-2 ALARM 4 4
CW_PWM
-3
STEER_CURRENT
-4
DGND JPC20-16
-1 L/L SOL2
NEUTRAL_PULSE 1 2
-15
(B+K2)B+L/L
JPC22-19
FU1_SENSE -18
JPC14-10 AUX1
DGND
-2 -17
DGND (B+K2)B+AUX1 SOL5T
-1
1 2
-8
-9 B-F -20
AUX2 SOL5B
1st SPEED 1 2
S12 LIMITING SWITCH JPS4-1 JPC20-1 -19
+12VP (B+K2)B+AUX2
NC -12
JPS4-3 COM DUMP SOL3
NO -2 JPC22-1 1
AC LIFT &
SPEED_LIMIT_1 2
-13
(B+K2)B+DUMP
JPC10-10
BUS_E+
-5 JPC20-4 JPY1-1 +
+12VP
ELECTRIC
BUS_E-
HRN JPC24-18 -2 0
-NEG PRESSURE PRESS
-6 -3 -
-IN H-1 JPC18-16 DGND
H HORN
STEER
-POS H-2
JPBR-2 JPS2-2 JPC20-5 JPDP-1
+12VP
DEADMAN
VR4
SENSOR
-1 -1 JPC20-14 JPC24-19 -3
BRAKE BRAKE DEADMAN
FAN-T -7 -2
JPB1-1 + JPB1-2 JPC18-17 DGND
- FAN
JPC20-2 JPS12-1
DEADMAN
FAN-FW +12VP
JPC22-8 -2
SWITCH
JPB2-1 JPB2-2 ON DEADMAN
+ - NC
S2
JPC18-7 -3 JPDS-COM JPDS-NO
FAN-FW2 DGND
JPB4-1 JPB4-2
+ -
FAN-DU
JPB3-1 JPB3-2
+ -
-10 JPC20-7 JPE4-1 RED
SOL1 L/H +12VP
2 1 JPC22-9 -3
JPC14-6 CHANNELA_4 WHT STEER
RELAY_ENABLE MOTOR
JPC22-21 -10 -2 BLU ENCODER
EPO_SENSE CHANNELB_4
JPC10-9 -4 BLK
DGND
JPC14-12
ROTATION
B+KEY JPC20-9 JPST-1 +
SWITCH
+12VP
END OF
STEER
JPC22-22 -2 0 S11
STEER_LIMIT
-11 -3 -
DGND
-7
B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
FLASHWARE
TXD JPC9-2
JPS3-2 -3
RXD
DGND -5
-3 JPC18-12
REACH_SOL
-4 -14
SIDESHIFT_SOL
COMMUNICATIONS
-5 -15 VBUS JPC2-1
TILT_SOL
D+ -2
USB
D- -3
DGND -4
-6 JPC22-18
NESTED_SWITCH
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-53
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
G2 HTI
TACH 1
REL-2
M
SOL-5B
1 2
1 A1
4 3 2 LS-1
3
P1 2
P1
2 1 4
3 A2
POD-1
SOL-5T
G1
1
CV-1 1 CYL-1
2 2
SOL-1
1
SOL-3
1
CFS-1
SOL-2
TANK
FILTER
S-RET
CYL-P
PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-17. Retract - Hydraulic (Series CA and FA)
8-54 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
REACH
RC
3 4
A2
1 2
RR
REACH1 TILT
3 4 TC
1 2
TR
TILT
MAIN LIFT
FREE LIFT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-55
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
Sideshift NOTE: LS-1 (load shuttle) also supplies a pilot
pressure to REL2 to supply the auxiliary
Sideshift allows the operator to move the fork
relief if pressure gets too high.
carriage to the left or right relative to the mast.
The amount of sideshift is 2 or 4 inches (5 or
10 cm) depending on the baseleg opening.
In the following discussion, the fork carriage is
sideshifted to the right. Refer to Figures 8-18
and 8-19.
1. When the deadman pedal is depressed, the
VM sends a command over BUS+/BUS-
lines to the lift power amplifier to energize
the lift (LPC) contactor.
2. The lift power amplifier internally supplies
B- to the lift contactor coil (LPC) at JPL1-2,
which closes the normally open contactor
tips.
3. When switch S9 (sideshift right switch) is
depressed, a circuit is completed between
JPC12-9 and JPC12-12 at the VM.
4. The VM energizes the following solenoids
via internal coil drivers:
• SOL3 (Dump) at JPC20-12
• SOL5B at JPC20-20
• SIDESHIFT SOL at JPC18-14
5. Pump P1 rotates at a speed predetermined
in software. Flow is ported to the PODS
valve at port 3 and out at port 4. Fluid
then flows through SOL-5B or SOL-5T,
depending on the direction of the function
requested. SOL5 is a proportional
solenoid, but the VM will send a fixed
voltage to it, regulating the speed of the
requested function. If more oil flows to
SOL5 than is needed for the function, back
pressure will be present at port 4, which is
also the pilot line for the PODS valve. This
will shift the spool of the PODS valve and
send the excess oil to SOL3 via port 2.
SOL3 is opened (energized) to allow the
excess oil to flow back to the filter and
reservoir. After leaving SOL5, the oil flows
to the load shuttle (LS-1). The load shuttle
ports oil back to the PODS valve (at port 1)
to help regulate the flow to the auxiliary
function. From LS-1, the fluid flows to the
sideshift solenoid on the carriage. The
sideshift solenoid is a normally closed
solenoid which allows fluid flow to the
requested function.
8-56 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
1026304B, 15 July 2007 8-57
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR BLACK -4 -5 -4
T VEL SENSOR+
PANEL TME T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
TP2 TP3 TP5 T VEL PHASE B
JPT3
RED -2 -8 -16
FU1 FU3 FU2 T TEMP+
(150A) (500A) (350A) TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 MOTOR TEMPERATURE TA
-2 1 1 1 X TPC Y JPS1-8 -2 TPC
-3 STR LPC TPC CONTACTOR
2 2
-4 2 U
U
B-
V
TM V
W
1 W
B+ +
1 TR
LR 2 MOTOR VELOCITY
2 RED JPL2-1 JPL1-3
L VEL SENSOR+
BLACK -4 -4
LR-2 TR-2 LME L VEL SENSOR-
WHITE -3 -5
L VEL PHASE A
BLUE -2 -6
L VEL PHASE B
RED JPL3-2 -16
STR
L TEMP+
Y X LMT
RED/BLK -1 -17
L TEMP-
X LPC Y JPS1-9
MOTOR TEMPERATURE LPC
LA
-2
CONTACTOR
B-
U
U
V
LM V
JPS1-5 JPS1-6 JPS1-7 JPS1-10 JPS1-11
W
W +
B+
JP
B-
TP4 STR-2
MS-A1
A1 +
MS SA
A2 -
MS-A2
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
T˚ K3 TS1-2
JPF1-1 JPS10-3
FU8 (15A/5A)
-2
1 2 JPF4-15 -5
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/
TS2-2
RELAY
CARD JPF2-8 JPS3-1
TS2-1 1 2 -3
REACH
B+ 1 SIDE
SHIFT
2 -4
1 2 -5
Buss+/- TILT
5v
4
B- -6
Input
8R828-011-224_D_C.EPS
Figure 8-18. Sideshift - Electrical (Series CA/FA)
8-58 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
VEHICLE
MANAGER
JPT1
-20
ID2 RED JPE1-1 JPC10-6
-21 +12V_EN1
IDGND WHT -3 JPC22-5
CHANNEL_A_1 JPC12-1 JPH1-1
-2 -12 +5VP +5VP
BLU
CHANNEL_B_1
STEER BLK -4 JPC18-5 +5VP
TILLER DGND
-3 -3
ENCODER RED JPE2-1 JPC10-7 P_THROTTLE VR1
+12V_EN2
WHT -3 JPC22-13
CHANNEL_A_2 DGND
BLU -2 -14 +5VP +5VP +
CHANNEL_B_2
0 S3
TA BLK -4 JPC18-6
DGND LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-1 -4 -4 0
REACH S4
B+K3
-7 -11 -11
DGND RETRACT -
-22 DGND
BUS_I+
BUS_I- -14 -5 -5
TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
JPL1 -8 -8 -
-15 SSHIFT_LEFT S8
BUS_I- DGND
DISPLAY -9 -9
-23 SSHIFT_RIGHT S9
BUS_I+ -12
-8 JPD3-1 B-1 -12
DGND +12VP DGND DGND
SOUNDER -13
-2 B-2
SOUNDER
HTR6
-7 -7
-22 -2 H_HTR
BUS_I+ BUS_I+ JPC14-5
-14 -3 JPD1-5
BUS_I- BUS_I- +12VP
-7 -4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
DGND JPC20-8 -2
-7 -4 +12VP
BUS_I- JPC22-7 -3
LA -8 -3
DGND
HGG_FAULT
HGG_CONTACTOR
JPC24-2 -4
-12 JPC10-3 -5
ID1 THERM_EN 4
-13
IDGND JPC24-13
+12VP JPAD-1
JPC10-8
AUX DEADMAN -2
JPC24-4
DGND -3
-1
B+K3
JPC18-11
STR_CONTACTOR JPC24-23 JPA-1
ROOM_TEMP
JPC6-6 -11 -2
DGND
+12VP
-5
CCW_PWM JPC18-18 SPL-6
-2 ALARM 4 4
CW_PWM
-3
STEER_CURRENT
-4
DGND JPC20-16
-1 L/L SOL2
NEUTRAL_PULSE 1 2
-15
(B+K2)B+L/L
JPC22-19
FU1_SENSE -18
JPC14-10 AUX1
DGND
-2 -17
DGND (B+K2)B+AUX1 SOL5T
-1
1 2
-8
-9 B-F -20
AUX2 SOL5B
1st SPEED 1 2
S12 LIMITING SWITCH JPS4-1 JPC20-1 -19
+12VP (B+K2)B+AUX2
NC -12
JPS4-3 COM DUMP SOL3
NO -2 JPC22-1 1
AC LIFT &
SPEED_LIMIT_1 2
-13
(B+K2)B+DUMP
JPC10-10
BUS_E+
-5 JPC20-4 JPY1-1 +
+12VP
ELECTRIC
BUS_E-
HRN JPC24-18 -2 0
-NEG PRESSURE PRESS
-6 -3 -
-IN H-1 JPC18-16 DGND
H HORN
STEER
-POS H-2
JPBR-2 JPS2-2 JPC20-5 JPDP-1
+12VP
DEADMAN
VR4
SENSOR
-1 -1 JPC20-14 JPC24-19 -3
BRAKE BRAKE DEADMAN
FAN-T -7 -2
JPB1-1 + JPB1-2 JPC18-17 DGND
- FAN
JPC20-2 JPS12-1
DEADMAN
FAN-FW +12VP
JPC22-8 -2
SWITCH
JPB2-1 JPB2-2 ON DEADMAN
+ - NC
S2
JPC18-7 -3 JPDS-COM JPDS-NO
FAN-FW2 DGND
JPB4-1 JPB4-2
+ -
FAN-DU
JPB3-1 JPB3-2
+ -
-10 JPC20-7 JPE4-1 RED
SOL1 L/H +12VP
2 1 JPC22-9 -3
JPC14-6 CHANNELA_4 WHT STEER
RELAY_ENABLE MOTOR
JPC22-21 -10 -2 BLU ENCODER
EPO_SENSE CHANNELB_4
JPC10-9 -4 BLK
DGND
JPC14-12
ROTATION
B+KEY JPC20-9 JPST-1 +
SWITCH
+12VP
END OF
STEER
JPC22-22 -2 0 S11
STEER_LIMIT
-11 -3 -
DGND
-7
B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
FLASHWARE
TXD JPC9-2
JPS3-2 -3
RXD
DGND -5
-3 JPC18-12
REACH_SOL
-4 -14
SIDESHIFT_SOL
COMMUNICATIONS
-5 -15 VBUS JPC2-1
TILT_SOL
D+ -2
USB
D- -3
DGND -4
-6 JPC22-18
NESTED_SWITCH
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-59
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
G2 HTI
TACH 1
REL-2
M
SOL-5B
1 2
1 A1
4 3 2 LS-1
3
P1 2
P1
2 1 4
3 A2
POD-1
SOL-5T
G1
1
CV-1 1 CYL-1
2 2
Legend: SOL-1
Pressure
1 Line
SOL-3 Return Line
Suction Line 1
Electrical
2
Control
Signal
CFS-1
SOL-2
TANK
FILTER
S-RET
CYL-P
PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-19. Sideshift - Hydraulic (Series CA and FA)
8-60 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
REACH
RC
3 4
A2
1 2
RR
REACH1 TILT
3 4 TC
1 2
TR
TILT
MAIN LIFT
FREE LIFT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-61
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
Lift while using Aux Functions 4, the pilot line will work to move the spool
to its second position.
Refer to Figures 8-20 and 8-21.
With the valve in its second position, fluid
1. The lift contactor is energized by will flow to Check Valve 1 (CV1). Fluid
depressing the deadman switch (S2). flows through CV1 and the de-energized
2. The lift power amplifier internally supplies SOL-1 (Load Holding). From there, fluid
B- to the lift contactor coil (LPC) at JPL1-2, passes through the free flow portion of the
which closes the normally open contactor flow limiters (located in the base of the lift
tips. cylinders) and into the lift cylinders.
3. When the lift contactor coil is energized, SOL3 (Dump) is used as a proportional
the contactor tips close, allowing B+ to be relief to limit system pressure to a safe
supplied to the lift power amplifier, which level. With this valve: 0V = 3500 psi
supplies voltage to the lift motor. (24132 kPa). The pressure relief will be set
by the VM and firmware at approx. 2V,
4. When VR2 is moved to request lift, a
which equals 3200 (22063 kPa) psi.
voltage is sent to the VM at JPC12-2. The
VM sees a voltage different from the The PODS valve also meters fluid to the
“learned” neutral voltage, and sends a requested aux function. As the metered
request to the lift power amplifier via flow enters SOL5B or 5T (depending on the
BUS+/BUS– (JPC14-11 and JPC14-4 to direction of function requested), the
JPL1-22 and JPL1-14). voltage applied to the valve by the VM will
open it.
5. The voltage supplied to the lift motor is
proportional to the amount of lift request SOL5 is a proportional solenoid. The VM
from VR2 (faster lift = higher motor sends a fixed voltage to it to open it a
voltage). specific amount, depending on the
function requested.
6. In order to operate reach or retract, switch
S4 or S5 is used to send an input to the The load shuttle sends pressure to the
VM at JPC12-4 or JPC12-11. pilot line of the PODS valve to allow the
valve to properly divide the fluid between
NOTE: The lift motor/pump is variable speed. lift and auxiliary.
Therefore, the farther VR2 is moved
from neutral, the faster the motor/pump When using auxiliary functions only (no
will rotate. lift) or lifting only (no aux), the speed of the
motor is approx. 400 rpm. If slow lift is
7. When the request to lift and reach is used along with an aux function, the
made, the VM energizes the following motor/pump speed may increase due to
solenoids via internal coil drivers: the need for more fluid to the functions.
• SOL3 (Dump) at JPC20-12
• SOL5T at JPC20-18 or SOL5B at
JPC20-20, depending on the direction
of the function chosen
• One of the following:
REACH SOL at JPC18-12
SIDESHIFT SOL at JPC18-14
TILT SOL at JPC18-15
8. As the pump (P1) begins to rotate, fluid
will flow into the PODS valve at port 3. The
Priority On Demand Spool will be used to
bias flow between lift and aux. Port 3 is
connected to port 4. With pressure at port
8-62 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
1026304B, 15 July 2007 8-63
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR BLACK -4 -5 -4
T VEL SENSOR+
PANEL TME T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
TP2 TP3 TP5 T VEL PHASE B
JPT3
RED -2 -8 -16
FU1 FU3 FU2 T TEMP+
(150A) (500A) (350A) TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 MOTOR TEMPERATURE TA
-2 1 1 1 X TPC Y JPS1-8 -2 TPC
-3 STR LPC TPC CONTACTOR
2 2
-4 2 U
U
B-
V
TM V
W
1 W
B+ +
1 TR
LR 2 MOTOR VELOCITY
2 RED JPL2-1 JPL1-3
L VEL SENSOR+
BLACK -4 -4
LR-2 TR-2 LME L VEL SENSOR-
WHITE -3 -5
L VEL PHASE A
BLUE -2 -6
L VEL PHASE B
RED JPL3-2 -16
STR
L TEMP+
Y X LMT
RED/BLK -1 -17
L TEMP-
X LPC Y JPS1-9
MOTOR TEMPERATURE LPC
LA
-2
CONTACTOR
B-
U
U
V
LM V
JPS1-5 JPS1-6 JPS1-7 JPS1-10 JPS1-11
W
W +
B+
JP
B-
TP4 STR-2
MS-A1
A1 +
MS SA
A2 -
MS-A2
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
T˚ K3 TS1-2
JPF1-1 JPS10-3
FU8 (15A/5A)
-2
1 2 JPF4-15 -5
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/
TS2-2
RELAY
CARD JPF2-8 JPS3-1
TS2-1 1 2 -3
REACH
B+ 1 SIDE
SHIFT
2 -4
Buss+/- 1 2 -5
TILT
5v
4
B- -6
Input
8R828-011-224_D_C.EPS
Figure 8-20. Lift with Aux - Electrical (Series CA/FA)
8-64 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
VEHICLE
MANAGER
JPT1
-20
ID2 RED JPE1-1 JPC10-6
-21 +12V_EN1
IDGND WHT -3 JPC22-5
CHANNEL_A_1 JPC12-1 JPH1-1
-2 -12 +5VP +5VP
BLU
CHANNEL_B_1
STEER BLK -4 JPC18-5 +5VP
TILLER DGND
-3 -3
ENCODER RED JPE2-1 JPC10-7 P_THROTTLE VR1
+12V_EN2
WHT -3 JPC22-13
CHANNEL_A_2 DGND
BLU -2 -14 +5VP +5VP +
CHANNEL_B_2
0 S3
TA BLK -4 JPC18-6
DGND LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-1 -4 -4 0
REACH S4
B+K3
-7 -11 -11
DGND RETRACT -
-22 DGND
BUS_I+
BUS_I- -14 -5 -5
TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
JPL1 -8 -8 -
-15 SSHIFT_LEFT S8
BUS_I- DGND
DISPLAY -9 -9
-23 SSHIFT_RIGHT S9
BUS_I+ -12
-8 JPD3-1 B-1 -12
DGND +12VP DGND DGND
SOUNDER -13
-2 B-2
SOUNDER
HTR6
-7 -7
-22 -2 H_HTR
BUS_I+ BUS_I+ JPC14-5
-14 -3 JPD1-5
BUS_I- BUS_I- +12VP
-7 -4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
DGND JPC20-8 -2
-7 -4 +12VP
BUS_I- JPC22-7 -3
LA -8 -3
DGND
HGG_FAULT
HGG_CONTACTOR
JPC24-2 -4
-12 JPC10-3 -5
ID1 THERM_EN 4
-13
IDGND JPC24-13
+12VP JPAD-1
JPC10-8
AUX DEADMAN -2
JPC24-4
DGND -3
-1
B+K3
JPC18-11
STR_CONTACTOR JPC24-23 JPA-1
ROOM_TEMP
JPC6-6 -11 -2
DGND
+12VP
-5
CCW_PWM JPC18-18 SPL-6
-2 ALARM 4 4
CW_PWM
-3
STEER_CURRENT
-4
DGND JPC20-16
-1 L/L SOL2
NEUTRAL_PULSE 1 2
-15
(B+K2)B+L/L
JPC22-19
FU1_SENSE -18
JPC14-10 AUX1
DGND
-2 -17
DGND (B+K2)B+AUX1 SOL5T
-1
1 2
-8
-9 B-F -20
AUX2 SOL5B
1st SPEED 1 2
S12 LIMITING SWITCH JPS4-1 JPC20-1 -19
+12VP (B+K2)B+AUX2
NC -12
JPS4-3 COM DUMP SOL3
NO -2 JPC22-1 1
AC LIFT &
SPEED_LIMIT_1 2
-13
(B+K2)B+DUMP
JPC10-10
BUS_E+
-5 JPC20-4 JPY1-1 +
+12VP
ELECTRIC
BUS_E-
HRN JPC24-18 -2 0
-NEG PRESSURE PRESS
-6 -3 -
-IN H-1 JPC18-16 DGND
H HORN
STEER
-POS H-2
JPBR-2 JPS2-2 JPC20-5 JPDP-1
+12VP
DEADMAN
VR4
SENSOR
-1 -1 JPC20-14 JPC24-19 -3
BRAKE BRAKE DEADMAN
FAN-T -7 -2
JPB1-1 + JPB1-2 JPC18-17 DGND
- FAN
JPC20-2 JPS12-1
DEADMAN
FAN-FW +12VP
JPC22-8 -2
SWITCH
JPB2-1 JPB2-2 ON DEADMAN
+ - NC
S2
JPC18-7 -3 JPDS-COM JPDS-NO
FAN-FW2 DGND
JPB4-1 JPB4-2
+ -
FAN-DU
JPB3-1 JPB3-2
+ -
-10 JPC20-7 JPE4-1 RED
SOL1 L/H +12VP
2 1 JPC22-9 -3
JPC14-6 CHANNELA_4 WHT STEER
RELAY_ENABLE MOTOR
JPC22-21 -10 -2 BLU ENCODER
EPO_SENSE CHANNELB_4
JPC10-9 -4 BLK
DGND
JPC14-12
ROTATION
B+KEY JPC20-9 JPST-1 +
SWITCH
+12VP
END OF
STEER
JPC22-22 -2 0 S11
STEER_LIMIT
-11 -3 -
DGND
-7
B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
FLASHWARE
TXD JPC9-2
JPS3-2 -3
RXD
DGND -5
-3 JPC18-12
REACH_SOL
-4 -14
SIDESHIFT_SOL
COMMUNICATIONS
-5 -15 VBUS JPC2-1
TILT_SOL
D+ -2
USB
D- -3
DGND -4
-6 JPC22-18
NESTED_SWITCH
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-65
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (AC Lift Motor)
G2 HTI
TACH 1
REL-2
M
SOL-5B
1 2
1 A1
4 3 2 LS-1
3
P1 2
P1
2 1 4
3 A2
POD-1
SOL-5T
G1
1
CV-1 1 CYL-1
2 2
SOL-1
1
SOL-3
1
CFS-1
SOL-2
TANK
FILTER
S-RET
CYL-P
PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-21. Lift with Aux - Hydraulic (Series CA and FA)
8-66 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (AC Lift Motor)
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
REACH
RC
3 4
A2
1 2
RR
REACH1 TILT
3 4 TC
1 2
TR
TILT
MAIN LIFT
FREE LIFT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-67
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
Hydraulic System 5. Pressurized hydraulic fluid from the steer
pump flows to the steering orbitrol.
Functional Operation 6. Turning the steering wheel directs
hydraulic fluid to one side of the hydraulic
(DC Lift Motor) steer motor. Turning the steering wheel in
the opposite direction directs fluid to the
other side of the hydraulic steer motor.
Series AA, BA, DA and EA
7. When steering is requested, oil leaving the
NOTE: The schematics in this chapter are steering valve will return to the reservoir
intended for general understanding of via the S-RET line.
theory of operation and do not reflect 8. Maximum hydraulic pressure in the
latest developments in circuitry. steering system is limited by the pressure
Do not use these schematics to relief valve. The relief is located on the
troubleshoot or repair the lift truck. steer valve. Relief pressure is set at
approx. 1600 psi (11,031 kPa).
Always use the schematics in the
Appendix for troubleshooting and
repair.
NOTE: On electrical schematics, only circuits
related directly with the hydraulic
functions will be addressed.
Steering System
System Components
Steer Valve
The steer valve is an orbital type rotary flow
valve with an auxiliary port. When no steering
is being done, fluid flows through the auxiliary
port (E). When steering is requested, fluid flows
first through the steer valve, hydraulic motor
and the steer return port (T). Any excess flow
exits out the auxiliary port. Steering has
priority over auxiliary functions.
Theory of Steering Function
Refer to Figures 8-22 and 8-23.
1. When the operator presses the deadman
pedal, a circuit is completed at the VM
between JPC22-8 and JPC18-7.
2. The VM energizes the STR contactor by
way of JPC18-11.
3. With the STR contactor energized, current
flows to the steer motor, causing it to run.
4. The steering system has priority over all
other auxiliary functions.
8-68 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
1026304B, 15 July 2007 8-69
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR T VEL SENSOR+
BLACK
PANEL TME
-4 -5 -4
T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
T VEL PHASE B
2 JPT3
1 RED
TPC -2 -8 -16
STR T TEMP+
2 1 TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 FU2 MOTOR TEMPERATURE TA
-2 (350A) X TPC Y JPS1-8 -2 TPC
-3 TP5 CONTACTOR
-4 U
U
B-
1 V
TM V
TR STR W
FU1 W
(150A) Y X B+ +
TP2 FU3 2
(500A) Y X
LPC
2
LPC
1
SPL-2
JPS1-5 JPS1-6 JPS1-7 JPS1-10 -9 JPS1-11
A1 +
A2
A1 +
LM
MS
A2 -
S1 -
JP
B-
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
K3 TS1-2
JPF1-1 T˚
JPS10-3
FU8 (15A/5A)
-2
-5
1 2 JPF4-15
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/ TS2
RELAY -2
CARD JPF2-8 JPS3-1
TS2-1
1 2 -3
REACH
1 2 -4
SIDE
SHIFT
1 2 -5
TILT
B+
Buss+/- 4
-6
5v
B-
Input
8R828-011-224_D_C.EPS
Figure 8-22. Steering System - Electrical (Series AA/BA/DA/EA)
8-70 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
VEHICLE
MANAGER
BW1 JPC22-15
JPT1 BRUSH_WEAR_1
ID2 -20
-21
IDGND
LM_A1 JPC12-1 JPH1-1
+5VP +5VP
BW2 -16
BRUSH_WEAR_2 +5VP
-3 -3
P_THROTTLE VR1
LM_A2 DGND
+5VP +5VP +
(ON LM) 0 S3
TA LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-23 -4 -4 0
REACH S4
BUS_I+
-15 -11 -11
BUS_I- RETRACT -
-8 DGND
DGND
-1 -5 -5
B+K3 TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
-8 -8 -
SSHIFT_LEFT S8
DGND
DISPLAY -9 -9
SSHIFT_RIGHT S9
-12
JPD3-1 B-1 -12
+12VP DGND DGND
SOUNDER
-2 B-2 -13
SOUNDER
HTR6
-7 -7
-2 H_HTR
BUS_I+ JPC14-5
-3 JPD1-5
BUS_I- +12VP
-4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
-7 -4 JPC20-8 -2
BUS_I- +12VP
JPC22-7 -3
-8 -3 HGG_FAULT
DGND JPC24-2 -4
HGG_CONTACTOR
JPC10-3 -5
THERM_EN 4
JPC24-13
+12VP JPAD-1
JPC18-11 JPC10-8
STR_CONTACTOR AUX DEADMAN -2
-9 JPC24-4
LIFT_CONTACTOR DGND -3
T˚ JPZ-1 JPC24-22
LIFT_MOT_TEMP
(ON LM) JPC24-23 JPA-1
-2 -10 ROOM_TEMP
DGND
-11 -2
DGND
JPC22-20
FU3_SENSE
-19 JPC18-18 SPL-6
FU1_SENSE ALARM 4 4
JPC14-10
DGND
-2
DGND
-1 JPC20-16
L/L SOL2
-8
1 2
-9 B-F -15
(B+K2)B+L/L
1st SPEED JPS4-1 JPC20-1
S12 +12VP AUX1 -18
LIMITING SWITCH
NC
JPS4-3 COM -17
NO -2 JPC22-1 (B+K2)B+AUX1 SOL5T
SPEED_LIMIT_1 1 2
JPC10-10
BUS_E+ -20
AUX2 SOL5B
-5
BUS_E- 1 2
HRN -19
(B+K2)B+AUX2
-NEG
-12
-IN H-1 JPC18-16 AUXDUMP SOL8
H HORN
1 2
-POS H-2 -13
(B+K2)B+AUXDUMP
JPBR-2 JPS2-2
PRESSURE
+12VP
JPC20-4
JPC24-18
JPY1-1
-2
+
0
PRESS
DC LIFT &
-1 -1 JPC20-14
HYDRAULIC
BRAKE BRAKE -6 -3 -
DGND
JPB1-1
FAN-T
+ -
JPB1-2 JPC18-17
FAN +12VP
JPC20-5 JPDP-1
STEERING
DEADMAN
VR4
SENSOR
JPC24-19 -3
FAN-FW DEADMAN
JPB2-1 JPB2-2
+ - -7 -2
DGND
FAN-LM JPC20-2 JPS12-1
JPB5-2
DEADMAN
JPB5-1 +12VP
+ - JPC22-8 -2
SWITCH
ON_DEADMAN
NC
FAN-FW2 S2
JPB4-1 JPB4-2 JPDS-COM
+ - -1 DGND JPC18-7 -3 JPDS-NO
SOL4 2nd_STAGE
2 1
FAN-DU
JPB3-1 JPB3-2
+ - -10
SOL1 L/H
2 1
JPC14-6
RELAY_ENABLE
JPC22-21
EPO_SENSE
JPC14-12
B+KEY
-7 B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
JPS3-2
-3 JPC18-12 TXD JPC9-2
REACH_SOL
FLASHWEAR
RXD -3
-4 -14
SIDESHIFT_SOL DGND -5
-5 -15
TILT_SOL
COMMUNICATIONS
VBUS JPC2-1
D+ -2
USB
-6 D- -3
JPC22-18
NESTED_SWITCH -4
DGND
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-71
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
PP
G1
M
LOAD HOLD
SOL-1
CV-1 CYL-1
1 2
P1
1
CYL-P
1
REL-1
MAIN RELIEF
2
CFS
SOL-2
2
LIFT/LOWER
HTI
FILTER
M SOL-5B
LS-1
PWR
A1
BYND 3 2 1
P3 2
1 4
3 A2
S-RET
P E T
2 SOL-5T
L R 1
3
1
SOL-8
CASE AUX DUMP 2 CE-1
DRAIN
G2
HYD STEER MOTOR TANK
DOSCKTANCE SHOWN.
HOSES ARE REVERSE
OF FORE/AFT. PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-23. Steering System - Hydraulic (Series AA/BA/DA/EA)
8-72 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
MAIN LIFT
FREE LIFT
CB-1
CV-3
2 PSI REL-3
2 1 2 1800 PSI RC
T B
REACH
A1 3 4 3
1 2 3
A2
2 1 1
RR
REACH
CB-2
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
A2
3 4 TC TILT
1 2
TR
TILT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-73
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
Lift/Lower System Sideshift Solenoid (S/S SOL)
S/S SOL is a normally closed solenoid valve
System Components used to block (de-energized) or allow (energized)
fluid flow to and from the sideshift cylinder.
Load Holding Valve (SOL1)
Tilt Solenoid (TILT SOL)
The load holding valve is a normally closed
solenoid valve used to hold the carriage in an TILT SOL is a normally closed solenoid valve
elevated position. It incorporates an override to used to block (de-energized) or allow (energized)
allow lowering the carriage manually. fluid flow to and from the tilt cylinder.
Proportional Lower Valve (SOL2) Brush Wear Indicators
The proportional lower valve is a pressure The brush wear indicators are located on the lift
compensated flow control solenoid valve used to motor. Their purpose is to provide an indication
lower the carriage. As the voltage to the valve when the motor brushes are worn and need
increases, the flow through the valve increases, replacement.
regardless of the pressure.
Lift Motor Temperature Sensor
SOL4 (Second Stage Solenoid) The lift motor temperature sensor is a
SOL4 is a two position normally open solenoid thermistor used to indicate the temperature of
whose function is to feed oil from pump P2 to the lift motor. It is mounted in the outer case of
the lift cylinders for high speed lift. When the motor.
de-energized, oil is ported from P2 to the
reservoir.
SOL5B/SOL5T
SOL5 is a proportional directional solenoid
valve providing directional control to the reach,
tilt, and sideshift functions. De-energized, flow
is blocked to the aux functions and directed to
the reservoir. When SOL5B is energized, flow is
directed to port A1 for tilt up, sideshift right, or
reach. When SOL5T is energized, flow is
directed to port A2 for tilt down, sideshift left, or
retract.
SOL8 (Aux Dump)
SOL8 is a two position normally open solenoid.
Its purpose is to provide a path for oil from P3
back to the reservoir when aux functions and
steering are not being used.
Reach/Retract Solenoid (R/R SOL)
R/R SOL is a normally closed solenoid valve
used to block (de-energized) or allow (energized)
fluid flow to and from the reach cylinders.
8-74 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
Theory of Lift/Lower Function
When the key switch is turned ON, the L/L
proportional valve moves to the full open
position. This relieves any pressure in the
hydraulic line by diverting any residual fluid
back to the tank. The L/L proportional valve
then closes.
With the key switch ON, moving the lift/lower
control on the multi-function control handle to
lift causes:
Variable Lift
Refer to Figures 8-24 and 8-25.
1. VR2 output voltage becomes lower than
when in the neutral position.
2. The VM senses this decrease in voltage at
JPC12-2. The VM energizes the STR
contactor coil at JPC18-11 and the Lift
contactor coil at JPC18-9. This closes the
contactor tips and starts the lift pump
motor (LM).
3. Initially, the VM commands the
proportional lift/lower valve (L/L) to move
to the full open position (back to tank),
then positions it proportionally to the
output request of VR2. For a slow lift rate,
the proportional valve will be open more,
allowing more fluid to return to the
reservoir than it would for faster lifting
rates.
4. Lift motor voltage is monitored at
JPC22-20 (FU3 Sense).
5. High speed lift operating parameters will
vary for different mast configurations.
Regardless of the mast configuration,
voltage from VR2 must be at least 90% of
the Learned maximum for lift before high
speed lift will be activated.
6. The weight of the load on the forks is
determined by inputs to the VM from the
pressure sensor at JPC24-18.
7. PP is used for Pump Pressure and G1 is
used to check the pressure in the system
with a load on the forks.
1026304B, 15 July 2007 8-75
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR T VEL SENSOR+
BLACK
PANEL TME
-4 -5 -4
T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
T VEL PHASE B
2 JPT3
1 RED
TPC -2 -8 -16
STR T TEMP+
2 1 TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 FU2 MOTOR TEMPERATURE TA
-2 (350A) X TPC Y JPS1-8 -2 TPC
-3 TP5 CONTACTOR
-4 U
U
B-
1 V
TM V
TR STR W
FU1 W
(150A) Y X B+ +
TP2 FU3 2
(500A) Y X
LPC
2
LPC
1
SPL-2
JPS1-5 JPS1-6 JPS1-7 JPS1-10 -9 JPS1-11
A1 +
A2
A1 +
LM
MS
A2 -
S1 -
JP
B-
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
K3 TS1-2
JPF1-1 T˚
JPS10-3
FU8 (15A/5A)
-2
-5
1 2 JPF4-15
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/ TS2
RELAY -2
CARD JPF2-8 JPS3-1
TS2-1
1 2 -3
REACH
1 2 -4
SIDE
SHIFT
B+ 1
TILT
2 -5
Buss+/-
5v 4
-6
B-
Sense/Input
12v
8R828-011-224_D_C.EPS
Figure 8-24. Variable Lift - Electrical (Series AA/BA/DA/EA)
8-76 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
VEHICLE
MANAGER
BW1 JPC22-15
JPT1 BRUSH_WEAR_1
ID2 -20
-21
IDGND
LM_A1 JPC12-1 JPH1-1
+5VP +5VP
BW2 -16
BRUSH_WEAR_2 +5VP
-3 -3
P_THROTTLE VR1
LM_A2 DGND
+5VP +5VP +
(ON LM) 0 S3
TA LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-23 -4 -4 0
REACH S4
BUS_I+
-15 -11 -11
BUS_I- RETRACT -
-8 DGND
DGND
-1 -5 -5
B+K3 TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
-8 -8 -
SSHIFT_LEFT S8
DGND
DISPLAY -9 -9
SSHIFT_RIGHT S9
-12
JPD3-1 B-1 -12
+12VP DGND DGND
SOUNDER
-2 B-2 -13
SOUNDER
HTR6
-7 -7
-2 H_HTR
BUS_I+ JPC14-5
-3 JPD1-5
BUS_I- +12VP
-4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
-7 -4 JPC20-8 -2
BUS_I- +12VP
JPC22-7 -3
-8 -3 HGG_FAULT
DGND JPC24-2 -4
HGG_CONTACTOR
JPC10-3 -5
THERM_EN 4
JPC24-13
+12VP JPAD-1
JPC18-11 JPC10-8
STR_CONTACTOR AUX DEADMAN -2
-9 JPC24-4
LIFT_CONTACTOR DGND -3
T˚ JPZ-1 JPC24-22
LIFT_MOT_TEMP
(ON LM) JPC24-23 JPA-1
-2 -10 ROOM_TEMP
DGND
-11 -2
DGND
JPC22-20
FU3_SENSE
-19 JPC18-18 SPL-6
FU1_SENSE ALARM 4 4
JPC14-10
DGND
-2
DGND
-1 JPC20-16
L/L SOL2
-8
1 2
-9 B-F -15
(B+K2)B+L/L
1st SPEED JPS4-1 JPC20-1
S12 +12VP AUX1 -18
LIMITING SWITCH
NC
JPS4-3 COM -17
NO -2 JPC22-1 (B+K2)B+AUX1 SOL5T
SPEED_LIMIT_1 1 2
JPC10-10
BUS_E+ -20
AUX2 SOL5B
-5
BUS_E- 1 2
HRN -19
(B+K2)B+AUX2
-NEG
-12
-IN H-1 JPC18-16 AUXDUMP SOL8
H HORN
1 2
-POS H-2 -13
(B+K2)B+AUXDUMP
JPBR-2 JPS2-2
PRESSURE
+12VP
JPC20-4
JPC24-18
JPY1-1
-2
+
0
PRESS
DC LIFT &
-1 -1 JPC20-14
HYDRAULIC
BRAKE BRAKE -6 -3 -
DGND
JPB1-1
FAN-T
+ -
JPB1-2 JPC18-17
FAN +12VP
JPC20-5 JPDP-1
STEERING
DEADMAN
VR4
SENSOR
JPC24-19 -3
FAN-FW DEADMAN
JPB2-1 JPB2-2
+ - -7 -2
DGND
FAN-LM JPC20-2 JPS12-1
JPB5-2
DEADMAN
JPB5-1 +12VP
+ - JPC22-8 -2
SWITCH
ON_DEADMAN
NC
FAN-FW2 S2
JPB4-1 JPB4-2 JPDS-COM
+ - -1 DGND JPC18-7 -3 JPDS-NO
SOL4 2nd_STAGE
2 1
FAN-DU
JPB3-1 JPB3-2
+ - -10
SOL1 L/H
2 1
JPC14-6
RELAY_ENABLE
JPC22-21
EPO_SENSE
JPC14-12
B+KEY
-7 B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
JPS3-2
-3 JPC18-12 TXD JPC9-2
REACH_SOL
FLASHWEAR
RXD -3
-4 -14
SIDESHIFT_SOL DGND -5
-5 -15
TILT_SOL
COMMUNICATIONS
VBUS JPC2-1
D+ -2
USB
-6 D- -3
JPC22-18
NESTED_SWITCH -4
DGND
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-77
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
PP
G1
M
LOAD HOLD
SOL-1
CV-1 CYL-1
1 2
P1
1
CYL-P
1
REL-1
MAIN RELIEF
2
CFS
SOL-2
2
LIFT/LOWER
HTI
FILTER
M SOL-5B
LS-1
PWR
A1
BYND 3 2 1
P3 2
1 4
3 A2
S-RET
P E T
2 SOL-5T
L R 1
3
1
SOL-8
CASE AUX DUMP 2 CE-1
DRAIN
G2
HYD STEER MOTOR TANK
DOSCKTANCE SHOWN.
HOSES ARE REVERSE
OF FORE/AFT. PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-25. Variable Lift - Hydraulic (Series AA/BA/DA/EA)
8-78 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
MAIN LIFT
FREE LIFT
CB-1
CV-3
2 PSI REL-3
2 1 2 1800 PSI RC
T B
REACH
A1 3 4 3
1 2 3
A2
2 1 1
RR
REACH
CB-2
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
A2
3 4 TC TILT
1 2
TR
TILT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-79
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
High-Speed Lift (lift trucks with dual lift damage to various systems of the lift
pump) truck. A temperature sensor on the lift
motor is used to detect overheating of the
Refer to Figures 8-26 and 8-27.
motor. The output of the temperature
1. High speed lift (SOL4 energized), is sensor is fed into the VM. As the
activated when the voltage from VR2 is at temperature rises in the lift motor, the VM
least 90% of the maximum Learned value cuts out power to the solenoid controlling
for Lift. When this voltage is reached, the the second lift pump (SOL4), thus
SOL4 is energized, stopping oil from the diverting the hydraulic fluid coming from
second lift pump (P2) from going to the the second pump back to the reservoir.
reservoir. Hydraulic flow from both The temperature at which the second
sections of the lift pump is sent to the lift pump diverts fluid back to the reservoir is
cylinder. about 240°F (115°C). This decreases the
2. The proportional lift/lower (SOL2) is load on the motor and should cool it down.
electrically positioned by the following If the temperature continues to rise
process: (greater than 262°F/128°C), the System
Card will cut out lift entirely.
a. Voltage generated by potentiometer VR2
is sent to and processed by the VM. NOTE: On certain series equipped with dual
b. A signal from the VM drives L/L. pumps, the maximum lift speed may be
reduced (SOL4 disabled) when forks
c. Voltage across the coil of L/L is initially travel above free-lift (S10 opens) and the
approx. 19V and will decrease as the load exceeds a specified weight, as
lift/lower control is moved to faster lift determined by the pressure transducer.
positions. This causes L/L to be fully
opened at maximum voltage and fully
closed at minimum voltage.
d. Voltage across L/L will vary depending
on the position of the lift/lower control:
• Low voltage = fast lift
• High voltage = slow lift
3. L/L (proportional lift/lower valve) controls
hydraulic flow from the lift pump to the lift
cylinder. As the lift/lower control is moved
to a faster lift position, proportional spool
valve L/L closes.
4. When VR2 (lift/lower control) returns to
the neutral position, the lift contactor is
immediately de-energized; but L/L is kept
energized until the lift pump motor stops
turning. This is done because a spinning
motor does not stop instantly; the motor
rotation is sensed by the pump sense line
at JPC22-20. If L/L was de-energized at
the same time as the motor, the fork
carriage would jump. Leaving L/L open
until the motor stops diverts any excess
hydraulic fluid back to the reservoir.
5. The VM monitors vehicle operation and
will control performance as required to
ensure safe vehicle operation and prevent
8-80 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
1026304B, 15 July 2007 8-81
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR T VEL SENSOR+
BLACK
PANEL TME
-4 -5 -4
T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
T VEL PHASE B
2 JPT3
1 RED
TPC -2 -8 -16
STR T TEMP+
2 1 TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 FU2 MOTOR TEMPERATURE TA
-2 (350A) X TPC Y JPS1-8 -2 TPC
-3 TP5 CONTACTOR
-4 U
U
B-
1 V
TM V
TR STR W
FU1 W
(150A) Y X B+ +
TP2 FU3 2
(500A) Y X
LPC
2
LPC
1
SPL-2
JPS1-5 JPS1-6 JPS1-7 JPS1-10 -9 JPS1-11
A1 +
A2
A1 +
LM
MS
A2 -
S1 -
JP
B-
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
K3 TS1-2
JPF1-1 T˚
JPS10-3
FU8 (15A/5A)
-2
-5
1 2 JPF4-15
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/ TS2
RELAY -2
CARD JPF2-8 JPS3-1
TS2-1
1 2 -3
REACH
1 2 -4
SIDE
SHIFT
B+ 1
TILT
2 -5
Buss+/-
5v 4
-6
B-
Sense/Input
12v
8R828-011-224_D_C.EPS
Figure 8-26. High Speed Lift - Electrical (Series AA/BA/DA/EA)
8-82 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
VEHICLE
MANAGER
BW1 JPC22-15
JPT1 BRUSH_WEAR_1
ID2 -20
-21
IDGND
LM_A1 JPC12-1 JPH1-1
+5VP +5VP
BW2 -16
BRUSH_WEAR_2 +5VP
-3 -3
P_THROTTLE VR1
LM_A2 DGND
+5VP +5VP +
(ON LM) 0 S3
TA LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-23 -4 -4 0
REACH S4
BUS_I+
-15 -11 -11
BUS_I- RETRACT -
-8 DGND
DGND
-1 -5 -5
B+K3 TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
-8 -8 -
SSHIFT_LEFT S8
DGND
DISPLAY -9 -9
SSHIFT_RIGHT S9
-12
JPD3-1 B-1 -12
+12VP DGND DGND
SOUNDER
-2 B-2 -13
SOUNDER
HTR6
-7 -7
-2 H_HTR
BUS_I+ JPC14-5
-3 JPD1-5
BUS_I- +12VP
-4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
-7 -4 JPC20-8 -2
BUS_I- +12VP
JPC22-7 -3
-8 -3 HGG_FAULT
DGND JPC24-2 -4
HGG_CONTACTOR
JPC10-3 -5
THERM_EN 4
JPC24-13
+12VP JPAD-1
JPC18-11 JPC10-8
STR_CONTACTOR AUX DEADMAN -2
-9 JPC24-4
LIFT_CONTACTOR DGND -3
T˚ JPZ-1 JPC24-22
LIFT_MOT_TEMP
(ON LM) JPC24-23 JPA-1
-2 -10 ROOM_TEMP
DGND
-11 -2
DGND
JPC22-20
FU3_SENSE
-19 JPC18-18 SPL-6
FU1_SENSE ALARM 4 4
JPC14-10
DGND
-2
DGND
-1 JPC20-16
L/L SOL2
-8
1 2
-9 B-F -15
(B+K2)B+L/L
1st SPEED JPS4-1 JPC20-1
S12 +12VP AUX1 -18
LIMITING SWITCH
NC
JPS4-3 COM -17
NO -2 JPC22-1 (B+K2)B+AUX1 SOL5T
SPEED_LIMIT_1 1 2
JPC10-10
BUS_E+ -20
AUX2 SOL5B
-5
BUS_E- 1 2
HRN -19
(B+K2)B+AUX2
-NEG
-12
-IN H-1 JPC18-16 AUXDUMP SOL8
H HORN
1 2
-POS H-2 -13
(B+K2)B+AUXDUMP
JPBR-2 JPS2-2
PRESSURE
+12VP
JPC20-4
JPC24-18
JPY1-1
-2
+
0
PRESS
DC LIFT &
-1 -1 JPC20-14
HYDRAULIC
BRAKE BRAKE -6 -3 -
DGND
JPB1-1
FAN-T
+ -
JPB1-2 JPC18-17
FAN +12VP
JPC20-5 JPDP-1
STEERING
DEADMAN
VR4
SENSOR
JPC24-19 -3
FAN-FW DEADMAN
JPB2-1 JPB2-2
+ - -7 -2
DGND
FAN-LM JPC20-2 JPS12-1
JPB5-2
DEADMAN
JPB5-1 +12VP
+ - JPC22-8 -2
SWITCH
ON_DEADMAN
NC
FAN-FW2 S2
JPB4-1 JPB4-2 JPDS-COM
+ - -1 DGND JPC18-7 -3 JPDS-NO
SOL4 2nd_STAGE
2 1
FAN-DU
JPB3-1 JPB3-2
+ - -10
SOL1 L/H
2 1
JPC14-6
RELAY_ENABLE
JPC22-21
EPO_SENSE
JPC14-12
B+KEY
-7 B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
JPS3-2
-3 JPC18-12 TXD JPC9-2
REACH_SOL
FLASHWEAR
RXD -3
-4 -14
SIDESHIFT_SOL DGND -5
-5 -15
TILT_SOL
COMMUNICATIONS
VBUS JPC2-1
D+ -2
USB
-6 D- -3
JPC22-18
NESTED_SWITCH -4
DGND
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-83
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
PP
G1
CV-2
M
LOAD HOLD
SOL-1
CV-1 CYL-1
1 2
P1
1
CYL-P
P2 1
P2
REL-1
SOL-4
2 MAIN RELIEF
2ND STAGE
2
CFS
1
SOL-2
2
LIFT/LOWER
HTI
FILTER
M SOL-5B
LS-1
PWR
A1
BYND 3 2 1
P3 2
1 4
3 A2
S-RET
P E T
2 SOL-5T
R L 1
3
1
SOL-8
CASE AUX DUMP 2 CE-1
DRAIN
G2
HYD STEER MOTOR TANK
FORE/AFT CONFIG
SHOWN
PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-27. High Speed Lift - Hydraulic (Series AA/BA/DA/EA)
8-84 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
MAIN LIFT
FREE LIFT
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
REACH
RC
3 4
A2
1 2
RR
REACH TILT
3 4 TC
1 2
TR
TILT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-85
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
Lower
Refer to Figures 8-28 and 8-29.
1. Lowering is accomplished via the
proportional valve SOL2 (L/L), a
two-position normally closed proportional
pressure compensated flow control valve.
Lowering speed is not a function of weight
on the forks. An increasing voltage
increases the flow through the valve
regardless of the pressure in the system.
The maximum lowering speed is
determined by flow regulator FR2 in the
back lift cylinder.
2. When VR2 is moved to request Lower, a
voltage is sent to the VM at JPC12-2. The
VM sees a voltage different from the
“learned” neutral voltage.
3. The VM energizes internal coil drivers for
SOL1 (load holding) at JPC18-10.
Proportional lower solenoid SOL2 (L/L)
opens proportionally to the requested rate
of lower via a signal from the VM at
JPC20-16.
4. With load holding solenoid SOL1
energized, fluid flows out of the lift
cylinders through the regulated portion of
the flow limiters, through load holding
solenoid SOL1, and then through
energized proportional lower solenoid
SOL2. After fluid exits these valves, it
returns to tank via the hydraulic fluid
filter.
8-86 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
1026304B, 15 July 2007 8-87
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR T VEL SENSOR+
BLACK
PANEL TME
-4 -5 -4
T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
T VEL PHASE B
2 JPT3
1 RED
TPC -2 -8 -16
STR T TEMP+
2 1 TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 FU2 MOTOR TEMPERATURE TA
-2 (350A) X TPC Y JPS1-8 -2 TPC
-3 TP5 CONTACTOR
-4 U
U
B-
1 V
TM V
TR STR W
FU1 W
(150A) Y X B+ +
TP2 FU3 2
(500A) Y X
LPC
2
LPC
1
SPL-2
JPS1-5 JPS1-6 JPS1-7 JPS1-10 -9 JPS1-11
A1 +
A2
A1 +
LM
MS
A2 -
S1 -
JP
B-
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
K3 TS1-2
JPF1-1 T˚
JPS10-3
FU8 (15A/5A)
-2
-5
1 2 JPF4-15
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/ TS2
RELAY -2
CARD JPF2-8 JPS3-1
TS2-1
1 2 -3
REACH
1 2 -4
SIDE
B+
SHIFT
1 2 -5
TILT
Buss+/-
5v 4
-6
B-
Sense/Input
12v
8R828-011-224_D_C.EPS
Figure 8-28. Lower - Electrical (Series AA/BA/DA/EA)
8-88 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
VEHICLE
MANAGER
BW1 JPC22-15
JPT1 BRUSH_WEAR_1
ID2 -20
-21
IDGND
LM_A1 JPC12-1 JPH1-1
+5VP +5VP
BW2 -16
BRUSH_WEAR_2 +5VP
-3 -3
P_THROTTLE VR1
LM_A2 DGND
+5VP +5VP +
(ON LM) 0 S3
TA LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-23 -4 -4 0
REACH S4
BUS_I+
-15 -11 -11
BUS_I- RETRACT -
-8 DGND
DGND
-1 -5 -5
B+K3 TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
-8 -8 -
SSHIFT_LEFT S8
DGND
DISPLAY -9 -9
SSHIFT_RIGHT S9
-12
JPD3-1 B-1 -12
+12VP DGND DGND
SOUNDER
-2 B-2 -13
SOUNDER
HTR6
-7 -7
-2 H_HTR
BUS_I+ JPC14-5
-3 JPD1-5
BUS_I- +12VP
-4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
-7 -4 JPC20-8 -2
BUS_I- +12VP
JPC22-7 -3
-8 -3 HGG_FAULT
DGND JPC24-2 -4
HGG_CONTACTOR
JPC10-3 -5
THERM_EN 4
JPC24-13
+12VP JPAD-1
JPC18-11 JPC10-8
STR_CONTACTOR AUX DEADMAN -2
-9 JPC24-4
LIFT_CONTACTOR DGND -3
T˚ JPZ-1 JPC24-22
LIFT_MOT_TEMP
(ON LM) JPC24-23 JPA-1
-2 -10 ROOM_TEMP
DGND
-11 -2
DGND
JPC22-20
FU3_SENSE
-19 JPC18-18 SPL-6
FU1_SENSE ALARM 4 4
JPC14-10
DGND
-2
DGND
-1 JPC20-16
L/L SOL2
-8
1 2
-9 B-F -15
(B+K2)B+L/L
1st SPEED JPS4-1 JPC20-1
S12 +12VP AUX1 -18
LIMITING SWITCH
NC
JPS4-3 COM -17
NO -2 JPC22-1 (B+K2)B+AUX1 SOL5T
SPEED_LIMIT_1 1 2
JPC10-10
BUS_E+ -20
AUX2 SOL5B
-5
BUS_E- 1 2
HRN -19
(B+K2)B+AUX2
-NEG
-12
-IN H-1 JPC18-16 AUXDUMP SOL8
H HORN
1 2
-POS H-2 -13
(B+K2)B+AUXDUMP
JPBR-2 JPS2-2
PRESSURE
+12VP
JPC20-4
JPC24-18
JPY1-1
-2
+
0
PRESS
DC LIFT &
-1 -1 JPC20-14
HYDRAULIC
BRAKE BRAKE -6 -3 -
DGND
JPB1-1
FAN-T
+ -
JPB1-2 JPC18-17
FAN +12VP
JPC20-5 JPDP-1
STEERING
DEADMAN
VR4
SENSOR
JPC24-19 -3
FAN-FW DEADMAN
JPB2-1 JPB2-2
+ - -7 -2
DGND
FAN-LM JPC20-2 JPS12-1
JPB5-2
DEADMAN
JPB5-1 +12VP
+ - JPC22-8 -2
SWITCH
ON_DEADMAN
NC
FAN-FW2 S2
JPB4-1 JPB4-2 JPDS-COM
+ - -1 DGND JPC18-7 -3 JPDS-NO
SOL4 2nd_STAGE
2 1
FAN-DU
JPB3-1 JPB3-2
+ - -10
SOL1 L/H
2 1
JPC14-6
RELAY_ENABLE
JPC22-21
EPO_SENSE
JPC14-12
B+KEY
-7 B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
JPS3-2
-3 JPC18-12 TXD JPC9-2
REACH_SOL
FLASHWEAR
RXD -3
-4 -14
SIDESHIFT_SOL DGND -5
-5 -15
TILT_SOL
COMMUNICATIONS
VBUS JPC2-1
D+ -2
USB
-6 D- -3
JPC22-18
NESTED_SWITCH -4
DGND
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-89
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
PP
G1
M
LOAD HOLD
SOL-1
CV-1 CYL-1
1 2
P1
1
CYL-P
1
REL-1
MAIN RELIEF
2
CFS
SOL-2
2
LIFT/LOWER
HTI
FILTER
M SOL-5B
LS-1
PWR
A1
BYND 3 2 1
P3 2
1 4
3 A2
S-RET
P E T
2 SOL-5T
L R 1
3
1
SOL-8
CASE AUX DUMP 2 CE-1
DRAIN
G2
HYD STEER MOTOR TANK
DOSCKTANCE SHOWN.
HOSES ARE REVERSE
OF FORE/AFT. PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-29. Lower - Hydraulic (Series AA/BA/DA/EA)
8-90 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
MAIN LIFT
FREE LIFT
CB-1
CV-3
2 PSI REL-3
2 1 2 1800 PSI RC
T B
REACH
A1 3 4 3
1 2 3
A2
2 1 1
RR
REACH
CB-2
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
A2
3 4 TC TILT
1 2
TR
TILT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-91
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
Auxiliary System completed between JPC12-11 and JPC12-12 at
the VM.
System Components The VM completes the path to the STR (steer
and aux) contactor coil at JPC18-11. This is
Load Shuttle accomplished by turning on the coil driver
located in the VM. This causes the STR
The load shuttle is a two input, pressure contactor tips to close, making the steer motor
activated, two position valve. In the shuttle, the (MS) rotate which causes pump P3 to pump oil.
higher of the input pressures passes through
the valve at the pressure out port. While the Pump P3 is used for steering and auxiliary
output port gives no usable flow, it can be used functions. Because steering is not being
to operate pressure-activated devices such as requested, oil enters the steer valve at port P
other shuttles, piloted check valves or piloted and exits at port E. From there, it flows through
metering valves. In this application, the load the Power Beyond (Pwr Bynd) port to SOL5.
shuttle reacts to the pressure applied from Depending on the direction of the function
SOL5B or SOL5T to the auxiliary functions and requested, either SOL5B or SOL5T is energized
applies a pressure feedback to a pilot on the by the VM at JPC20-2 (SOL5B) or JPC20-17
logic element in the auxiliary manifold. (SOL5T). SOL5 is a proportional solenoid. The
VM will, however, send a fixed voltage to it,
Logic Element depending on the function requested. In order
to keep all of the oil being dumped from
The logic element is a metering valve that uses returning to the reservoir, SOL8 (Aux Dump) is
manifold pressure input from the supply side of energized by the VM at JPC20-12.
the hydraulic circuit (Pilot 1), pressure feedback
from load shuttles in the load side of the circuit With SOL8 (Aux Dump) closed, oil flows to the
(Pilot 3), and a calibrated spring to meter Compensator/Logic Element. The amount that
hydraulic fluid flow to the auxiliary functions. the Compensator/Logic Element opens depends
Fluid not needed for the selected function is on the pressure at port 1 of the Compensator/
returned back to the reservoir through port 2. Logic Element. With SOL5 energized, fluid flows
to the load shuttle (LS-1). The Load Shuttle
Theory of Auxiliary Functions sends its pilot pressure out of port 2 to the
Compensator/Logic Element at port 3. The
Compensator/Logic Element has an internal
Reach
calibrated spring. The pilot pressure at port 3
Reach extends the forks away from the mast aids the spring to regulate how much oil flows
assembly. The reach/retract function can be back to the reservoir in order to keep the
configured to have single speed reach/retract or function operating at the correct speed. Once
two speed reach/retract. Single speed reach the oil has passed the Load Shuttle (LS-1), it
moves at the speed of high-speed reach. exits the main manifold and flows to the reach
solenoid, which is energized by the VM at
In order to use two speed reach, depress S5
JPC18-12.
(retract) after depressing S4 (reach). Doing this
switches from low speed to high-speed reach.
Speed of the reach is dependent on how it is Low-Speed (of two-speed) Reach
configured. Refer to Figures 8-30 and 8-31. Low-speed reach is activated by depressing the
reach button (S4) only, when configured for
High-speed or single-speed reach two-speed reach.
When switch S4 (reach) is depressed, a circuit Low-speed reach is accomplished by opening
is completed between JPC12-4 and JPC12-12 at SOL5B or SOL5T, thus providing less oil flow to
the VM. the reach cylinders. Since SOL5 is a
On lift trucks with two speed reach, when proportional solenoid, a lower voltage to the
switch S5 (retract) is also depressed, a circuit is solenoid results in the lower speed.
8-92 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
1026304B, 15 July 2007 8-93
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR T VEL SENSOR+
BLACK
PANEL TME
-4 -5 -4
T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
T VEL PHASE B
2 JPT3
1 RED
TPC -2 -8 -16
STR T TEMP+
2 1 TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 FU2 MOTOR TEMPERATURE TA
-2 (350A) X TPC Y JPS1-8 -2 TPC
-3 TP5 CONTACTOR
-4 U
U
B-
1 V
TM V
TR STR W
FU1 W
(150A) Y X B+ +
TP2 FU3 2
(500A) Y X
LPC
2
LPC
1
SPL-2
JPS1-5 JPS1-6 JPS1-7 JPS1-10 -9 JPS1-11
A1 +
A2
A1 +
LM
MS
A2 -
S1 -
JP
B-
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
K3 TS1-2
JPF1-1 T˚
JPS10-3
FU8 (15A/5A)
-2
-5
1 2 JPF4-15
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/ TS2
RELAY -2
CARD JPF2-8 JPS3-1
TS2-1
1 2 -3
REACH
1 2 -4
SIDE
SHIFT
-5
B+
1 2
TILT
Buss+/-
4
5v -6
B-
Sense/Input
12v
8R828-011-224_D_C.EPS
Figure 8-30. Reach - Electrical (Series AA/BA/DA/EA)
8-94 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
VEHICLE
MANAGER
BW1 JPC22-15
JPT1 BRUSH_WEAR_1
ID2 -20
-21
IDGND
LM_A1 JPC12-1 JPH1-1
+5VP +5VP
BW2 -16
BRUSH_WEAR_2 +5VP
-3 -3
P_THROTTLE VR1
LM_A2 DGND
+5VP +5VP +
(ON LM) 0 S3
TA LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-23 -4 -4 0
REACH S4
BUS_I+
-15 -11 -11
BUS_I- RETRACT -
-8 DGND
DGND
-1 -5 -5
B+K3 TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
-8 -8 -
SSHIFT_LEFT S8
DGND
DISPLAY -9 -9
SSHIFT_RIGHT S9
-12
JPD3-1 B-1 -12
+12VP DGND DGND
SOUNDER
-2 B-2 -13
SOUNDER
HTR6
-7 -7
-2 H_HTR
BUS_I+ JPC14-5
-3 JPD1-5
BUS_I- +12VP
-4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
-7 -4 JPC20-8 -2
BUS_I- +12VP
JPC22-7 -3
-8 -3 HGG_FAULT
DGND JPC24-2 -4
HGG_CONTACTOR
JPC10-3 -5
THERM_EN 4
JPC24-13
+12VP JPAD-1
JPC18-11 JPC10-8
STR_CONTACTOR AUX DEADMAN -2
-9 JPC24-4
LIFT_CONTACTOR DGND -3
T˚ JPZ-1 JPC24-22
LIFT_MOT_TEMP
(ON LM) JPC24-23 JPA-1
-2 -10 ROOM_TEMP
DGND
-11 -2
DGND
JPC22-20
FU3_SENSE
-19 JPC18-18 SPL-6
FU1_SENSE ALARM 4 4
JPC14-10
DGND
-2
DGND
-1 JPC20-16
L/L SOL2
-8
1 2
-9 B-F -15
(B+K2)B+L/L
1st SPEED JPS4-1 JPC20-1
S12 +12VP AUX1 -18
LIMITING SWITCH
NC
JPS4-3 COM -17
NO -2 JPC22-1 (B+K2)B+AUX1 SOL5T
SPEED_LIMIT_1 1 2
JPC10-10
BUS_E+ -20
AUX2 SOL5B
-5
BUS_E- 1 2
HRN -19
(B+K2)B+AUX2
-NEG
-12
-IN H-1 JPC18-16 AUXDUMP SOL8
H HORN
1 2
-POS H-2 -13
(B+K2)B+AUXDUMP
JPBR-2 JPS2-2
PRESSURE
+12VP
JPC20-4
JPC24-18
JPY1-1
-2
+
0
PRESS
DC LIFT &
-1 -1 JPC20-14
HYDRAULIC
BRAKE BRAKE -6 -3 -
DGND
JPB1-1
FAN-T
+ -
JPB1-2 JPC18-17
FAN +12VP
JPC20-5 JPDP-1
STEERING
DEADMAN
VR4
SENSOR
JPC24-19 -3
FAN-FW DEADMAN
JPB2-1 JPB2-2
+ - -7 -2
DGND
FAN-LM JPC20-2 JPS12-1
JPB5-2
DEADMAN
JPB5-1 +12VP
+ - JPC22-8 -2
SWITCH
ON_DEADMAN
NC
FAN-FW2 S2
JPB4-1 JPB4-2 JPDS-COM
+ - -1 DGND JPC18-7 -3 JPDS-NO
SOL4 2nd_STAGE
2 1
FAN-DU
JPB3-1 JPB3-2
+ - -10
SOL1 L/H
2 1
JPC14-6
RELAY_ENABLE
JPC22-21
EPO_SENSE
JPC14-12
B+KEY
-7 B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
JPS3-2
-3 JPC18-12 TXD JPC9-2
REACH_SOL
FLASHWEAR
RXD -3
-4 -14
SIDESHIFT_SOL DGND -5
-5 -15
TILT_SOL
COMMUNICATIONS
VBUS JPC2-1
D+ -2
USB
-6 D- -3
JPC22-18
NESTED_SWITCH -4
DGND
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-95
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
PP
G1
M
LOAD HOLD
SOL-1
CV-1 CYL-1
1 2
P1
1
CYL-P
1
REL-1
MAIN RELIEF
2
CFS
SOL-2
2
LIFT/LOWER
HTI
FILTER
M SOL-5B
LS-1
PWR
A1
BYND 3 2 1
P3 2
1 4
3 A2
S-RET
P E T
2 SOL-5T
L R 1
3
1
SOL-8
CASE AUX DUMP 2 CE-1
DRAIN
G2
HYD STEER MOTOR TANK
DOSCKTANCE SHOWN.
HOSES ARE REVERSE
OF FORE/AFT. PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-31. Reach - Hydraulic (Series AA/BA/DA/EA)
8-96 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
MAIN LIFT
FREE LIFT
CB-1
CV-3
2 PSI REL-3
2 1 2 1800 PSI RC
T B
REACH
A1 3 4 3
1 2 3
A2
2 1 1
RR
REACH
CB-2
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
A2
3 4 TC TILT
1 2
TR
TILT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-97
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
Sideshift
Sideshift allows the operator to move the fork
carriage to the left or right relative to the mast.
The amount of sideshift is 2 or 4 inches (5 or
10 cm) depending on the baseleg opening.
In the following discussion, the fork carriage is
sideshifted to the right. Refer to Figures 8-32
and 8-33.
When switch S9 (sideshift right) is depressed, a
circuit is completed between JPC12-9 and
JPC12-12 at the VM. The VM completes the
path to the STR (steer and aux) contactor coil at
JPC18-11. This is accomplished by turning on
the coil driver located in the VM. This causes
the STR contactor tips to close, making the
steer motor (MS) rotate, which causes pump P3
to pump oil.
Pump P3 is used for steering and auxiliary
functions. Because steering is not being
requested, oil enters the steer valve at port P
and exits at port E. From there, it flows through
the Power Beyond (Pwr Bynd) port to SOL5.
Depending on the direction of the function
requested, either SOL5B or SOL5T is energized
by the VM at JPC20-2 (SOL5B) or JPC20-17
(SOL5T). SOL5 is a proportional solenoid. The
VM will, however, send a fixed voltage to it,
depending on the function requested. In order
to keep all of the oil being dumped from
returning to the reservoir, SOL8 (Aux Dump) is
energized by the VM at JPC20-12.
With SOL8 (Aux Dump) closed, oil flows to the
Compensator/Logic Element. The amount that
the Compensator/Logic Element opens depends
on the pressure at port 1 of the Compensator/
Logic Element. With SOL5 energized, fluid flows
to the load shuttle (LS-1). The Load Shuttle
sends its pilot pressure out of port 2 to the
Compensator/Logic Element at port 3. The
Compensator/Logic Element has an internal
calibrated spring. The pilot pressure at port 3
aids the spring to regulate how much oil flows
back to the reservoir. Once the oil has passed
the Load Shuttle (LS-1), it exits the main
manifold and flows to the sideshift solenoid,
which is energized by the VM at JPC18-14.
8-98 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
1026304B, 15 July 2007 8-99
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR T VEL SENSOR+
BLACK
PANEL TME
-4 -5 -4
T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
T VEL PHASE B
2 JPT3
1 RED
TPC -2 -8 -16
STR T TEMP+
2 1 TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 FU2 MOTOR TEMPERATURE TA
-2 (350A) X TPC Y JPS1-8 -2 TPC
-3 TP5 CONTACTOR
-4 U
U
B-
1 V
TM V
TR STR W
FU1 W
(150A) Y X B+ +
TP2 FU3 2
(500A) Y X
LPC
2
LPC
1
SPL-2
JPS1-5 JPS1-6 JPS1-7 JPS1-10 -9 JPS1-11
A1 +
A2
A1 +
LM
MS
A2 -
S1 -
JP
B-
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
K3 TS1-2
JPF1-1 T˚
JPS10-3
FU8 (15A/5A)
-2
-5
1 2 JPF4-15
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/ TS2
RELAY -2
CARD JPF2-8 JPS3-1
TS2-1
1 2 -3
REACH
1 2 -4
SIDE
SHIFT
B+ 1
TILT
2 -5
Buss+/-
4
5v -6
B-
Sense/Input
12v
8R828-011-224_D_C.EPS
Figure 8-32. Sideshift - Electrical (Series AA/BA/DA/EA)
8-100 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
VEHICLE
MANAGER
BW1 JPC22-15
JPT1 BRUSH_WEAR_1
ID2 -20
-21
IDGND
LM_A1 JPC12-1 JPH1-1
+5VP +5VP
BW2 -16
BRUSH_WEAR_2 +5VP
-3 -3
P_THROTTLE VR1
LM_A2 DGND
+5VP +5VP +
(ON LM) 0 S3
TA LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-23 -4 -4 0
REACH S4
BUS_I+
-15 -11 -11
BUS_I- RETRACT -
-8 DGND
DGND
-1 -5 -5
B+K3 TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
-8 -8 -
SSHIFT_LEFT S8
DGND
DISPLAY -9 -9
SSHIFT_RIGHT S9
-12
JPD3-1 B-1 -12
+12VP DGND DGND
SOUNDER
-2 B-2 -13
SOUNDER
HTR6
-7 -7
-2 H_HTR
BUS_I+ JPC14-5
-3 JPD1-5
BUS_I- +12VP
-4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
-7 -4 JPC20-8 -2
BUS_I- +12VP
JPC22-7 -3
-8 -3 HGG_FAULT
DGND JPC24-2 -4
HGG_CONTACTOR
JPC10-3 -5
THERM_EN 4
JPC24-13
+12VP JPAD-1
JPC18-11 JPC10-8
STR_CONTACTOR AUX DEADMAN -2
-9 JPC24-4
LIFT_CONTACTOR DGND -3
T˚ JPZ-1 JPC24-22
LIFT_MOT_TEMP
(ON LM) JPC24-23 JPA-1
-2 -10 ROOM_TEMP
DGND
-11 -2
DGND
JPC22-20
FU3_SENSE
-19 JPC18-18 SPL-6
FU1_SENSE ALARM 4 4
JPC14-10
DGND
-2
DGND
-1 JPC20-16
L/L SOL2
-8
1 2
-9 B-F -15
(B+K2)B+L/L
1st SPEED JPS4-1 JPC20-1
S12 +12VP AUX1 -18
LIMITING SWITCH
NC
JPS4-3 COM -17
NO -2 JPC22-1 (B+K2)B+AUX1 SOL5T
SPEED_LIMIT_1 1 2
JPC10-10
BUS_E+ -20
AUX2 SOL5B
-5
BUS_E- 1 2
HRN -19
(B+K2)B+AUX2
-NEG
-12
-IN H-1 JPC18-16 AUXDUMP SOL8
H HORN
1 2
-POS H-2 -13
(B+K2)B+AUXDUMP
JPBR-2 JPS2-2
PRESSURE
+12VP
JPC20-4
JPC24-18
JPY1-1
-2
+
0
PRESS
DC LIFT &
-1 -1 JPC20-14
HYDRAULIC
BRAKE BRAKE -6 -3 -
DGND
JPB1-1
FAN-T
+ -
JPB1-2 JPC18-17
FAN +12VP
JPC20-5 JPDP-1
STEERING
DEADMAN
VR4
SENSOR
JPC24-19 -3
FAN-FW DEADMAN
JPB2-1 JPB2-2
+ - -7 -2
DGND
FAN-LM JPC20-2 JPS12-1
JPB5-2
DEADMAN
JPB5-1 +12VP
+ - JPC22-8 -2
SWITCH
ON_DEADMAN
NC
FAN-FW2 S2
JPB4-1 JPB4-2 JPDS-COM
+ - -1 DGND JPC18-7 -3 JPDS-NO
SOL4 2nd_STAGE
2 1
FAN-DU
JPB3-1 JPB3-2
+ - -10
SOL1 L/H
2 1
JPC14-6
RELAY_ENABLE
JPC22-21
EPO_SENSE
JPC14-12
B+KEY
-7 B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
JPS3-2
-3 JPC18-12 TXD JPC9-2
REACH_SOL
FLASHWEAR
RXD -3
-4 -14
SIDESHIFT_SOL DGND -5
-5 -15
TILT_SOL
COMMUNICATIONS
VBUS JPC2-1
D+ -2
USB
-6 D- -3
JPC22-18
NESTED_SWITCH -4
DGND
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-101
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
PP
G1
M
LOAD HOLD
SOL-1
CV-1 CYL-1
1 2
P1
1
CYL-P
1
REL-1
MAIN RELIEF
2
CFS
SOL-2
2
LIFT/LOWER
HTI
FILTER
M SOL-5B
LS-1
PWR
A1
BYND 3 2 1
P3 2
1 4
3 A2
S-RET
P E T
2 SOL-5T
L R 1
3
1
SOL-8
CASE AUX DUMP 2 CE-1
DRAIN
G2
HYD STEER MOTOR TANK
DOSCKTANCE SHOWN.
HOSES ARE REVERSE
OF FORE/AFT. PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-33. Sideshift - Hydraulic (Series AA/BA/DA/EA)
8-102 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
MAIN LIFT
FREE LIFT
CB-1
CV-3
2 PSI REL-3
2 1 2 1800 PSI RC
T B
REACH
A1 3 4 3
1 2 3
A2
2 1 1
RR
REACH
CB-2
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
A2
3 4 TC TILT
1 2
TR
TILT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-103
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
Tilt
Fork tilt allows the operator to raise or lower the
tips of the forks. Standard fork tilt is 5° up and
2° down.
In the following discussion, the forks are tilted
up. Refer to Figures 8-34 and 8-35.
When switch S6 (tilt up) is depressed, a circuit
is completed between JPC12-5 and JPC12-12 at
the VM. The VM completes the path to the STR
(steer and aux) contactor coil at JPC18-11. This
is accomplished by turning on the coil driver
located in the VM. This causes the STR
contactor tips to close, making the steer motor
(MS) rotate which causes pump P3 to pump oil.
Pump P3 is used for steering and auxiliary
functions. Because steering is not being
requested, oil enters the steer valve at port P
and exits at port E. From there, it flows through
the Power Beyond (Pwr Bynd) port to SOL5.
Depending on the direction of the function
requested, either SOL5B or SOL5T is energized
by the VM at JPC20-2 (SOL5B) or JPC20-17
(SOL5T). SOL5 is a proportional solenoid. The
VM will, however, send a fixed voltage to it,
depending on the function requested. In order
to keep all of the oil being dumped from
returning to the reservoir, SOL8 (Aux Dump) is
energized by the VM at JPC20-12.
With SOL8 (Aux Dump) closed, oil flows to the
Compensator/Logic Element. The amount that
the Compensator/Logic Element opens depends
on the pressure at port 1 of the Compensator/
Logic Element. With SOL5 energized, fluid flows
to the load shuttle (LS-1). The Load Shuttle
sends its pilot pressure out of port 2 to the
Compensator/Logic Element at port 3. The
Compensator/Logic Element has an internal
calibrated spring. The pilot pressure at port 3
aids the spring to regulate how much oil flows
back to the reservoir. Once the oil has passed
the Load Shuttle (LS-1), it exits the main
manifold and flows to the tilt solenoid, which is
energized by the VM at JPC18-13.
8-104 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
1026304B, 15 July 2007 8-105
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
MOTOR VELOCITY JPT2 JPS2 JPT1
RED -1 -6 -3
CONTACTOR T VEL SENSOR+
BLACK
PANEL TME
-4 -5 -4
T VEL SENSOR-
TP1 WHITE -3 -4 -5
T VEL PHASE A
BLUE -2 -3 -6
T VEL PHASE B
2 JPT3
1 RED
TPC -2 -8 -16
STR T TEMP+
2 1 TMT RED/BLK -1 -7 -17
T TEMP-
JP
B+
JPS1-1 FU2 MOTOR TEMPERATURE TA
-2 (350A) X TPC Y JPS1-8 -2 TPC
-3 TP5 CONTACTOR
-4 U
U
B-
1 V
TM V
TR STR W
FU1 W
(150A) Y X B+ +
TP2 FU3 2
(500A) Y X
LPC
2
LPC
1
SPL-2
JPS1-5 JPS1-6 JPS1-7 JPS1-10 -9 JPS1-11
A1 +
A2
A1 +
LM
MS
A2 -
S1 -
JP
B-
TP4
JPF1-3
JPF2-1
JPF1-6
JPF3-3
4
-5
-4
-5
-6
-7
-8
JPS7
-2
JPF3-1 -3
T˚ T˚
FU6 (15A)
-2 -4
JPF1-4
1 2
K3 TS1-2
JPF1-1 T˚
JPS10-3
FU8 (15A/5A)
-2
-5
1 2 JPF4-15
TS1-1
JPF4-3 FU7 (15A/5A) K1
JPF2-9 -1
-4 1 2
TS1-1
SPL-1
JPS10-4
-2
-3
-5
JPF4-13
-6
K4 K3 K2 K1
-5
2 1
-12 EPO
-11
-8
FU5 (15A) S1 KEYSWITCH
-1 -10 1 2
1 2
K2 K4
-2 JPF2-4
-6
-7
T˚ JPF4-7
FUSE/ TS2
RELAY -2
CARD JPF2-8 JPS3-1
TS2-1
1 2 -3
REACH
1 2 -4
SIDE
SHIFT
B+ 1
TILT
2 -5
Buss+/-
4
5v -6
B-
Sense/Input
12v
8R828-011-224_D_C.EPS
Figure 8-34. Tilt - Electrical (Series AA/BA/DA/EA)
8-106 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
VEHICLE
MANAGER
BW1 JPC22-15
JPT1 BRUSH_WEAR_1
ID2 -20
-21
IDGND
LM_A1 JPC12-1 JPH1-1
+5VP +5VP
BW2 -16
BRUSH_WEAR_2 +5VP
-3 -3
P_THROTTLE VR1
LM_A2 DGND
+5VP +5VP +
(ON LM) 0 S3
TA LIFT
-2 -2
VR2
-
PRIMARY CONTROL HANDLE
DGND DGND
-10 -10
P_HORN +5VP +
-23 -4 -4 0
REACH S4
BUS_I+
-15 -11 -11
BUS_I- RETRACT -
-8 DGND
DGND
-1 -5 -5
B+K3 TILT_UP S6 +5VP +
-6 -6 0 S5
TILT_DOWN S7
-8 -8 -
SSHIFT_LEFT S8
DGND
DISPLAY -9 -9
SSHIFT_RIGHT S9
-12
JPD3-1 B-1 -12
+12VP DGND DGND
SOUNDER
-2 B-2 -13
SOUNDER
HTR6
-7 -7
-2 H_HTR
BUS_I+ JPC14-5
-3 JPD1-5
BUS_I- +12VP
-4 -6 -11 JPC24-12 JPG1-1
DGND BUS_I+ HGG_CNTRL_PWM
-7 -4 JPC20-8 -2
BUS_I- +12VP
JPC22-7 -3
-8 -3 HGG_FAULT
DGND JPC24-2 -4
HGG_CONTACTOR
JPC10-3 -5
THERM_EN 4
JPC24-13
+12VP JPAD-1
JPC18-11 JPC10-8
STR_CONTACTOR AUX DEADMAN -2
-9 JPC24-4
LIFT_CONTACTOR DGND -3
T˚ JPZ-1 JPC24-22
LIFT_MOT_TEMP
(ON LM) JPC24-23 JPA-1
-2 -10 ROOM_TEMP
DGND
-11 -2
DGND
JPC22-20
FU3_SENSE
-19 JPC18-18 SPL-6
FU1_SENSE ALARM 4 4
JPC14-10
DGND
-2
DGND
-1 JPC20-16
L/L SOL2
-8
1 2
-9 B-F -15
(B+K2)B+L/L
1st SPEED JPS4-1 JPC20-1
S12 +12VP AUX1 -18
LIMITING SWITCH
NC
JPS4-3 COM -17
NO -2 JPC22-1 (B+K2)B+AUX1 SOL5T
SPEED_LIMIT_1 1 2
JPC10-10
BUS_E+ -20
AUX2 SOL5B
-5
BUS_E- 1 2
HRN -19
(B+K2)B+AUX2
-NEG
-12
-IN H-1 JPC18-16 AUXDUMP SOL8
H HORN
1 2
-POS H-2 -13
(B+K2)B+AUXDUMP
JPBR-2 JPS2-2
PRESSURE
+12VP
JPC20-4
JPC24-18
JPY1-1
-2
+
0
PRESS
DC LIFT &
-1 -1 JPC20-14
HYDRAULIC
BRAKE BRAKE -6 -3 -
DGND
JPB1-1
FAN-T
+ -
JPB1-2 JPC18-17
FAN +12VP
JPC20-5 JPDP-1
STEERING
DEADMAN
VR4
SENSOR
JPC24-19 -3
FAN-FW DEADMAN
JPB2-1 JPB2-2
+ - -7 -2
DGND
FAN-LM JPC20-2 JPS12-1
JPB5-2
DEADMAN
JPB5-1 +12VP
+ - JPC22-8 -2
SWITCH
ON_DEADMAN
NC
FAN-FW2 S2
JPB4-1 JPB4-2 JPDS-COM
+ - -1 DGND JPC18-7 -3 JPDS-NO
SOL4 2nd_STAGE
2 1
FAN-DU
JPB3-1 JPB3-2
+ - -10
SOL1 L/H
2 1
JPC14-6
RELAY_ENABLE
JPC22-21
EPO_SENSE
JPC14-12
B+KEY
-7 B+K4
-13
B+K2
-14
B+K2
JPC24-24
BATTERY_SENSE_IN
JPS3-2
-3 JPC18-12 TXD JPC9-2
REACH_SOL
FLASHWEAR
RXD -3
-4 -14
SIDESHIFT_SOL DGND -5
-5 -15
TILT_SOL
COMMUNICATIONS
VBUS JPC2-1
D+ -2
USB
-6 D- -3
JPC22-18
NESTED_SWITCH -4
DGND
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-107
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Hydraulic System Functional Operation (DC Lift Motor)
PP
G1
M
LOAD HOLD
SOL-1
CV-1 CYL-1
1 2
P1
1
CYL-P
1
REL-1
MAIN RELIEF
2
CFS
SOL-2
2
LIFT/LOWER
HTI
FILTER
M SOL-5B
LS-1
PWR
A1
BYND 3 2 1
P3 2
1 4
3 A2
S-RET
P E T
2 SOL-5T
L R 1
3
1
SOL-8
CASE AUX DUMP 2 CE-1
DRAIN
G2
HYD STEER MOTOR TANK
DOSCKTANCE SHOWN.
HOSES ARE REVERSE
OF FORE/AFT. PRESSURE LINES
RETURN AND PILOT LINES
COMPONENT BOUNDARIES
Legend:
Pressure Line
Return Line
Sense or Pilot
8R828-011-224_D_C.EPS
Figure 8-35. Tilt - Hydraulic (Series AA/BA/DA/EA)
8-108 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Hydraulic System Functional Operation (DC Lift Motor)
MAIN LIFT
FREE LIFT
CB-1
CV-3
2 PSI REL-3
2 1 2 1800 PSI RC
T B
REACH
A1 3 4 3
1 2 3
A2
2 1 1
RR
REACH
CB-2
SIDE SHIFT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1
A2
3 4 TC TILT
1 2
TR
TILT
8R828-011-224_D_C.EPS
1026304B, 15 July 2007 8-109
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Electric Brake Operation
Electric Brake Operation Brake Application
If the lift truck is traveling when the deadman
pedal is released, the Vehicle Manager causes
Overview the lift truck to plug to a stop. When the Vehicle
The Model 7400/7420/7440 lift truck uses an Manager senses the lift truck has stopped, it
electric brake. With the brake coil de-energized, de-energizes the brake coil. The magnetic field
the brake is in a “normally applied” state due to holding the brake released now collapses. The
spring pressure. With the brake coil energized, springs in the brake coil push the armature
the brake is held in a released state due to plate and pads down on the top of the rotor.
magnetic force. Upward pressure of the springs against the coil
body causes the base plate and pads to be
The brake assembly of coil, armature plate,
pulled up against the bottom of the rotor. The
base plate, and pads slides up and down on
brake pads prevent the rotor, and the drive
three shoulder bolts threaded into the end bell
motor shaft to which it is attached, from
of the drive motor. The armature plate and base
rotating. See Figure 8-37.
plate are spaced apart by three hollow total air
gap adjusters (spacers). The total gap is
adjusted by the amount the adjuster is Brake Release Screws
threaded into the coil body. Once this gap is set,
Two brake release screws are stored in the
it is held in place by three locking bolts that
brake coil body as shown in the upper photo in
thread through the coil and the total air gap
Figure 8-38. These screws are not used when
adjusters.
removing the entire brake assembly from the
When the brake is electrically released, the drive motor, but are used when disassembling
assembly slides down the shoulder bolts and the brake itself. The lower photo in Figure 8-38
rests on the lower air gap adjusters. The lower shows the brake release bolts threaded through
air gap adjusters are threaded pedestals that the coil. The screws press on the base plate,
are set so as to divide the total air gap evenly overcoming the spring pressure and separating
between the rotor and the top and bottom brake the base plate and coil body. You can now
pads. remove the three locking bolts, total air gap
adjusters, and rotor.
Brake Release
When the deadman pedal is depressed, the
brake coil is energized. The current flow creates
a magnetic field which draws the armature
plate against the coil body, compressing the
brake coil springs. The brake assembly of coil
body, armature plate, base plate, and pads
lowers by the amount of the lower air gap. Half
of the total air gap (minus a 0.007 in. shim) is
between the rotor and the pads on the base
plate; the remainder the total air gap is between
the rotor and the pads on the armature plate.
The rotor, attached to the drive motor shaft, is
free to rotate. See Figure 8-36.
8-110 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Electric Brake Operation
Locking Bolt
Coil
Body Brake Armature 0.007 in.
Pad Plate Shim
Shoulder 0.007 in.
Bolt Gap
Rotor
0.011 in.
Adjuster
+ Gap
Lock Nut
0.012 in.
+ Gap
0.030 in.
Total
Base Brake Air Gap
Lower Air Plate Pad
Gap
Adjuster
Encoder
Bearing
8BrakeDisengaged-7400-Gold.jpg
Figure 8-36. 7400 Electric Brake Disengaged (Coil Energized)
Coil Locking
Body Brake Armature 0.007 in. Bolt
Pad Plate Shim
Shoulder Total
Bolt Air Gap
Rotor 0.030
Adjuster in.
Lock Nut
Total
Lower Air Gap
Air Gap Adjuster
0.012 in.
Base Brake
Plate Pad
Lower
Air Gap Encoder
Adjuster Bearing
8BrakeEngaged-7400-Gold.jpg
Figure 8-37. 7400 Electric Brake Engaged (Coil De-energized
1026304B, 15 July 2007 8-111
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Electric Brake Operation
Brake Release
Screws (Stored)
Brake Release
Screws (Installed)
8
Figure 8-38. Brake Release Screws
8-112 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Pinout Matrix
Pinout Matrix variable, it indicates the state of a
related component that will cause the
signal to vary.
The pinout matrix chart lists functions and
normal voltages of terminals and harness b. Identifies possible causes for lack of
connector pins. The matrix columns have the proper signal.
following meanings: 5. Normal Level: the approximate voltage that
1. Item #: sequential number to aid in you should see on that wire for the state
reference. indicated. Unless otherwise indicated,
voltages are measured with respect to (wrt)
2. Connection: the actual wire numbers or
B– at TP4.
component abbreviations on the electrical
schematic. 6. Signal Source: the device or connection
that supplies the signal directly to the
3. Function Description: brief definition of
wire.
the signal carried on the wire.
7. Signal User: the device or connection to
4. Theory of Operation:
which the wire directly delivers the signal.
a. A detailed description of the signal
carried on the wire. If the signal can be
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
1. JPC10-3 THERM_EN Voltage from the VM to the Glass Guard ON: VM Glass
Control Card to control the heaters in the < 0.5VDC Guard
primary and secondary control handles and OFF: Control
the heated floor pad. > 10.5 VDC Card
2. JPC10-4 DGND Reference for the bump detector < 0.5VDC VM
3. JPC10-5 Bus E– The wire that carries the negative 2.53VDC VM Warehouse
component of the digital communications Manage-
between the VM and the optional ment
Warehouse Management Module. If this Module
connection is missing, the VM cannot
communicate. Troubleshoot using resistance
checks. No useful information can be
gained by measuring the voltage on this
wire.
4. JPC10-6 +12VEN1 This voltage is used as a connect detect to Encoder VM Steer Tiller
Series verify the steer tiller encoder is connected to connected: Encoder
CA/FA (AC the VM. 9.0VDC
lift) Disconnected
+10.7 to
13VDC
5. JPC10-7 +12VEN2 This voltage is used as a connect detect to Encoder VM Steer Tiller
Series verify the steer tiller encoder is connected to connected: Encoder
CA/FA (AC the VM. 9.0VDC
lift) Disconnected
+10.7 to
13VDC
6. JPC10-9 DGND Reference for the steer motor encoder < 0.5VDC VM Steer
Series Motor
CA/FA (AC Encoder
lift)
1026304B, 15 July 2007 8-113
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
7. JPC10-10 Bus E+ The wire that carries the positive component 2.53VDC VM Warehouse
of the digital communications between the Manage-
VM and the optional Warehouse ment
Management Module (WMM). If this Module
connection is missing, the WMM cannot
communicate. Troubleshoot using resistance
checks. No useful information can be
gained by measuring the voltage on this
wire.
8. JPC12-1 +5VP +5VDC supply to the solid state 4.9VDC VM Primary
potentiometers and switches in the primary control
control handle. If this is less than 4.75 to handle
5.25V, the handle will not function
correctly. Measure wrt DGND JPC12-12.
9. JPC12-2 Lift Input to the VM from the “wiper” of the Neutral: VR2 VM
primary lift control. Measure wrt DGND 1.0V
JPC12-12. Full Forward:
1.84VDC;
Full Reverse:
0.30VDC
10. JPC12-3 P Throttle Input to the VM from the “wiper” of the Neutral: VR1 VM
primary throttle control. Measure wrt 1.2VDC;
DGND JPC12-12. Full Forward:
1.9VDC;
Full Reverse:
0.45VDC
11. JPC12-4 Reach Input to the VM from the reach switch S4. S4 open: S4 VM
Note: When other aux function switches are > 4.0VDC
activated, reading can change by as much S4 closed:
as 0.5V. < 0.5VDC
12. JPC12-5 Tilt Up Input to the VM from the tilt up button S6. S6 open: S6 VM
Note: When other aux function switches are > 4.0VDC
activated, reading can change by as much S6 closed:
as 0.5V < 0.5VDC
13. JPC12-6 Tilt Down Input to the VM from the tilt down button S7. S7 open: S7 VM
Note: When other aux function switches are > 4.0VDC
activated, reading can change by as much S7 closed:
as 0.5V < 0.5VDC
14. JPC12-7 H HTR DC supply to handle heater HTR6. OFF: VM Primary
< 0.5VDC control
ON: 7.5 to handle
8.5VDC
15. JPC12-8 SShift Left Input to the VM from the sideshift left button S8 open: S8 VM
S8. Note: When other aux function > 4.0VDC
switches are activated, reading can change S8 closed:
by as much as 0.5V < 0.5VDC
8-114 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
16. JPC12-9 SShift Right Input to the VM from the sideshift right S9 open: S9 VM
button S9. Note: When other aux function > 4.0VDC
switches are activated, reading can change S9 closed:
by as much as 0.5V < 0.5VDC
17. JPC12-10 P Horn Input to the VM from the primary (primary S9 open: S3 VM
control handle) horn switch S3. Note: > 4.0VDC
When other aux function switches are S3 closed:
activated, reading can change by as much < 0.5VDC
as 0.5V
18. JPC12-11 Retract Input to the VM from the retract switch S5. S5 open: S5 VM
Note: When other aux function switches are > 4.0VDC
activated, reading can change by as much S5 closed:
as 0.5V < 0.5VDC
19. JPC12-12 DGND Reference for all switches and < 0.5VDC VM Primary
potentiometers in the primary control control
handle. If this voltage is not < 0.5VDC wrt handle
TP4 on the power panel, then intermittent
handle codes may appear.
20. JPC14-1 B–F This connects B–F on the VM to TP4 (B–) < 0.5VDC Relay/ VM
through FU6 on the Relay/ Control Fuse Control Fuse
Panel. These B– provide the return for Panel
everything not using DGND or AGND as
reference.
21. JPC14-2 DGND This connects DGND and AGND on the VM < 0.5VDC Relay/ VM
to TP4(B–) through FU6 on the Relay/ Control Fuse
Control Fuse Panel. This is the reference for Panel
all circuits on the truck that are referenced
to either DGND or AGND.
22. JPC14-3 DGND Reference for the control circuits in the TPC, < 0.5VDC VM TPC/LPC/
LPC, and Operator Display Display
23. JPC14-4 BUS E– The wire that carries the negative 2.24VDC VM TPA, LPA, &
BUS I– component of the digital communications Operator
between the VM and the TPA, LPA (AC Lift), Display
& the Operator Display. If this connection is
missing, then neither the LPA nor the OD
can communicate with the VM.
Troubleshoot using resistance checks in
Test I23.No useful information can be
gained by measuring the voltage on this
wire.
24. JPC14-5 +12VP Operating voltage from the VM to the +10.5 to VM Operator
Operator Display 13VDC Display
25. JPC14-6 Relay Enable Control path for K1, K2, K3, & K4 on the Relays OFF: VM K1, K2,
Relay/ Control Fuse Panel. After S1 is B+ K3, & K4
closed, all relays are energized Relays ON:
simultaneously during Selftest if the voltage < 3.0VDC
at Battery Sense In is at an acceptable level.
1026304B, 15 July 2007 8-115
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
26. JPC14-7 B+K4 B+ provided to the VM when K4 tips are K4 tips K4 tips Brake
closed. This voltage is used to power the closed: B+ circuits
electric brake circuits, which must remain K4 tips open:
energized when the EPO is opened. 0.2V
27. JPC14-8 B–F This connects DGND and AGND on the VM < 0.5VDC Relay/ VM
to TP4(B–) through FU6 on the Relay/ Control Fuse
Control Fuse Panel. This is the reference for Panel
all circuits on the truck that are referenced
to either DGND or AGND.
28. JPC14-9 B–F This connects DGND and AGND on the VM < 0.5VDC Relay/ VM
to TP4(B–) through FU6 on the Relay/ Control Fuse
Control Fuse Panel. This is the reference for Panel
all circuits on the truck that are referenced
to either DGND or AGND.
29. JPC14-10 DGND This connects DGND and AGND on the VM < 0.5VDC Relay/ VM
to TP4(B–) through FU6 on the Relay/ Control Fuse
Control Fuse Panel. This is the reference for Panel
all circuits on the truck that are referenced
to either DGND or AGND.
30. JPC14-11 BUS I+ The wire that carries the positive component 2.8VDC VM TPA, LPA, &
of the digital communications between the Operator
VM and the TPA, LPA (AC Lift), and the Display
Operator Display. If this connection is
missing, then the VM cannot communicate.
Troubleshoot using resistance checks in
Test I23. No useful information can be
gained by measuring the voltage on this
wire.
31. JPC14-12 B+Key B+ that is switched by S1 key switch and S1 closed: S1 VM
used to power functions on the VM that are B+
initiated after S1 is closed, and are not S1 open:
affected by the EPO. This includes the VM 0.3VDC
power supplies and the operation of the
microprocessor and execution of the
firmware.
32. JPC14-13 B+K2 B+ provided to the VM when K2 tips are K2 tips K2 tips Hydraulic
closed. This voltage is used to power the closed: B+ solenoids
hydraulic solenoids on the tractor and on K2 tips open:
the carriage. They will be de-energized 0.3VDC
when the EPO is open.
33. JPC14-14 B+K2 B+ provided to the VM when K2 tips are K2 tips K2 tips Hydraulic
closed. This voltage is used to power the closed: B+ solenoids
hydraulic solenoids on the tractor and on K2 tips open:
the carriage. They will be de-energized 0.3VDC
when the EPO is open.
8-116 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
34. JPC18-1 2nd Stage This is the control path for the 2nd pump De-energized K2 tips VM
Series solenoid. This solenoid diverts the oil to the B+
AA/BA/DA/ lift cylinder when it is energized and to the Energized: ?
EA (DC lift) tank when de-energized. Its operation is
controlled by the VM based on lift request,
weight on the forks, and lift motor
temperature.
35. JPC18-5 DGND Reference for channel 1 of the Steer Tiller < 0.5VDC VM Steer
Series Encoder at JPC14-10 and JPC14-2. B– Encoder
CA/FA (AC
lift)
36. JPC18-6 DGND Reference for channel 2 of the Steer Tiller < 0.5VDC VM Steer
Series Encoder at JPC14-10 and JPC14-2. B– Encoder
CA/FA (AC
lift)
37. JPC18-7 DGND Reference for the deadman switch S2 < 0.5VDC VM S2
38. JPC18-9 Lift Contactor Control path for the lift contactor (LPC). The De-energized K2 tips VM
Series voltage is controlled by a coil driver inside B+
AA/BA/DA/ the VM. Energized:
EA (DC lift) 12.3VDC
39. JPC18-10 L/H Control path for the load holding solenoid De-energized VM L/H SOL1
SOL1 that is switched to B– by the VM to (K2 tips
energize the L/H solenoid coil (lowering). closed): B+
Energized:
13.3VDC
40. JPC18-11 STR Control path for the steer contactor that is De-energized VM STR
Contactor switched to B– by the VM to energize the (K2 tips Contactor
coil closed): B+
Energized:
13.4VDC
41. JPC18-12 Reach Control path for Reach solenoid coil De-energized VM Reach
(K2 tips Solenoid
closed): B+
Energized:
13.2VDC
42. JPC18-14 Sideshift Control path for sideshift solenoid coil De-energized VM Sideshift
(K2 tips Solenoid
closed): B+
Energized:
13.1VDC
43. JPC18-15 Tilt Control path for Tilt solenoid coil De-energized VM Tilt
(K2 tips Solenoid
closed): B+
Energized:
13.1VDC
1026304B, 15 July 2007 8-117
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
44. JPC18-16 Horn Control path for the horn coil that is De-energized VM Horn
switched to B– by the VM to energize the (K2 tips
coil closed): B+
Energized:
0.02 VDC
45. JPC18-17 Fan Control path for the amplifier and motor De-energized VM Fans
compartment fans which are controlled (K2 tips
together by the VM closed): B+
Energized:
0.09VDC
46. JPC20-1 +12VP +12VDC supply for unspecified function +10.7 to VM n/a
13VDC
47. JPC20-2 +12VP +12VDC supply for unspecified function +10.7 to VM n/a
13VDC
48. JPC20-3 +12VP +12VDC supply for unspecified function +10.7 to VM n/a
13VDC
49. JPC20-4 +12VP +12VDC supply for the pressure transducer +10.7 to VM Pressure
CYL-P 13VDC Transducer
50. JPC20-5 +12VP +12VDC supply to the deadman sensor +10.7 to VM VR4
potentiometer VR4 13VDC
51. JPC20-6 +12VP +12VDC supply for unspecified function +10.7 to VM n/a
13VDC
52. JPC20-7 +12VP +12VDC supply for the steer motor encoder +10.7 to VM Steer Encdr
13VDC
53. JPC20-8 +12VP +12VDC supply for heated glass mast +10.7 to VM Glass
guard, ThermaKit handle, and heated floor 13VDC Guard
mat. ThermaKit
Control
Card
54. JPC20-9 +12VP +12VDC supply to the steer limit switch S11 +10.7 to VM S11
13VDC
55. JPC20-12 Main Relief Control path for SOL3, a combination De-energized VM SOL3
Series Dump proportional relief & dump valve. This is B+
CA/FA (AC used both as a variable system relief and to When lift
lift) dump oil back to the reservoir when lift is request
no longer requested and the lift stops:
motor/pump is slowing down. This permits 12VDC for 1
immediate lower without waiting for the to 2 seconds.
pump to stop turning. Aux functions
energized:
24VDC
56. JPC20-12 Aux. Dump This is the control path for the aux dump De-energized VM SOL8
Series solenoid SOL8. This solenoid diverts the B+
AA/BA/DA/ steering/auxiliary hydraulic fluid to the Energized:
EA (DC lift) reservoir when de-energized (no aux 3.7VDC
function requested) and to the aux functions
when energized.
8-118 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
57. JPC20-13 B+Dump B+ from the K2 tips to SOL3 B+ VM SOL3
Series
CA/FA (AC
lift)
58. JPC20-13 B+AuxDump B+ from the K2 tips to SOL8 B+ VM SOL8
Series
AA/BA/DA/
EA (DC lift)
59. JPC20-14 Brake Control path for the electrically released Brake fully VM Brake
brake on the drive motor. This voltage on: B+
varies depending on the voltage from the Brake
deadman sensor VR4 and the braking released:
mode of the truck. 0VDC at first,
then 9VDC
60. JPC20-15 B+L/L B+ supplied to SOL2 from K2 tips when K2 B+ VM SOL2
is energized
61. JPC20-16 L/L Control path for the lift/lower solenoid De-energized VM SOL2
SOL2. Voltage present during lower B+;
depends on the lower request from VR2. No lower:
37.6VDC
varies
propor-
tionally to
Full lower:
18.8VDC
62. JPC20-17 B+Aux1 B+ supply for SOL5T solenoid B+ VM SOL5T
63. JPC20-18 Aux1 Control path for one of the directional De-energized VM SOL5T
solenoids (SOL5B) for the aux functions B+
sideshift left, tilt down, and retract. Energized:
Sideshift Left:
20VDC;
Tilt Down:
17.5V;
Retract High:
20VDC;
Retract Low:
24VDC
64. JPC20-19 B+Aux2 B+ supply for SOL5B solenoid. B+ VM SOL5B
65. JPC20-20 Aux2 Control path for one of the directional De-energized VM SOL5B
solenoids (SOL5B) for the aux functions B+
sideshift right, tilt up, and reach. Energized:
Sideshift
Right:
20VDC;
Tilt Up:
18.0V;
Reach High:
20VDC;
Reach Low:
24VDC
1026304B, 15 July 2007 8-119
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
66. JPC22-1 Speed Limit 1 This input is used by the VM to determine Telescopics VM VM
when the telescopic is unnested. Speed is nested:
reduced at this point to the value set in < 0.5VDC;
Configure. Telescopics
unnested:
> 4VDC
67. JPC22-2 Bump Status Return to VM Open: 5VDC
Closed:
0VDC
68. JPC22-3 Clogged Return to VM Open: VM VM
Filter 4.5VDC
Closed:
< 0.5VDC
69. JPC22-4 Closed: VM VM
0VDC
70. JPC22-5 Channel A 1 Channel A 1 is one part of the steering Either > Steer Tiller VM
Series request from the steer tiller encoder on 4.5VDC or < Encoder
CA/FA (AC electric steer trucks when the steering tiller is 0.5VDC
lift) moved. It is a square wave signal (0VDC & when tiller
4.5VDC) identical to Channel B 1 but stationary.
different phase. The VM uses the phase DC value
relationship of the two channels to when turning
determine the direction and speed of the handle
steering request. When the tiller is approx.
stationary, the voltage can be either high or 2.5VDC.
low, depending upon which part of the
square wave the tiller comes to rest on.
71. JPC22-6 Lift Limit Return to VM Open: 5VDC VM
Closed:
0VDC
72. JPC22-7 HGG_Fault Fault line from heated glass mast guard to ON: 0VDC Glass Guard VM
VM, to determine if the HGG Cntrl_Pwm is OFF: 5VDC Control Card
working correctly. The fault line is a PWM
voltage ranging from 0 to 5 VDC.
73. JPC22-8 On Input to the VM from the deadman switch > +4VDC S2 VM
Deadman S2. This is used by the VM to determine released
whether to ignore or comply with other < 0.5VDC
operational requests from either of the depressed
control handles. It also initiates the
application of the electric brake.
8-120 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
74. JPC22-9 ChannelA_4 Channel A 4 is one part of the steering Not turning: Steer Motor VM
Series position feedback from the steer motor either 0VDC Encoder
CA/FA (AC encoder when the drive unit is rotated. It is or 4.5VDC
lift) a square wave signal (0VDC & 4.5VDC) Turning
identical to Channel B 4 but different either
phase. The VM uses the phase relationship direction:
of the two channels to determine that the 1.8VDC
direction and speed of the steering
response is the same as that requested.
When the drive unit is stationary, the
voltage can be either high or low,
depending upon which part of the square
wave the drive unit comes to rest on.
75. JPC22-10 ChannelB_4 Channel B 4 is one part of the steering Not turning: Steer Motor VM
Series position feedback from the steer motor either 0VDC Encoder
CA/FA (AC encoder when the drive unit is rotated. It is or 4.5VDC
lift) a square wave signal (0VDC & 4.5VDC) Turning
identical to Channel A 4 but different either
phase. The VM uses the phase relationship direction:
of the two channels to determine that the 1.8VDC
direction and speed of the steering
response is the same as that requested.
When the drive unit is stationary, the
voltage can be either high or low,
depending upon which part of the square
wave the drive unit comes to rest on.
76. JPC22-11 DGND Reference for S11 < 0.5VDC VM S11
Series B–
CA/FA (AC
lift)
77. JPC22-12 Channel B 1 Channel B 1 is one part of the steering Either > Steer Tiller VM
Series request from the steer tiller encoder on 4.5VDC or < Encoder
CA/FA (AC electric steer trucks when the steering tiller is 0.5VDC
lift) moved. It is a square wave signal (0VDC & when tiller
4.5VDC) identical to Channel A 1 but stationary.
different phase. The VM uses the phase DC value
relationship of the two channels to when turning
determine the direction and speed of the handle
steering request. When the tiller is approx.
stationary, the voltage can be either high or 2.5VDC.
low, depending upon which part of the
square wave the tiller comes to rest on.
1026304B, 15 July 2007 8-121
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
78. JPC22-13 Channel A 2 Channel A 2 is one part of the steering Either > Steer Tiller VM
Series request from the steer tiller encoder on 4.5VDC or < Encoder
CA/FA (AC electric steer trucks when the steering tiller is 0.5VDC
lift) moved. It is a square wave signal (0VDC & when tiller
4.5VDC) identical to Channel B 2 but stationary.
different phase. The VM uses the phase DC value
relationship of the two channels to when turning
determine the direction and speed of the handle
steering request. When the tiller is approx.
stationary, the voltage can be either high or 2.5VDC.
low, depending upon which part of the
square wave the tiller comes to rest on.
79. JPC22-14 Channel B 2 Channel B 2 is one part of the steering Either > Steer Tiller VM
Series request from the steer tiller encoder on 4.5VDC or < Encoder
CA/FA (AC electric steer trucks when the steering tiller is 0.5VDC
lift) moved. It is a square wave signal (0VDC & when tiller
4.5VDC) identical to Channel A 2 but stationary.
different phase. The VM uses the phase DC value
relationship of the two channels to when turning
determine the direction and speed of the handle
steering request. When the tiller is approx.
stationary, the voltage can be either high or 2.5VDC.
low, depending upon which part of the
square wave the tiller comes to rest on.
80. JPC22-15 Brush Wear Brush wear indicator on the armature (A1 Brushes not Armature VM
Series 1 brush) of the lift motor. The VM uses this worn: 0VDC;
AA/BA/DA/ voltage to stop lift and sound an alarm Brushes
EA (DC lift) when the brushes are worn. worn:
Armature
voltage
34VDC
81. JPC22-16 Brush Wear Brush wear indicator on the armature (A2 Brushes not Armature VM
Series 2 brush) of the lift motor. The VM uses this worn: 0VDC;
AA/BA/DA/ voltage to stop lift and sound an alarm Brushes
EA (DC lift) when the brushes are worn. worn:
Armature
voltage
34VDC
82. JPC22-18 Nested Control path for the optional nested switch K2 tips K2 tips VM
Switch S14 on the carriage. Voltage will be B+ closed
when the carriage is nested & K2 tips (carriage
closed and 0VDC when the carriage is not nested): B+;
nested. The VM reduces travel speed to the Open
configured value (0 to 3.5mph) when the (unnested):
switch is open. 0VDC
83. JPC22-19 FU1 Sense B+ when there is not an open between Closed: B+ STR2 VM
Series battery positive and STR2. This voltage is Open:
CA/FA (AC used by the VM to determine the state of Voltage
lift) FU1 and the STR contactor tips. drops slowly
to 0VDC
8-122 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
84. JPC22-19 FU1 Sense B+ when there is not an open between Closed: B+ STR2 VM
Series battery positive and TP2. This voltage is Open: 0VDC
AA/BA/DA/ used by the VM to determine the state of
EA (DC lift) FU1 and the STR contactor.
85. JPC22-20 FU3 Sense B+ when there is not an open between STR & LPC LPC1 VM
Series battery positive and LPC1. This voltage is closed: B+;
AA/BA/DA/ used by the VM to determine the state of the Either open:
EA (DC lift) LPC, FU3, and the STR contactor. 0VDC when
lifting
86. JPC22-21 EPO Sense Sense wire used by the VM to determine EPO closed: EPO VM
when the EPO is open. This is used to B+;
initiate braking and codes. Open: 0VDC
87. JPC22-22 Steer Limit The steer limit switch stops drive unit Open S11 VM
Series rotation when closed. This switch is closed (metal): 4 to
CA/FA (AC just before the hard stops are reached for 7VDC
lift) both CW and CCW rotation. Closed (air):
0.7VDC
88. JPC24-1 +12VP 12 volts for unspecified function +10.7 to VM n/a
13VDC
89. JPC24-2 HGG Control line for the Glass Guard/ ThermaKit ON: 0 VDC VM Glass
Control Card to turn the GGC Contactor on OFF: Guard/
and off. 12.0VDC ThermaKit
Control
Card
90. JPC24-4 DGND Reference for Training Pedal switch S24 <0.5VDC VM S24
91. JPC24-5 B– B– for unspecified function <0.5VDC VM n/a
92. JPC24-6 AGND Reference for the pressure transducer CYL-P < 0.5VDC VM Pressure
Transducer
93. JPC24-7 AGND Reference for the deadman potentiometer < 0.5VDC VM VR4
VR4
94. JPC24-8 DGND Reference for Bump Detector <0.5VDC VM Bump
Detector
95. JPC24-10 AGND Reference for the lift motor temperature < 0.5VDC VM VM
Series sensor
AA/BA/DA/
EA (DC lift)
96. JPC24-11 AGND Reference for the ambient temperature < 0.5VDC Ambient VM
sensor. Temp Sensor
97. JPC24-12 HGG_Contrl A PWM voltage from the VM to the Glass OFF: 12VDC VM Glass
_PWM Guard/ ThermaKit COntrol Card. Voltage Full ON: Guard/
varies with the ambient temperature as the 0VDC ThermaKit
VM attempts to regulate/heat the glass Control
guard. Card
98. JPC24-16 BUMP Return to VM from Bump Detector
1026304B, 15 July 2007 8-123
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
99. JPC24-18 Pressure Analog DC voltage that varies directly as No load: Pressure VM
the pressure varies 1.0VDC; Transducer
1000lb.
(454 kg) out
of free lift:
1.8VDC;
2500 lb.
(1134 kg)
2.5VDC
100. JPC24-19 Deadman Analog voltage that varies with the position Deadman VR4 VM
of the deadman pedal. This is used by the fully
VM to apply proportional braking with the depressed:
electric brake. 4.5VDC;
Fully
released:
2.5VDC
101. JPC24-22 Lift Mot Temp Analog DC voltage that varies directly as 70°F: VM VM
Series the temperature of the lift motor changes. 2.2VDC;
AA/BA/DA/ The VM uses this voltage to cutout 2nd Open or
EA (DC lift) pump at 271°F and eliminate lift at 271°F. disconnected
5VDC
102. JPC24-23 Room Temp Input to the VM from the ambient 73°F: 3VDC Ambient VM
temperature sensor. This is used to tell the Temp Sensor
optional glass mast guard heater when to
turn on.
103. JPC24-24 Battery Sense B+ present when the battery is plugged in B+ B+ at JPF4-1 VM
In supplied through a thermistor on the Relay/ (Drops no
Control Fuse Panel. This is used on the VM voltage)
to determine that the correct battery has
been connected. It will accept any voltage
between 28VDC and 45VDC. If the correct
battery is sensed, then Relay Enable is
energized during start-up. After start-up, this
voltage is used to determine the BSOC.
104. JPC4-1 +5VDC +5VDC supply to the solid state 5VDC± VM Secondary
potentiometer and switch in the optional 0.25V control
secondary control handle. Measure wrt handle
DGND JPC12-12.
105. JPC4-2 AGND Reference for the switches and < 0.5VDC VM Secondary
potentiometer in the optional secondary control
control handle. If this voltage is not < handle
0.5VDC wrt TP4 on the power panel, then
intermittent handle codes may appear.
106. JPC4-3 S Horn Input to the VM from horn button S10 in the S10 Open: VM Secondary
optional secondary control handle. >4.5VDC; control
Closed: handle
< 0.5VDC
8-124 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
107. JPC4-4 S Throttle Input to the VM from the “wiper” of the Neutral: VM Primary
primary (primary control handle) throttle 1.1VDC; control
control. Measure wrt AGND JPC4-2. Full handle
Tractor-first:
1.6VDC;
Full
Forks-first:
0.5VDC
108. JPC6-1 Neutral Pulse This input tells the VM that the steer power Deadman VM Steer
Series amplifier is connected and functioning. Up: 4.6VDC; power
CA/FA (AC CCW steer: amplifier
lift) 4.5VDC;
CW steer:
0.0VDC;
No steering:
voltage
varies
109. JPC6-2 CW PWM This is a control voltage used to rotate the At rest: VM Steer
Series drive unit in the CW direction. The average 11.5VDC; power
CA/FA (AC DC value will vary depending on the CCW steer: amplifier
lift) amount and speed of steering requested. 11.6VDC;
CW steer
fast: 5VDC;
CW steer
slow: 9VDC;
At rest:
11.5VDC
110. JPC6-3 Steer Current Analog voltage which varies with the steer Steering Steer power VM
Series motor current and is sent from the steer CW: amplifier
CA/FA (AC power amplifier to the VM. This voltage is 1.8VDC
lift) used by the VM to establish current reading At rest:
for current limit. 2.5VDC
Steering
CCW:
3.2VDC
111. JPC6-4 AGND Reference for the control circuits in the steer < 0.5VDC VM Steer
Series power amplifier. If missing, the steer power
CA/FA (AC amplifier will not be powered up. amplifier
lift)
112. JPC6-5 CCW PWM This is a chopped voltage used to rotate the Steering VM Steer
Series drive unit in the CCW direction. The CW: power
CA/FA (AC average dc value will vary depending on 11.6VDC amplifier
lift) the amount and speed of steering At rest:
requested. 11.5VDC
Steering
CCW:
9V slow
5V fast
1026304B, 15 July 2007 8-125
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
113. JPC6-6 +12VP Operating voltage from the VM for the +10.7 to VM Steer
Series control circuits in the steer power amplifier. 13VDC power
CA/FA (AC If this is missing, the steering will be amplifier
lift) inoperable.
114. JPF1-1 B– B– for FU8, B– 15A fuse for optional Aux < 0.5VDC Power Panel Optional
power B– TP4 Aux Power
115. JPF1-2 B– B– for FU8, B– 15A fuse for optional Aux < 0.5VDC Power Panel Optional
power B– TP4 Aux Power
116. JPF1-3 B+F or B–F Provides either B+ or B– to the lift power K3 FU5 to B+ LPA
Series amplifier pre-charge circuit, depending on De-energized FU6 to B–
CA/FA (AC the state of relay K3. Voltage
lift) drops slowly
to 0;
Energized:
B+
117. JPF1-4 B–F B–F from FU8 to power the optional <0.5VDC FU8 to B– Aux Power,
Warehouse Management Module Warehouse
Manage-
ment
Module,
Bump
Detector
118. JPF1-5 B+F or B–F Provides either B+ or B– to the traction K3 FU5 to B+ TPA
power amplifier pre-charge circuit, De-energized FU6 to B–
depending on the state of relay K3. B–;
Energized:
B+
119. JPF1-6 B+F or B–F Provides either B+F or B–F to the B+K3 on K3 FU5 to B+ Lift &
the lift (JPL1-1 AC Lift) and the travel (JPT1-1) De-energized FU6 to B– Traction
power amplifiers. B–; Power
Energized: Amplifiers
B+
120. JPF2-1 B+K2 B+K2 to power TPC (Traction Power), LPC B+ when K2 K2 tips TPC, LPC,
(Lift Power), and STR (Steering) contactors energized and STR
Contactors
121. JPF2-2 B+K2 B+K2 to power the horn B+ when K2 K2 tips Horn
energized
122. JPF2-3 B+K2 B+K2 to power the compartment fans B+ when K2 K2 tips Fans
energized
123. JPF2-4 B+K4 B+K4 to the VM B+ when K4 K4 tips VM
energized
124. JPF2-5 B+K2 B+K2 to power SOL1 (load holding B+ when K2 K2 tips L/H SOL1
solenoid) energized
125. JPF2-6 B+K2 B+K2 to the VM B+ when K2 K2 tips VM
energized
8-126 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
126. JPF2-7 B+K2 B+K2 to the VM B+ when K2 K2 tips VM
energized
127. JPF2-8 B+K2 B+K2 to the reach, sideshift, tilt solenoids B+ when K2 K2 tips Carriage
and nested switch S14. energized Functions
128. JPF2-9 B+ B+ for key-operated auxiliary power B+ when K1 K1 tips Optional
is energized Aux Power
129. JPF3-1 B– B– for FU6 (15A), which provides B– to the < 0.5VDC Power Panel VM
Vehicle Manager TP4
130. JPF3-2 B– B– for FU6 (15A), which provides B– to the < 0.5VDC Power Panel VM
Vehicle Manager TP4
131. JPF3-3 B–F B–F for DGND on the VM < 0.5VDC FU6 VM
132. JPF3-4 B–F B–F for DGND on the VM < 0.5VDC FU6 VM
133. JPF3-5 B–F B–F for the VM < 0.5VDC FU6 VM
134. JPF3-6 B–F B–F for the VM < 0.5VDC FU6 VM
135. JPF3-7 B–F B–F for the VM < 0.5VDC FU6 VM
136. JPF3-8 B–F B–F for S12, 1st Speed Limiting Switch on < 0.5VDC FU6 S12
mast
137. JPF3-12 B–F B–F for Clogged Filter Switch < 0.5VDC FU6 Clogged
Filter
Switch
138. JPF4-1 B+ B+ from TP1 to FU5, to supply K2, K3, & K4 B+ TP1 FU5 & VM
relay tips; K4 relay coil; & key switch S1.
This also supplies Battery_Sense_In on the
VM.
139. JPF4-2 B+ B+ from TP1 to FU5, to supply K2, K3, & K4 B+ TP1 FU5 & VM
relay tips; K4 relay coil; & key switch S1.
This also supplies Battery_Sense_In on the
VM.
140. JPF4-3 B+ B+ From TP1 to FU7 to supply auxiliary B+ TP1 FU7 and
power option and warehouse management Aux Power
module.
141. JPF4-4 B+ B+ From TP1 to FU7 to supply auxiliary B+ TP1 FU7 and
power option Aux Power
142. JPF4-5 B+EPO B+ supply from EPO to K1, K2, & K3. All S1 and EPO EPO K1, K2,
functions associated with those functions closed: B+; K3,
will be inoperable when the EPO is open. Either open:
This also supplies voltage to EPO Sense on 0.05VDC
the VM.
1026304B, 15 July 2007 8-127
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
143. JPF4-6 B+EPO B+ to EPO Sense on the VM. Tells the VM if S1 and EPO EPO VM EPO
the EPO is open or closed. closed: B+; Sense
Either open:
0.05VDC
144. JPF4-7 Battery_ B+ to Battery_Sense_In on the VM B+ TP1 VM
Sense_In
145. JPF4-8 B+Key B+Key to supply all functions powered from B+ S1 closed FU5 Various
key switch S1
146. JPF4-10 B+ B+ from FU5 to key switch S1 FU5 good: FU5 Key switch
B+ S1
FU5 open:
0VDC
147. JPF4-11 B+Key B+ from S1 to the VM B+ S1 closed S1 VM
148. JPF4-12 B+Key B+ from S1 to the EPO B+ S1 closed S1 EPO
149. JPF4-13 Relay Enable Return path for relays K1, K2, K3, & K4 Key ON & VM K1, K2,
all relays K3, & K4
de-energized
B+;
Key OFF, or
Key ON &
any relay
energized:
< 1.5VDC
150. JPF4-15 B+ B+ for battery connected aux power B+ FU7 Optional
Aux Power
151. JPL1-1 B+K3 B+ present when K3 is energized. This is B+ when K3 K3 LPA
Series used to power the control circuits of the LPA. energized
CA/FA (AC It is also used by the LPA to produce
lift) +12VDC for the L Vel Sensor + and the
internal circuits of the LPA. If voltage is not
present, check K3 coil and tip circuit.
152. JPL1-2 LPC Control path for the LPC Contactor. The lift LPC LPA LPC
Series Contactor power amplifier supplies B– to the contactor de-energized Contactor
CA/FA (AC by way of the B– terminal. B+;
lift) LPC
energized:
18VDC to
22VDC.
153. JPL1-3 L Vel Sensor+ +12VDC supply to the bearing encoder on +10.9 to LPA Lift Velocity
Series the lift motor. This voltage is produced by 13VDC Sensor
CA/FA (AC the lift power amplifier B+K3
lift)
154. JPL1-4 L Vel Sensor– Return path for the bearing encoder in the < 0.5VDC DGND on Lift Velocity
Series lift motor. Returns through DGND JPL1-7 VM Sensor
CA/FA (AC through the Operator Display to the VM.
lift)
8-128 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
155. JPL1-5 L Vel Phase A This square wave is generated whenever Motor Lift Velocity LPA
Series there is movement of the bearing encoder in Stationary: Sensor
CA/FA (AC the lift motor. It is either high (>8VDC) or Either
lift) low (<1VDC). The frequency varies directly > 8VDC or
with the speed of the drive motor. Identical < 1VDC;
formation to L Vel Phase B, except for the Turning:
phasing between the two. The LPA uses the 4VDC to
quadrature phase relationship between 6VDC.
Phases A & B to determine lift speed.
156. JPL1-6 L Vel Phase B This square wave is generated whenever Motor Lift Velocity LPA
Series there is movement of the bearing encoder in Stationary: Sensor
CA/FA (AC the lift motor. It is either high (>8VDC) or Either
lift) low (<1VDC). The frequency varies directly > 8VDC or
with the speed of the drive motor. Identical < 1VDC;
formation to L Vel Phase A, except for the Turning:
phasing between the two. The LPA uses the 4VDC to
quadrature phase relationship between 6VDC.
Phases A & B to determine lift speed.
157. JPL1-7 DGND B– DGND from VM through the Operator < 0.5VDC Operator LPA
Display to the LPA. If it is missing, neither Display
LPA nor TPA will function.
158. JPL1-8 DGND B– Provides DGND to the TPA from the LPA < 0.5VDC LPA TPA
Series
CA/FA (AC
lift)
159. JPL1-14 BUS–I– The wire that carries the negative 2.2VDC Operator LPA
Series component of the digital communications Display
CA/FA (AC between the Operator Display and the LPA
lift) and VM. If this connection is missing, then
the LPA and TPA cannot communicate with
the Operator Display or VM. Troubleshoot
using resistance checks in Test I23. No
useful information can be gained by
measuring the voltage on this wire.
160. JPL1-15 BUS–I– The wire that carries the negative 2.2VDC LPA TPA
Series component of the digital communications
CA/FA (AC between the LPA and the TPA. If this
lift) connection is missing then the TPA cannot
communicate with the LPA, Display, or VM.
Troubleshoot using resistance checks in Test
I23. No useful information can be gained
by measuring the voltage on this wire.
161. JPL1-16 L Temp + Analog voltage which varies with the lift 75°F (24°C): LM LPA
Series motor temperature. Used by the lift power Approx. temperature
CA/FA (AC amplifier to adjust motor performance with 1.5VDC sensor
lift) temperature.
162. JPL1-17 L Temp – Reference for the lift motor temperature < 0.5VDC DGND on Temp
Series sensor. B– VM Sensor
CA/FA (AC
lift)
1026304B, 15 July 2007 8-129
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
163. JPL1-22 BUS I+ The wire that carries the positive component 2.94VDC Operator LPA
Series of the digital communications between the Display
CA/FA (AC LPA and the Operator Display and VM. If
lift) this connection is missing then the LPA and
TPA cannot communicate with the Operator
Display or VM. Troubleshoot using
resistance checks in Test I23. No useful
information can be gained by measuring
the voltage on this wire.
164. JPL1-23 BUS I+ The wire that carries the positive component 2.94VDC LPA TPA
Series of the digital communications between the
CA/FA (AC LPA and the TPA. If this connection is
lift) missing then the TPA cannot communicate
with the LPA, Display, or VM. Troubleshoot
using resistance checks in Test I23. No
useful information can be gained by
measuring the voltage on this wire.
165. JPT1-1 B+K3 B+ present when K3 is energized. This is B+ when K3 K3 TPA
Series used to power the control circuits of the energized.
CA/FA (AC TPA. It is also used by the TPA to produce
lift) +12VDC for the T Vel Sensor + and the
internal circuits of the TPA. If voltage is not
present, check K3 coil and tip circuit.
166. JPT1-2 TPC Control path for the TPC Contactor. The TPC TPA TPC
Contactor traction power amplifier supplies B– to the de-energized Contactor
contactor by way of the B– terminal. B+;
TPC
Energized:
18 to
22VDC.
167. JPT1-3 T Vel Sensor+ +12VDC supply to the bearing encoder on +10.7 to TPA Travel
the traction motor. This voltage is produced 13VDC Velocity
by the traction power amp from B+K3. Sensor
168. JPT1-4 T Vel Sensor– Return path for the bearing encoder in the < 0.5VDC DGND on Travel
traction motor. Returns through DGND VM Velocity
JPT1-7 to the LPA, Operator Display, and to Sensor
the VM.
169. JPT1-5 T Vel Phase A This is generated whenever there is Motor Travel TPA
movement of the bearing encoder in the Stationary: Velocity
drive motor. It is a square wave that is Either Sensor
either high (>8VDC) or low (<1VDC). The > 8VDC or
frequency varies directly with the speed of < 1VDC;
the drive motor. Identical formation to T Vel Turning:
Phase B, except for the phasing between 4VDC to
the two. The TM/VFC uses the quadrature 6VDC.
phase relationship between Phases A & B to
determine travel direction and speed.
8-130 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
170. JPT1-6 T Vel Phase B This is generated whenever there is Motor Travel TPA
movement of the bearing encoder in the Stationary: Velocity
drive motor. It is a square wave that is Either Sensor
either high (>8VDC) or low (<1VDC). The > 8VDC or
frequency varies directly with the speed of < 1VDC;
the drive motor. Identical formation to T Vel Turning:
Phase A, except for the phasing between 4VDC to
the two. The TM/VFC uses the quadrature 6VDC.
phase relationship between Phases A & B to
determine travel direction and speed.
171. JPT1-7 DGND DGND for the TPA from the LPA < 0.5VDC LPA TPA
Series B–
CA/FA (AC
lift)
172. JPT1-7 DGND DGND from the VM for the control side of < 0.5VDC VM TPA
Series the TPA. If this ground is missing, the TPA B–
AA/BA/DA/ will not function.
EA (DC lift)
173. JPT1-8 DGND DGND from the VM via the Operator < 0.5VDC VM TPA
Series Display for the Traction Power Amplifier. If
AA/BA/DA/ this ground is missing, the TPA will not
EA (DC lift) function.
174. JPT1-14 BUS I– The wire that carries the negative 2.2VDC LPA TPA
Series component of the digital communications
CA/FA (AC from the LPA and VM to the TPA. If this
lift) connection is missing then the TPA cannot
communicate with the VM, LPA, or Display.
Troubleshoot using resistance checks in Test
I23. No useful information can be gained
by measuring the voltage on this wire.
175. JPT1-14 Bus_I– The wire that carries the negative 2.2VDC VM TPA
Series component of the digital communications
AA/BA/DA/ between the VM and the TPA. If this
EA (DC lift) connection is missing the TPA cannot
communicate with the VM. Troubleshoot
using resistance checks in Test I23. No
useful information can be gained by
measuring the voltage on this wire.
176. JPT1-15 Bus_I– The wire that carries the negative 2.2VDC TPA Display
Series component of the digital communications
AA/BA/DA/ between the TPA and the Operator Display.
EA (DC lift) If this connection is missing then the
Operator Display cannot communicate.
Troubleshoot using resistance checks in
Test I23. No useful information can be
gained by measuring the voltage on this
wire.
177. JPT1-16 T Temp+ Analog voltage which varies with the drive 75°F (24°C): DM TPA
motor temperature. Used by the traction Approx. temperature
power amplifier to adjust motor 1.0VDC sensor
performance with temperature.
1026304B, 15 July 2007 8-131
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
178. JPT1-17 T Temp– Reference for the drive motor temperature < 0.5VDC DGND on Temp
sensor B– VM sensor
179. JPT1-22 BUS I+ The wire that carries the positive component 2.93VDC LPA TPA
Series of the digital communications from the LPA
CA/FA (AC and VM to the TPA. If this connection is
lift) missing then the TPA cannot communicate
with the VM, LPA, or Display. Troubleshoot
using resistance checks in Test I23. No
useful information can be gained by
measuring the voltage on this wire.
180. JPT1-22 Bus_I+ The wire that carries the positive component 2.93VDC VM TPA
Series of the digital communications between the
AA/BA/DA/ VM and the TPA. If this connection is
EA (DC lift) missing then the TPA cannot communicate
with the VM. Troubleshoot using resistance
checks in Test I23. No useful information
can be gained by measuring the voltage on
this wire.
181. JPT1-23 Bus _I+ The wire that carries the positive component 2.93VDC TPA Display
Series of the digital communications between the
AA/BA/DA/ TPA and the Operator Display. If this
EA (DC lift) connection is missing then the TPA cannot
communicate. Troubleshoot using resistance
checks in Test I23. No useful information
can be gained by measuring the voltage on
this wire.
182. LPA (+) LPA B+ B+ to the LPA used to pre-charge the B+ fully B+K3 and B+ LPA
Series amplifier and also to produce the AC charged or from LPC
CA/FA (AC phases U, V, & W when the LPC is closed to LPC
lift) power the lift motor. The voltage present energized.
will increase from 0VDC to B+ as the
amplifier charges.
183. LPA B– LPA B– B– from TP4 on the Power Panel. It is used < 0.5VDC TP4 LPA
Series for the power circuits on the LPA. Without B–
CA/FA (AC B– U, V, & W cannot be produced and the
lift) lift motor will not turn.
184. LPA B+ N/A Not used on this product Not used N/A N/A
Series
CA/FA (AC
lift)
185. TPA (+) TPA B+ B+ to the TPA used to pre-charge the B+ fully B+K3 and B+ TPA
amplifier and also to produce the AC charged or from TPC
phases U, V, & W when the TPC is closed to TPC
power the drive motor. The voltage present energized.
will increase from 0VDC to B+ as the
amplifier charges.
186. TPA B– TPA B– B– from TP4 on the Power Panel. It is used < 0.5VDC TP4 TPA
for the power circuits on the TPA. Without B–
B– U, V, & W cannot be produced and the
drive motor will not turn.
8-132 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
187. TPA B+ N/A Not used on this product Not used N/A N/A
188. U on LPA Lift Motor One of three phases from the LPA to the lift ACV LPA Lift Motor
Series Phase U motor. This AC voltage is produced by LPA between
CA/FA (AC and is dependent on B+ at the (+) terminal phases.
lift) and B– of the LPA. This AC voltage is Stationary:
measured between any two phases and 0VAC;
varies from 0VAC at rest to about 24VAC Full lift:
on full lift request. When lift knob is initially 24VAC
moved to full lift, meter reading may show
120VAC before stabilizing at about
24VAC.
189. U on TPA Drive Motor One of three phases from the TPA to the ACV TPA Drive
Phase U Drive Motor. This AC voltage is produced between Motor
by TPA and is dependent on B+ at the (+) phases.
terminal and B– of the TPA. This AC voltage Stationary:
is measured between any two phases and 0VAC;
varies from 0VAC at rest to about 24VAC Full travel:
on full acceleration. Stall condition 24VAC;
produces about 4VAC. Stall:
Approx.
4VAC
190. V on LPA Lift Motor One of three phases from the LPA to the lift ACV LPA Lift Motor
Series Phase V motor. This AC voltage is produced by LPA between
CA/FA (AC and is dependent on B+ at the (+) terminal phases.
lift) and B– of the LPA. This AC voltage is Stationary:
measured between any two phases and 0VAC;
varies from 0VAC at rest to about 24VAC Full lift:
on full lift request. When lift knob is initially 24VAC
moved to full lift, meter reading may show
120VAC before stabilizing at about
24VAC.
191. V on TPA Drive Motor One of three phases from the TPA to the ACV TPA Drive
Phase V Drive Motor. This AC voltage is produced between Motor
by TPA and is dependent on B+ at the (+) phases.
terminal and B– of the TPA. This AC voltage Stationary:
is measured between any two phases and 0VAC;
varies from 0VAC at rest to about 24VAC Full travel:
on full acceleration. Stall condition 24VAC;
produces about 4VAC. Stall:
Approx.
4VAC
192. W on LPA Lift Motor One of three phases from the LPA to the lift ACV LPA Lift Motor
Series Phase W motor. This AC voltage is produced by LPA between
CA/FA (AC and is dependent on B+ at the (+) terminal phases.
lift) and B– of the LPA. This AC voltage is Stationary:
measured between any two phases and 0VAC;
varies from 0VAC at rest to about 24VAC Full lift:
on full lift request. When lift knob is initially 24VAC
moved to full lift, meter reading may show
120VAC before stabilizing at about
24VAC.
1026304B, 15 July 2007 8-133
Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
Pinout Matrix
Function Normal Signal Signal
Item Connection Theory of Operations
Description Level Source User
193. W on TPA Drive Motor One of three phases from the TPA to the ACV TPA Drive
Phase W Drive Motor. This AC voltage is produced between Motor
by TPA and is dependent on B+ at the (+) phases.
terminal and B– of the TPA. This AC voltage Stationary:
is measured between any two phases and 0VAC;
varies from 0VAC at rest to about 24VAC Full travel:
on full acceleration. Stall condition 24VAC;
produces about 4VAC. Stall:
Approx.
4VAC
8-134 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Section A. Appendix
1026304B, 15 July 2007 A-1
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Lubrication Specification Chart
Lubrication Specification
Chart
Table A-1. Lubrication Specification Chart
Approved Raymond Lubricants
Where Used Type Specification/Grade Raymond Part Number
Drive Unit Gear Case Gear 75W-90 Synthetic Gear 990-655/001 (1 qt./0.9 liters)
(all-weather Lubricant Oil 990-655/003 (1 gal./3.8 liters)
(-20°F to +120°F) API Service Classification
(-29°C to +49°C) GL-5
Hydraulic Reservoir Hydraulic ISO VG 46 990-616/04(1 qt./0.9 liter)
(Non-Cold Storage Trucks) Fluid 990-616/01 (1 gal./3.8 liters)
(+50°F to +120°F) 990-616/02(2 gal./7.6 liters)
(+10°C to +49°C) 990-616/03(5 gal./18.9 liters)
Hydraulic Reservoir Hydraulic ISO VG 32 1017238
(In and Out of Freezer)) Fluid
(0°F to +50°F)
(-18°C to +10°C)
Hydraulic Reservoir Hydraulic MIL-H-5606E 990-618/TX1 (1 gal./3.8 liters)
(Confined to Freezer) Fluid 990-618/01 (1 gal./3.8 liters)
(-20°F to 0°F)
(-29°C to -18°C)
Mast Uprights, Bearings, Grease NLGI 2 1012992
etc.
(all-weather)
(-20°F to +120°F)
(-29°C to +49°C)
Lift Chains Teflon Aerosol 990-652/001 (spray)
Grease
A-2 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Thread Adhesives, Sealants, and Lubricants
Thread Adhesives,
Sealants, and Lubricants
Table A-2. Thread Adhesives, Sealants, Lubricants
Loctite*
Application Raymond P/N
Number/Color
Thread-locking 1/4 in. and below 990-403 222/Purple
Thread-locking 1/4 to 3/4 in. 990-536 242/Blue
Thread-locking 1/4 to 3/4 in. contamination tolerant 990-462 243/Blue
Thread-locking 1 in. and under 990-544 271/Red
Thread-locking 1 in. and under, contamination tolerant 990-463 603/Green
Thread-locking 1 in. and over 990-571 277/Red
Thread-locking Cleaner 990-538 707
Thread-locking Primer 990-533 T747
Primerless Thread-locking 1 1/2 in. and below 1013829 2440
Hydraulic Sealant 990-552 569
RTV Silicone Sealant 990-659 5900/Black
Other
Manufacturer
designation
Molybdenum Anti-Seize Compound (Molykote) 990-638 /Silver
Corrosion Inhibitor Coating 990-644
Cold Storage silicone sealing compound 990-445
NOTE: * Loctite is a registered trademark of the
Loctite Corporation. Brand endorsement
is not implied here, but listed only as a
commonly identified product.
1026304B, 15 July 2007 A-3
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Torque Chart - Hydraulic Fittings
Torque Chart - Hydraulic
Fittings
Table A-3. Torque Chart - Hydraulic Fittings
SAE Straight Thread Steel Plugs
JIC
SAE Dash Thread (37° Flare Thread) Hollow Hex Head Plug
Hex Head Plug P50N
Size Size HP50N
Nm Ft. lb. Nm Ft. lb. Nm Ft. lb.
-2 5/16-24 4±1 3±1 4 ± 0.6 3 ± 0.5 10 ± 0.6 7.5 ± 0.5
-3 3/8-24 8±1 6±1 7 ± 0.6 5 ± 0.5 19 ± 1 14 ± 1
-4 7/16-20 16 ± 1 12 ± 1 15 ± 1 11 ± 1 24 ± 1 18 ± 1
-5 1/2-20 20 ± 1 15 ± 1 20 ± 1 15 ± 1 30 ± 1 22 ± 1
-6 9/16-18 28 ± 1 21 ± 1 24 ± 1 18 ± 1 37 ± 3 27 ± 2
-8 3/4-16 61 ± 3 45 ± 2 62 ± 3 46 ± 2 65 ± 3 48 ± 2
-10 7/8-14 81 ± 7 60 ± 5 102 ± 7 75 ± 5 122 ± 7 90 ± 5
-12 1 1/16-12 115 ± 7 85 ± 5 115 ± 7 85 ± 5 149 ± 7 110 ± 5
-14 1 3/16-12 142 ± 7 105 ± 5 176 ± 8 130 ± 6 197 ± 8 145 ± 6
-16 1 5/16-12 163 ± 7 120 ± 5 183 ± 8 135 ± 6 217 ± 8 160 ± 6
-20 1 5/8-12 230 ± 14 170 ± 10 305 ± 16 225 ± 12 305 ± 16 225 ± 12
-24 1 7/8-12 271 ± 20 200 ± 15 339 ± 16 250 ± 12 339 ± 16 250 ± 12
-32 2 1/2-12 366 ± 27 270 ± 20 441 ± 20 325 ± 15 441 ± 20 325 ± 15
A-4 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Torque Chart - Straight Thread Face Seal O-Rings
Torque Chart - Straight
Thread Face Seal
O-Rings
Table A-4. Torque Chart - Straight Thread Face Seal O-Rings
SAE Dash Tube Size
Nm Ft. lb.
Size Thread Size
-4 9/16-18 24 ± 1 18 ± 1
-6 11/16-18 37 ± 3 27 ± 2
-8 13/16-16 54 ± 3 40 ± 2
-10 1-14 85 ± 4 63 ± 3
-12 1 3/16-12 122 ± 5 90 ± 4
-14 1 5/16-32 129 ± 8 95 ± 6
-16 1 7/16-12 163 ± 11 120 ± 8
-20 1 11/16-12 190 ± 11 140 ± 8
-24 2-12 224 ± 11 165 ± 8
-32 2 1/2-12 488 ± 14 360 ± 10
1026304B, 15 July 2007 A-5
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Torque Chart - Standard (Ferrous)
Torque Chart - Standard
(Ferrous)
*
Table A-5. Torque Chart - Standard Ferrous
Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts
Size Tightening Torque Tightening Torque Tightening Torque
Dry Oiled* Dry Oiled* Dry Oiled*
in. lb. in. lb. in. lb. in. lb. in. lb. in. lb.
4-40 5 4 8 6 12 9
4-48 6 5 9 7 13 10
6-32 10 8 16 12 23 17
8-32 19 14 30 22 41 31
8-36 20 15 31 23 43 32
10-24 27 21 43 32 60 45
10-32 31 23 49 36 68 51
1/4-20 66 49 96 75 144 108
1/4-28 78 56 120 86 168 120
ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.
5/16-18 11 8 17 13 25 18
5/16-24 12 9 19 14 25 20
3/8-16 20 15 30 23 45 35
3/8-24 23 17 35 25 50 35
7/16-14 30 24 50 35 70 55
7/16-20 35 25 55 40 80 60
1/2-13 50 35 75 55 110 80
1/2-20 55 40 90 65 120 90
9/16-12 65 50 110 80 150 110
9/16-18 75 55 120 90 170 130
5/8-11 90 70 150 110 220 170
5/8-18 110 85 180 130 240 180
A-6 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Torque Chart - Standard (Ferrous)
Table A-5. Torque Chart - Standard Ferrous
Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts
Size Tightening Torque Tightening Torque Tightening Torque
Dry Oiled* Dry Oiled* Dry Oiled*
ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.
3/4-10 160 120 260 200 380 280
3/4-16 180 140 300 220 420 320
7/8-9 140 110 400 300 600 460
7/8-14 155 120 440 320 660 500
1-8 220 160 580 440 900 680
1-12 240 170 640 480 1000 740
1 1/8-7 300 220 800 600 1280 960
1 1/8-12 340 260 880 660 1440 1080
1 1/4-7 420 320 1120 840 1820 1360
1 1/4-12 460 360 1240 920 2000 1500
1 3/8-6 560 420 1460 1100 2380 1780
1 3/8-12 640 460 1680 1260 2720 2040
1 1/2-6 740 560 1940 1460 3160 2360
1 1/2-12 840 620 2200 1640 3560 2660
NOTE: * Use “oiled” values for bolts with
thread locking compound
1026304B, 15 July 2007 A-7
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Torque Chart - Metric (Ferrous)
Torque Chart - Metric
(Ferrous)
Table A-6. Torque Chart - Ferrous Metric
Ferrous Metric Bolts, Coarse Thread
(The grade rating is stamped on the head of the bolt.)
Grade 8.8 Grade 10.9
Diameter
Torque (with bolts oiled*) Torque (with bolts oiled*)
(in millimeters)
Newton-meters Foot-pounds Newton-meters Foot-pounds
6 8.1 6 12.2 9
8 20.3 15 28.4 21
10 40.7 30 58.3 43
12 74.6 55 101.7 75
16 176.3 130 245.4 181
20 345.7 255 474.5 350
24 589.8 435 820.3 605
NOTE: * Use “oiled” values for bolts with
thread locking compound
A-8 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Torque Chart - Metric (Brass)
Torque Chart - Metric
(Brass)
Table A-7. Torque Chart - Brass Metric
Brass MS63 Metric Bolts, Coarse Thread
Diameter Torque (with bolts oiled*)
(in millimeters) Newton-meters Inch-pounds
3 0.5 4.4
3.5 0.79 7.0
4 1.1 10
5 2.1 19
6 3.8 34
8 9 79
10 17 150
NOTE: * Use “oiled” values for bolts with
thread locking compound
1026304B, 15 July 2007 A-9
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Torque Chart - Standard (Brass)
Torque Chart - Standard
(Brass)
Table A-8. Torque Chart - Standard Brass
Brass MS63 Standard Bolts, Coarse Thread
Torque (with bolts oiled*)
Size
Newton-meters Inch-pounds
4-40 0.37 3.3
4-48 0.40 3.6
6-32 0.69 6.1
6-40 0.77 6.8
8-32 1.24 11
8-36 1.24 11
10-24 1.58 14
10-32 1.92 17
1/4-20 3.96 35
1/4-28 4.52 40
5/16-18 8.25 73
5/16-24 9.15 81
3/8-16 14.69 130
3/8-24 16.61 147
* NOTE: Use”oiled” values for bolts with
thread locking compound
A-10 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Decimal Equivalent Chart
Decimal Equivalent Chart
Table A-9. Decimal Equivalent Chart
To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 .397
1/32 .031 .03 .794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
1026304B, 15 July 2007 A-11
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Decimal Equivalent Chart
Table A-9. Decimal Equivalent Chart
To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
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
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
A-12 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Decimal Equivalent Chart
Table A-9. Decimal Equivalent Chart
To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
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
1026304B, 15 July 2007 A-13
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Standard/Metric Conversions
Standard/Metric
Conversions
Figure A-1. Standard/Metric Conversion Chart
To Convert... Multiply...
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.764
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Pints (US) to Liters Pints x 0.473
Liters to Pints (US) Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons (US) to Liters Gallons x 3.785
Liters to Gallons (US) Liters x 0.264
A-14 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Standard/Metric Conversions
Figure A-1. Standard/Metric Conversion Chart
To Convert... Multiply...
Ounces (avoirdupois) to Grams Ounces x 28.35
Grams to Ounces (avoirdupois) Ounces x 0.035
Ounces (avoirdupois) to Kilograms Ounces x 0.028
Kilograms to Ounces (avoirdupois) Kilograms x 35.274
Pounds to Kilograms Pounds x 0.454
Kilograms to Pounds Kilograms x 2.205
Pounds per Square Inch (psi) to Kilopascals (kPa) Pounds per Square Inch (psi) x 6.895
Kilopascals to Pounds per Square Inch Kilopascals x 0.145
Pounds per Square Inch (psi) to Kilograms per Pounds per Square Inch (psi) x 0.070
square centimeter (kg/cm2)
Kilograms per square centimeter (kg/cm2) to Pounds Kilograms per Square Centimeter (kg/cm2) x 14.223
per Square Inch (psi)
Inch Pounds (in. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.356
Newton Meters (Nm) to Foot Pounds (ft. lb.) Newton Meters x 0.738
Miles per Hour to Kilometers per Hour Miles per Hour x 1.609
Kilometers per Hour to Miles per Hour Kilometers per Hour x 0.621
Fahrenheit to Celsius (°F - 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) + 32
1026304B, 15 July 2007 A-15
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Standard/Metric Conversions
A-16 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Electrical Schematics
Electrical Schematics
Section A. Appendix
Turn to next page for electrical schematics.
1026304B, 15 July 2007 A-17
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Series CA/FA (AC lift) Electrical Schematics
Model 74xx Series CA/FA (AC lift)
AR1004765_G1L.EPS
Figure A-2. Model 7400/7420/7440 Series CA/FA (AC lift) Electrical Schematic (Sheet 1 of 3)
A-18 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Electrical Schematics Model 74xx Series CA/FA (AC lift)
Model 74xx Series CA/FA (AC lift)
AR1004765_G1R.EPS
Figure A-3. Model 7400/7420/7440 Series CA/FA (AC lift) Electrical Schematic (Sheet 1 of 3)
1026304B, 15 July 2007 A-19
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Series AA/BA/DA/EA (DC lift) Electrical Schematics
Model 74xx Series AA/BA/DA/EA (DC lift)
AR1004765_G2L.EPS
Figure A-4. Model 7400/7420/7440 Series AA/BA/DA/EA (DC lift) Electrical Schematic (Sheet 2 of 3)
A-20 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Electrical Schematics Model 74xx Series AA/BA/DA/EA (DC lift)
Model 74xx Series AA/BA/DA/EA (DC lift)
AR1004765_G2R.EPS
Figure A-5. Model 7400/7420/7440 Series AA/BA/DA/EA (DC lift) Electrical Schematic (Sheet 2 of 3)
1026304B, 15 July 2007 A-21
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Options (All Series) Electrical Schematics
Model 74xx Options (All Series)
A B C D
D-x
RLY-A
RLY-7
2 TRAVEL LIGHT AND ALARM RLY
RLY-4
RLY-B
JPTL-1 JPTL-1
D-y
TRAVEL
LIGHTS
TP1 #1 & 2
FU9 ALARM
(10A)
VM +
JPTL-2
H2 JPTL-2
JPC18-18 SPL-6 -
ALARM
3 TP4(B-)
SECONDARY CONTROL HANDLE AUX START
3
3
VM JPC4-1
JPH3-1 +
VM
+5VP JPC10-2 S23-1 S23
S10 AUX START
-3 -3 0 S23-2
S_HORN DGND
-4
-2 -
-2
JPH2-1
DGND
-4 -2 VR3
OCSS Display
S_THROTTLE JPD1-1
+12 VP
-3
4 CAN I/O EXPANDER
MODULE
RCVR_1 EMTR_1 JPCS1-1 JPX1-1
JPX2-4
BLU BRN AC LIFT
+12 VP +12 VP
BRN TPA
PHOTO BEAM UPPER JPCS1-2 JPX1-4
BLK JPX2-9 JPT1-8
BLU
DOUT_0 DGND DGND
JPX1-5 JPT1-15
CAN L CAN L
RCVR_2 EMTR_2 JPCS3-1 JPX2-5 JPX1-2 JPT1-23
BLU BRN
+12 VP CAN H CAN H
BRN
PHOTO BEAM LOWER
BLK
JPCS3-2 JPX2-10 JPX1-3
BLU
DOUT_1 RTERM
JPX1-6
RTERM
DC LIFT
5 JPT1-7
TPA
DGND
JPCS4-3 JPX2-7
DIN_1 JPT1-14
CAN L
JPCS4-1 JPX2-3
+12 VP JPT1-22
CAN H
JPCS4-4 JPX2-8
DGND
JPCS2-2 JPX2-2 ROOM TEMPERATURE
DIN_0
SENSOR
JPCS2-1 JPX2-1
+12 VP VM JPC24-23 JPA-1 0 T
JPCS2-4 JPX2-6 ROOM-TEMP
DGND -
-11 -2
6 DGND
NESTED SWITCH
FUSE
RELAY
CARD
S14
B+K2
JPF2-8 JPS3-1 TS2-1 COM
NC
TS2-6
VM
NO JPS3-6 JPC22-18
NESTED
SWITCH
AR1004765_G3L.EPS
Figure A-6. Model 7400/7420/7440 Options (All Series) Electrical Schematic (Sheet 3 of 3)
A-22 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Electrical Schematics Model 74xx Options (All Series)
Model 74xx Options (All Series)
D E F
HTI SYSTEM
RED JPE3-1 JPS11-1 JPD2-1 AUX POWER
2 +12VP CONNECTION
B+ Key
BLK -4 -4 -2
DGND VANTAGE POINT SYSTEM
HEIGHT B-
ENCODER
WHT -3 -3 -3
CHANNEL A JPVS1-1
+VBAT
BLU -2 -2 -4 -2
CHANNEL B
POWER GND VEHICLE
-3 MANAGER
CAMERA 1 SELECT
HTI JPHI-1 JPS13-1 -5 -4 JPVT1-1 JPC18-8
DISPLAY +5VP SYSTEM
CAMERA 2 SELECT
-2 -4 -8 TRIGGER
DGND -5
-3 -2 -6 CAMERA 3 SELECT
DATA
-6
-4 -3 -7 TOGGLE
SBUSY
-7
NO FUNCTION
3 DISPLAY -8
NOT CONNECTED
2
S18
1
-9
7400 MULTIPLEXER
TILT TILT PRESS
PRESSURE INSTALLATION
SWITCH
-10
DGND
WAREHOUSE MANAGEMENT MODULE
PS7
JPC10-10 -2 BUS_E+
4 VM JPC10-5 -3 BUS_E-
JPF1-4 -4
B-FU8
FUSE
RELAY
CARD JPF4-15 -5 B+FU7
JPF2-9 -1
B+K1
COLD STORAGE COMFORT PACKAGE
5
TH2 T°
JPHTB-1
B+FU14
-2
THERM
HTR3
GLASS
FLOOR PAD
GUARD/THERMAKIT
CONTROL
JPHTC-1 TH3 T°
B+FU14
HEATER
SECONDARY
-2 HANDLE
THERM
HTR4
FU14 B+FU14
B+
(10A) FU13
6 B+FU14
JPHTA-1 TH1 T°
HTR2
8.25 WATT
-2
THERM
PRIMARY
HTR1
HANDLE
VM
JPC24-12 JPG1-1 GGC
HGG_CNTRL_PWM (50A)
+12VP
JPC20-8 -2 TP1 TP6 1 2 JPHGG-1
JPC22-7 -6
HGG_FAULT HTR5
HGG_CONTACTOR
JPC24-2 -4 FU10 HEATED
JPC10-3 -5 GLASS
THERM_EN B+
-2
HGG_CNTRL
7 HGG_CONTACTOR
Y
GGC
X
B- B+FU14
TP4
AR1004765_G3C.EPS
Figure A-7. Model 7400/7420/7440 Options (All Series) Electrical Schematic (Sheet 3 of 3)
1026304B, 15 July 2007 A-23
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Options (All Series) Electrical Schematics
Model 74xx Options (All Series)
G H
2
CLOGGED FILTER SWITCH
2
S19
1
JPC22-3
VM
FILTER
JPF3-12
B-FU6
FUSE/
RELAY
CARD
JPF2-9
3 BUMP DETECTOR
JPS7-1
RED JPS10-4 SPL-1
VM
BUMP
YELLOW -1 JPC24-16
BUMP
DETECT YELLOW -2 -5
DGND
PURPLE -5 JPC22-2
BUMP STATUS
BLUE -6 JPC24-8
DGND
BLACK -3 JPS7-4
JPF1-4
WARNING LIGHT & STROBE LIGHT
FU11
WL
(10A) JPW5-2 BLACK +
SPL-1 - WHITE
4 JPW5-1
TP4
AUX. POWER (BATTERY) AUX. POWER (KEY)
RELAY RELAY
JPF1-4 JPF1-4
CONTROL CONTROL
FUSE FUSE
JPF4-15 PANEL JPF2-9 PANEL
OR
2 1 2 1
B- B+ B- B+
TS1 TS1
5
WORKING LIGHTS & FAN
36V
LIGHT
JPW1-1 S20 JPW1-2
36V
S21 LIGHT
JPW2-1 JPW2-2
36V
FU12
TP1 JPW3-1 S22 FAN JPW3-2
(10A)
+ -
TP4
6
HIGH SPEED TRAVEL SWITCH
VM JPC20-3 JPS6-1 +
+12VP
JPC22-4 -2 0 S25
HS TRAVEL SW
-3 -
JPF3-11
B-FU6
FUSE/
RELAY
CARD
AR1004765_G3R.EPS
Figure A-8. Model 7400/7420/7440 Options (All Series) Electrical Schematic (Sheet 3 of 3)
A-24 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Electrical Schematics Model 74xx Options - Vantage Point
Model 74xx Options - Vantage Point
Vantage Point System
Multiplexer
C1-1 Video Out
-2 Video Shield
-3 +12 VDC
-4
Camera GND
JPVS8-1 JPVS4-1 JPVS3-1 C2-1 MON-1 JPVS5-1
Video Out Video Out Video Out
-2 -2 -2 -2 -2 -2
Video Shield Video Shield Video Shield
-3 -3 -3 -3 -3 -3
+12 VDC +12 VDC +12 VDC
-4 -4 -4 -4 -4 -4
GND GND GND
OTM Cable C3-1 Video Out
-2 Video Shield
-3 +12 VDC
-4 GND
Display Unit
AUX Power
Monitor Power Supply Connection
JPVS2-1 JPVS1-1
+16 V +16 V +Vin B+ Key
-2 -2
GND GND Power GND B-
JPVS5-1
-3 -3
Video Out Camera 1 Select Camera 1 Select Camera 1 Select
-4 -4
-2 Video Shield Camera 2 Select Camera 2 Select Camera 2 Select
-5 -5
-3 +12 VDC Camera 3 Select Camera 3 Select Camera 3 Select
-6 -6
-4 GND Toggle Toggle Toggle
-7 -7
No Function No Function No Function
-8 -8
Not Connected Not Connected Not Connected
JPVT1-1
AD20011355_A1.EPS D20011355_A2.EPS
Figure A-9. Model 7400/7420/7440 Options (All Series) Electrical Schematic (Vantage Point)
1026304B, 15 July 2007 A-25
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Legend Electrical Schematics
Model 74xx Legend
AR1004765_G4L.EPS
Figure A-10. Model 7400/7420/7440 Electrical Schematic Legend (Page 1 of 3)
A-26 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Electrical Schematics Model 74xx Legend
Model 74xx Legend
AR1004765_G4C.EPS
Figure A-11. Model 7400/7420/7440 Electrical Schematic Legend (Page 2 of 3)
1026304B, 15 July 2007 A-27
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Legend Electrical Schematics
Model 74xx Legend
Figure A-6 through
Figure A-8
AR1004765_A4R.EPS
Figure A-12. Model 7400/7420/7440 Electrical Schematic Legend (Page 3 of 3)
A-28 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Power Distribution Diagrams Model 74xx Legend
Power Distribution Diagrams
Turn to next page for power distribution
diagrams.
1026304B, 15 July 2007 A-29
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Series CA/FA (AC lift) (Page 1 of 2) Power Distribution Diagrams
Model 74xx Series CA/FA (AC lift) (Page 1 of 2)
TP1
TP2 TP3 TP5
JPB+ + FU1 FU3 FU2
(150A) (500A) (350A)
1 1
STR LPC TPC
2 2
Y X X
STR LPC TPC
X Y Y
JPS1-9 JPS1-8
JPC18-11
JPS1-11
JPS1-10 CD
JPL1-2 JPT1-2
STR-2 + LPC + TPC
CONTACTOR CONTACTOR
MS-A1 U U JPC20-12
+ U U
A1
V V SOL
SA MS
LM V LA TM V TA CD 3
W W JPC20-13
W W
A2 - JPC20-20
MS-A2 B+K3 - B+K3 -
TP4 SOL
JPL1-1
CD 5B
JPB-
- JPT1-1 JPC20-19
JPB- JPC20-18
TP4
JPF2-1
JPF1-6 JPF3-3 JPC14-10
-4 -2 DGND SOL
CD 5T
JPF3-1 JPF3-5 JPC14-1 JPC20-17
-2 FU6 -6 -8
-7 -9 JPC20-16
B-F
(15A) (PGND)
JPF1-1 SOL
-2 FU8
JPF1-4
CD 2
JPS7-4 JPC20-15
(15A/5A)
TS1-2 JPS10-3
JPF4-3 JPF4-15
FU7 JPS10-5
-4 K1
TS1-1
(15A/5A) JPF2-9
JPF4-1 JPS10-1
-2 FU5 K3
TS1-1
SPL-1
(15A) JPF4-5
-12
JPS10-4
2 EPO 1
K4 K3 K2 K1
JPC18-15 JPS3-5
-8 CD
-10 S1
KEY SWITCH
K2 K4 -14 -4
R2 R1 CD
JPC14-6
-13
CD
JPF2-4 -7
-12 -3
-6 -13 CD
-7 -14
-5 JPC18-10
SOL1 CD
2 1
TRAVEL (OPTL) TRAVEL
LIGHT ALARM JPC18-16
CD
- + (OPTL)
JPTL-1 TS2-3
JPTL-2 1 2
JPC18-18 REACH
FU9 CD
H
10A 2 JPF2-8 JPS3-1 TS2-1 1 2 -4
SIDE
SHIFT
HRN
-2 H-2 -POS
JP510-1 1 2 -5
-IN TILT
H
SPL-6 H-1
-3 JPS2-2
-NEG
FU11
WL
SPL-1 (10A) JPW5-2 BLACK WHITE JPBR-1 JPS2-1 JPC20-14
+ -
BRAKE
WARNING LT OR
STROBE LT (OPTL) CD
JPW5-1
JPBR-2
FAN-T
36V JPB1-1 JPB1-2 JPC18-17
+ -
FAN CD
FU12 JPW3-1 S22 JPW3-2
+ -
FAN-FW
JPB2-1 JPB2-2
(10A) + -
S21 LIGHT
JPW2-1 JPW2-2
FAN-FW2
36V JPB4-1 JPB4-2
+ -
LIGHT
JPW1-1 S20 JPW1-2
FAN-DU
36V JPB3-1 JPB3-2
+ -
ARD20003899_A1L.EPS
Figure A-13. Model 7400/7420/7440 Series CA/FA (AC lift) (Page 1 of 2)
A-30 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Power Distribution Diagrams Model 74xx Series CA/FA (AC lift) (Page 2 of 2)
Model 74xx Series CA/FA (AC lift) (Page 2 of 2)
LEGEND
IDENT. DESCRIPTION
BRAKE ELECTRIC BRAKE
COIL DRIVER CIRCUIT
CD EMERGENCY POWER OFF
EMERGENCY POWER OFF
EPO COIL DRIVER CIRCUIT
FAN-FW2 SECOND DASH PLATE COOLING FAN
FAN-T TRACTION AMPLIFIER COOLING FAN
FAN-FW DASH PLATE COOLING FAN
FAN-DU TRACTION MOTOR COOLING FAN
FU1 POWER FUSE FOR STEER
FU2 POWER FUSE FOR TRAVEL
FU3 POWER FUSE FOR LIFT
FU5 CONTROL FUSE FOR VEHICLE MANAGER B+ 15A
FU6 CONTROL FUSE FOR VEHICLE MANAGER B- 15A
FU7 CONTROL FUSE FOR AUX. POWER B+ 15A/5A
FU8 CONTROL FUSE FOR AUX. POWER B- 15A/5A
FU9 CONTROL FUSE FOR TRAVEL LIGHT & ALARM 10A
FU11 CONTROL FUSE FOR WARNING LIGHT & STROBE 10A
FU12 CONTROL FUSE FOR WORKING LIGHTS & FAN 10A
H (HRN) HORN
H2 TRAVEL ALARM
JPB BATTERY CONNECTOR
JPB1 CONNECTOR FOR FAN-T
JPB2 CONNECTOR FOR FAN-FW
JPB3 CONNECTOR FOR FAN-DU
JPB4 CONNECTOR FOR FAN-FW2
JPBR BRAKE CONNECTOR
JPC14 B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM
JPC18 COIL DRIVERS CONNECTOR ON VM
JPC20 PROPORTIONAL COIL DRIVERS ON VM
JPF1 B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY CARD
JPF2 B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD
JPF3 B- CONNECTOR ON FUSE/RELAY CARD
JPF4 KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/RELAY CARD
JPL1 LIFT POWER AMP CONNECTOR
JPS1 CONTACTOR PANEL INTERFACE CONNECTOR
JPS2 DRIVE UNIT INTERFACE CONNECTOR
JPS3 OVER THE MAST CABLE INTERFACE CONNECTOR
JPS7 EXTERNAL CAN COMMUNICATIONS INTERFACE CONNECTOR
JPS10 BUMP DETECTOR INTERFACE CONNECTOR
JPT1 TRACTION AMP CONNECTOR
JPTL CONNECTOR FOR TRAVEL LIGHT
JPW1 CONNECTOR FOR WORKING LIGHT
JPW2 CONNECTOR FOR WORKING LIGHT
JPW3 CONNECTOR FOR OPERATOR FAN
JPW5 CONNECTOR FOR WARNING LIGHT & STROBE
K1 KEYSWITCH RELAY-OPTIONS
K2 KEYSWITCH RELAY-SOLENIODS, ATTACHMENTS, HORN
K3 KEYSWITCH RELAY, POWER AMPS
K4 KEYSWITCH RELAY-HEATERS
LA LIFT POWER AMPLIFIER
LM AC LIFT MOTOR
LPC LIFT POWER CONTACTOR
MS STEER PUMP MOTOR
REACH REACH SOLENOID
S1 KEY SWITCH
S20 WORKING LIGHT SWITCH
S21 WORKING LIGHT SWITCH
S22 OPERATOR COOLING FAN SWITCH
SA AUX. MOTOR POWER AMPLIFIER
SIDESHIFT SIDE SHIFT SOLENOID
SOL1 LOAD/HOLD SOLENOID
SOL2 LIFT/LOWER PROPORTIONAL SOLENOID
SOL3 PROPORTIONAL DUMP SOLENOID
SOL5B SOLENOID FOR AUX. OIL DIRECTION CONTROL
SOL5T SOLENOID FOR AUX. OIL DIRECTION CONTROL
SPL-1 SPLICE FOR WARNING & STROBE LIGHT
SPL-6 SPLICE FOR TRAVEL LIGHT & ALARM
STR STEER POWER CONTACTOR
TA TRACTION POWER AMPLIFIER
TILT SOLENOID FOR TILT
TM AC TRACTION MOTOR
TP1 TIE POINT ON B+
TP2 TIE POINT ON AUXILIARY MOTOR FUSE
TP3 TIE POINT ON LIFT MOTOR FUSE
TP4 TIE POINT ON B-
TP5 TIE POINT ON TRACTION MOTOR FUSE
TPC TRACTION POWER CONTACTOR
TS1 TERMINAL STRIP AUX POWER
TS2 TERMINAL STRIP CARRIAGE FUNCTIONS
WL WARNING LIGHT
ARD20003899_A1R.EPS
Figure A-14. Model 7400/7420/7440 Series CA/FA (AC lift) (Page 2 of 2)
1026304B, 15 July 2007 A-31
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Series AA/BA/DA/EA (DC Lift) (1 of 2) Power Distribution Diagrams
Model 74xx Series AA/BA/DA/EA (DC Lift) (1 of 2)
TP1
JPB+
X
Y 1
1 TPC
TPC
STR STR 2
2
Y
X JPS1-11 JPC18-11
CD
FU2
(350A)
FU1 FU3
(150A) (500A) JPS1-8
Y
TP2 -9
1 -9
LPC CD
LPC
2
X
HORN
-NEG
-IN H-1 -16
H CD
JPT1-2 H-2
-POS
A1 + +
+ TP6
A1
JPS1-10 U
MS U
A2 V
A2 -
LM TM V TA
W
W
JPS2-2
B- B+K3
- S1
JPB- TP4
JPT1-1
JPF2-1 JPF2-2 JPF1-6 JPBR2-2 JPBR-1 JPS2-1 JPC20-14
BRAKE CD
JPF3-3 JPC14-10
-4 -2
DGND
JPF3-1 JPF3-5 JPC14-1
-2 FU6 -6 -8
-7 -9 B-F (PGND)
JPC20-16
(15A) JPF4-13 -6
CD
SOL
CD 2
JPF1-1 2 1 JPC20-15
JPF2-5 SOL JPC18-1
-2 FU8 CD
4
R2 R1 JPC20-18
(15A/5A)
2 1 -10
SOL SOL
JPF4-3
1
CD CD 5T
-4 FU7 K1 K3 K2 K1 JPC20-17
JPF4-5
(15A/5A) JPC20-20
JPF4-1 -12
-2 FU5 K3
-8
2 EPO 1 CD SOL
5B
K4
JPC20-19
(15A) -10 S1
K2
K4 JPF2-6 KEY SWITCH JPC14-13 JPC20-12
-7 -14 B+K2
-4 -7 CD SOL
8
TS1-1 B+K4 JPC20-13
JPF2-3 JPF2-8
-2
-1 FAN-DU JPC18-15
JPB3-1 JPB3-2 CD
JPF4-15 JPF1-4 JPF2-9 + -
TRAVEL (OPTL)
LIGHT FAN-FW2
JPB4-1 JPB4-2
- + + -
JPTL-1 -14
JPTL-2
FAN-LM JPC18-17 CD
JPB5-1 JPB5-2
FU9 + - CD
TRAVEL
H
10A 2
ALARM FAN-FW
(OPTIONAL) JPB2-1 JPB2-2
+ -
-12
JPC18-18 CD
JP510-1 JPS3-1 JPB1-1
FAN-T
JPB1-2 CD
+ -
SPL-6
FU11
WL TS2-1 TS2-3
SPL-1 (10A) JPW5-2 BLACK WHITE 1 2 JPS3-3
+ -
REACH
WARNING LT OR
STROBE LT (OPTL)
JPW5-1
1 2 -4 -4
SIDE
36V SHIFT
FU12 JPW3-1 S22 FAN JPW3-2
+ -
1 2 -5 -5
(10A) TILT
S21 LIGHT
JPW2-1 JPW2-2
36V
LIGHT
JPW1-1 S20 JPW1-2
36V
ARD20004161_A1L.EPS
Figure A-15. Model 7400/7420/7440 Series AA/DA (DC single pump lift) Page 1 of 2)
A-32 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Power Distribution Diagrams Model 74xx Series AA/BA/DA/EA (DC lift) (2 of 2)
Model 74xx Series AA/BA/DA/EA (DC lift) (2 of 2)
LEGEND
IDENT. DESCRIPTION
BRAKE ELECTRIC BRAKE
CD COIL DRIVER CIRCUIT
EPO EMERGENCY POWER OFF
FAN-FW2 SECOND DASH PLATE COOLING FAN
FAN-LM LIFT MOTOR COOLING FAN
FAN-T TRACTION AMPLIFIER COOLING FAN
FAN-FW DASH PLATE COOLING FAN
FAN-DU TRACTION MOTOR COOLING FAN
FU1 POWER FUSE FOR STEER
FU2 POWER FUSE FOR TRAVEL
FU3 POWER FUSE FOR LIFT
FU5 CONTROL FUSE FOR VEHICLE MANAGER B+ 15A
FU6 CONTROL FUSE FOR VEHICLE MANAGER B- 15A
FU7 CONTROL FUSE FOR AUX. POWER B+ 15A/5A
FU8 CONTROL FUSE FOR AUX. POWER B- 15A/5A
FU9 CONTROL FUSE FOR TRAVEL LIGHT & ALARM 10A
FU11 CONTROL FUSE FOR WARNING LIGHT & STROBE 10A
FU12 CONTROL FUSE FOR WORKING LIGHTS & FAN 10A
H (HRN) HORN
H2 TRAVEL ALARM
JPB BATTERY CONNECTOR
JPB1 CONNECTOR FOR FAN-T
JPB2 CONNECTOR FOR FAN-FW
JPB3 CONNECTOR FOR FAN-DU
JPB4 CONNECTOR FOR FAN-FW2
JPB5 CONNECTOR FOR FAN-LM
JPBR BRAKE CONNECTOR
JPC14 B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM
JPC18 COIL DRIVERS CONNECTOR ON VM
JPC20 PROPORTIONAL COIL DRIVERS ON VM
JPF1 B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY CARD
JPF2 B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD
JPF3 B- CONNECTOR ON FUSE/RELAY CARD
JPF4 KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/RELAY CARD
JPS1 CONTACTOR PANEL INTERFACE CONNECTOR
JPS2 DRIVE UNIT INTERFACE CONNECTOR
JPS3 OVER THE MAST CABLE INTERFACE CONNECTOR
JPTL CONNECTOR FOR TRAVEL LIGHT
JPT1 TRACTION AMP CONNECTOR
JPW1 CONNECTOR FOR WORKING LIGHT
JPW2 CONNECTOR FOR WORKING LIGHT
JPW3 CONNECTOR FOR OPERATOR FAN
JPW5 CONNECTOR FOR WARNING LIGHT & STROBE
K1 KEYSWITCH RELAY-OPTIONS
K2 KEYSWITCH RELAY-SOLENIODS, ATTACHMENTS, HORN
K3 KEYSWITCH RELAY, POWER AMPS
K4 KEYSWITCH RELAY-HEATERS
LM DC LIFT MOTOR
LPC LIFT POWER CONTACTOR
MS STEER PUMP MOTOR
REACH REACH SOLENOID
S1 KEY SWITCH
S20 WORKING LIGHT SWITCH
S21 WORKING LIGHT SWITCH
S22 OPERATOR COOLING FAN SWITCH
SIDESHIFT SIDE SHIFT SOLENOID
SOL1 LOAD/HOLD SOLENOID
SOL2 LIFT/LOWER PROPORTIONAL SOLENOID
SOL4 SECOND STAGE PUMP SELECT SOLENOID
SOL5B SOLENOID FOR AUX. OIL DIRECTION CONTROL
SOL5T SOLENOID FOR AUX. OIL DIRECTION CONTROL
SOL8 AUX. DUMP SOLENOID
SPL-1 SPLICE FOR WARNING & STROBE LIGHT
SPL-6 SPLICE FOR TRAVEL LIGHT & ALARM
STR STEER POWER CONTACTOR
TA TRACTION POWER AMPLIFIER
TILT SOLENOID FOR TILT
TM AC TRACTION MOTOR
TP1 TIE POINT ON B+
TP2 TIE POINT ON AUXILIARY MOTOR FUSE
TP4 TIE POINT ON B-
TPC TRACTION POWER CONTACTOR
TS1 TERMINAL STRIP AUX POWER
TS2 TERMINAL STRIP CARRIAGE FUNCTIONS
WL WARNING LIGHT
ARD20004161_A1R.EPS
Figure A-16. Model 7400/7420/7440 Series AA/DA (DC single pump lift) Page 2 of 2)
1026304B, 15 July 2007 A-33
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Series AA/BA/DA/EA (DC lift) (2 of 2) Power Distribution Diagrams
A-34 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Hydraulic Schematics
Hydraulic Schematics
Section A. Appendix
Turn to next page for hydraulic schematics.
1026304B, 15 July 2007 A-35
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Series CA/FA (AC lift) (Page 1 of 2) Hydraulic Schematics
Model 74xx Series CA/FA (AC lift) (Page 1 of 2)
NOTE:
FILTER-2 ONLY ON 7420 AND 7440
ARD20000117_C1L.EPS
Figure A-17. Model 7400/7420/7440 Series CA/FA (AC lift) (Page 1 of 2)
A-36 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Hydraulic Schematics Model 74xx Series CA/FA (AC lift) (Page 2 of 2)
Model 74xx Series CA/FA (AC lift) (Page 2 of 2)
SINGLE REACH WITH TILT AND SIDESHIFT
Note: Number and location
of flow limiters can vary.
ARD20000117_C3R1.EPS, D20000117_C3R2.EPS, DX20000117_C2.EPS
Figure A-18. Model 7400/7420/7440 Series CA/FA (AC lift) with Reach/Deep-Reach, Tilt, Sideshift (Page 2 of 2)
1026304B, 15 July 2007 A-37
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Series AA/DA (DC lift) (Page 1 of 2) Hydraulic Schematics
Model 74xx Series AA/DA (DC lift) (Page 1 of 2)
ARD20002287_D2L.EPS
Figure A-19. Model 7400/7420/7440 Series AA/DA (DC single pump lift) (Standard Performance, Page 1 of 2)
A-38 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Hydraulic Schematics Model 74xx Series AA/BA/DA/EA (Page 2 of 2, Single Reach)
Model 74xx Series AA/BA/DA/EA
(Page 2 of 2, Single Reach)
Note: Number and location
of flow limiters can vary.
ARD20002287_D1R.EPS
Figure A-20. Model 7400/7420/7440 AA/BA/DA/EA (Aux, DC Lift, Single Reach, Tilt, Sideshift)
1026304B, 15 July 2007 A-39
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Series BA/EA (DC Lift, Page 1 of 2) Hydraulic Schematics
Model 74xx Series BA/EA (DC Lift, Page 1 of 2)
ARD20002287_D1L.EPS
Figure A-21. Model 7400/7420/7440 BA/EA (DC Lift, High Performance, Page 1 of 2)
A-40 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Hydraulic Schematics Model 74xx Series AA/BA/DA/EA (Page 2 of 2, Deep-Reach ®)
Model 74xx Series AA/BA/DA/EA
(Page 2 of 2, Deep-Reach ®)
Note: Number and location
of flow limiters can vary.
ARD20002287_D2R.EPS
Figure A-22. Model 7400/7420/7440 AA/BA/DA/EA (Aux, DC Lift, Deep-Reach ®, Tilt, Sideshift)
1026304B, 15 July 2007 A-41
Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
Model 74xx Series AA/BA/DA/EA (Page 2 of 2, Deep-Reach ®) Hydraulic Schematics
A-42 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section I. Index
Section I. Index
Numerics Battery
Charging . . . . . . . . . . . . . . . . . . . . 7-115
2d Pump Valve SOL4 Cleaning Exterior . . . . . . . . . . . . . 7-114
Location . . . . . . . . . . . . . .7-145 to 7-146 Connector/Cables . . . . . . . . . . . . . 7-113
Torque . . . . . . . . . . . . . . . . . . . . . .7-153 Gate Inspection . . . . . . . . . . . . . . . 7-108
Maintenance . . . . . . . . . . . . . . . . . 7-115
Roller Inspection . . . . . . . . . . . . . . 7-108
A Safety . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Specifications . . . . . . . . . . . . . . . . . . 3-3
Abbreviations, List of . . . . . . . . . . . . . . 1-5 State-of-Charge (BSOC) . . . . 5-11, 7-115
AC Motor Tests . . . . . . . . . . . . . . . . . 5-10 Configuring . . . . . . . . . . . . . . . . . 6-12
AC Motor Troubleshooting . . . . . . . . . 5-10 Testing . . . . . . . . . . . . . . . . . . . . . 7-115
Acceleration Bearings
Lift, Configuring . . . . . . . . . . . . . . . 6-12 Mast, Shimming . . . . . . . . . . . . . . 7-194
Lower, Configuring . . . . . . . . . . . . . 6-12 Carriage to Inner Tele
Travel, Configuring . . . . . . . . . . . . 6-11 Model 7400 . . . . . . . . . . . . . . 7-241
Acronyms, List of . . . . . . . . . . . . . . . . 1-5 Model 7420 . . . . . . . . . . . . . . 7-254
Active Service Mode . . . . . . . . . . 6-16, 6-18 Model 7440 . . . . . . . . . . . . . . 7-264
Adjustment Inner Tele to Outer Tele
Auxiliary Pressure . . . . . . . 7-130, 7-140 Model 7400 . . . . . . . . . . . . . . 7-240
Lift Pressure . . . . . . . . . . . . . . . . .7-137 Model 7420 . . . . . . . . . . . . . . 7-253
Proportional Valve . . . . . . . . . . . . .7-139 Model 7440 . . . . . . . . . . . . . . 7-263
Reach Cylinder . . . . . . . . . . . . . . .7-181 Outer Tele to Main Frame
Alarm, Travel, Configuring . . . . . . . . 6-11 Model 7400 . . . . . . . . . . . . . . 7-239
Ambient Temperature Sensor (T) . . . .7-112 Model 7420 . . . . . . . . . . . . . . 7-252
AMP Connectors . . . . . . . . . . . . . . . .7-118 Model 7440 . . . . . . . . . . . . . . 7-262
Analog Tests . . . . . . . . . . . .6-121 to 6-150 Reach Carriage . . . . . . . . . . . . . . . 7-193
Summary List . . . . . . . . . . . . . . . .6-119 Bleeding Hydraulic System . . . . . . . . 7-134
See Tests, Analog for Individual Tests Bow Pads . . . . . . . . . . . . . . . . . . . . . 7-196
Anchors, Chain . . . . . . . . . . . . . . . . .7-201 Brake . . . . . . . . . . . . . . . . . . 7-95 to 7-101
Auto Power Off ™Device . . . . . . . . . . . . 6-15 Adjustment . . . . . . . . . . . . . . 7-76, 7-96
Auxiliary Dump Valve SOL8 Application, Theory . . . . . . . . . . . . 8-110
Location . . . . . . . . . . . . . .7-145 to 7-146 Assembly/Disassembly . . . . . . . . . . 7-98
Torque . . . . . . . . . . . . . . . . . . . . . .7-153 Overview . . . . . . . . . . . . . . . . . . . . 8-110
Auxiliary Functions, Troubleshooting 5-19 Pads . . . . . . . . . . . . . . . . . . . . . . . . 7-98
Auxiliary Manifold . . . . . . . . . 7-131, 7-147 Release Screws, Use of . . . . . . . . . 8-110
Auxiliary Motor (DC lift) . . . . . . . . . . .7-108 Release, Theory . . . . . . . . . . . . . . . 8-110
Auxiliary Pressure Adjustment 7-130, 7-140 Theory of Operation . . . . . . . . . . . 8-110
Auxiliary Pump (DC lift) . . . . . . . . . . .7-130 BSOC (Battery State-of-Charge) 5-11, 7-115
Auxiliary Valve SOL5B/5T Configuring . . . . . . . . . . . . . . . . . . . 6-12
Location . . . . . . . . . . . . . .7-141 to 7-146 Setting BSOC Cutout . . . . . . . . . . . 5-12
Torque . . . . . . . . . . . . . . . . 7-152, 7-153 Bump Response, Configuring . . . . . . . 6-14
Backlash, Drive Unit . . . . . . . . . . . . . 7-92
Baseleg . . . . . . . . . . . . . . . . . 7-188, 7-191
1026304B, 15 July 2007 I-1
Section I. Index Model 7400/7420/7440 Reach-Fork ® Truck
C
Main Lift
Cable Installation, Mast 7400 . . . . . . . . . . . . . . . . . . . . . 7-208
Model 7400 . . . . . . . . . . . . . . . . . . 7-242 7420 . . . . . . . . . . . . . . . . . . . . . 7-209
Model 7420 . . . . . . . . . . . . . . . . . . 7-254 7440 . . . . . . . . . . . . . . . . . . . . . 7-210
Model 7440 . . . . . . . . . . . . . . . . . . 7-264 Maintenance . . . . . . . . . . . . . . . . . . 4-25
Cable Removal, Mast Changing Password or SuperWrd . . . . . 6-6
Model 7400 . . . . . . . . . . . . . . . . . . 7-235 Check Valve
Model 7420 . . . . . . . . . . . . . . . . . . 7-247 CV-1
Model 7440 . . . . . . . . . . . . . . . . . . 7-258 Location . . . . . . . . . . . 7-141 to 7-146
Cable, Over-the-Mast . . . . . . . . . . . . 7-220 Torque . . . . . . . . . . . . . .7-152, 7-153
Cable Only Replacement . . . . . . . . 7-230 CV-2
Conversion for Bulk Cable Use . . . 7-229 Location . . . . . . . . . . . 7-145 to 7-146
Cable, Terminology . . . . . . . . . . . . . . 6-115 Torque . . . . . . . . . . . . . . . . . . . 7-153
Card CV-3 . . . . . . . . . . . . . . . . . . . . . . . 7-149
Relay/Control Fuse Panel . . . . . . . 6-117 Location . . . . . . . . . . . . . . . . . . 7-149
Tilt/Sideshift Switch Torque . . . . . . . . . . . . . . . . . . . 7-154
Series AA/BA/CA . . . . . . . . 7-54, 7-55 Circuit Card Connectors . . . . . . . . . 6-116
Series DA/EA/FA . . . . . . . . 7-65, 7-66 Relay/Control Fuse Panel . . . . . . . 6-117
Vehicle Manager . . . . . . . . . . . . . . 6-116 Vehicle Manager . . . . . . . . . . . . . . 6-116
Carriage . . . . . . . . . . . . . . . . . . . . . . 7-198 Cleaning
Bearings . . . . . . . . . . . . . . . . . . . . 7-193 Lift Truck . . . . . . . . . . . . . . . . . 2-4, 2-5
Configuring Reach/Retract . . . . . . . 6-13 Motors . . . . . . . . . . . . . . . . . . . . . . 4-17
Installation into Mast Clock, Setting . . . . . . . . . . . . . . . . . . . 6-15
Model 7400 . . . . . . . . . . . . . . . . 7-242 Clogged Filter Switch CFS-1 . . . . . . . 7-112
Model 7420 . . . . . . . . . . . . . . . . 7-254 Location . . . . . . . . . . . . . 7-141 to 7-146
Model 7440 . . . . . . . . . . . . . . . . 7-264 Torque . . . . . . . . . . . . . . . .7-152, 7-153
Manually Lowering . . . . . . . . . . . . 7-138 Coast Distance, Configuring . . . . . . . . 6-11
Removal from Mast Codes
Model 7400 . . . . . . . . . . . . . . . . 7-235 Fault Codes
Model 7420 . . . . . . . . . . . . . . . . 7-247 See Fault Codes
Model 7440 . . . . . . . . . . . . . . . . 7-258 Power Amplifier . . . . . . . . . . . . . . . . 6-21
Stops . . . . . . . . . . . . . . . . . . . . . . . 7-190 Summary List . . . . . . . . . . . . . . . . . 6-19
Caster Assembly . . . . . . . . . . . . . . . . . 7-45 Cold Storage Conditioning . . . . . . . . 7-127
Height Adjustment . . . . . . . . . . . . . 7-46 Cold Storage, Theory of Operation . . . 8-24
Caster, Steerable . . . . . . . . . . . . . . . . . 7-45 Compensating Element Valve CE1
Height Adjustment . . . . . . . . . . . . . 7-46 Location . . . . . . . . . . . . . 7-145 to 7-146
Caution, Definition . . . . . . . . . . . . . . . .2-2 Torque . . . . . . . . . . . . . . . . . . . . . 7-153
CB1 & CB2 Counterbalance Valve . . . 7-130 Component Locator Photos . . . . 7-7 to 7-21
Location . . . . . . . . . . . . . . . . . . . . 7-149 Configure Mode . . . . . . . . . . . 3-7, 6-4, 6-6
Torque . . . . . . . . . . . . . . . . . . . . . . 7-154 Factory Defaults, Restoring . . . .6-8, 6-11
CE1 Compensating Element Valve Menu Settings . . . . . . . . . . 6-10 to 6-15
Location . . . . . . . . . . . . . 7-145 to 7-146 See also Individual Parameter Name
Torque . . . . . . . . . . . . . . . . . . . . . . 7-153 Connectors
CFS-1 Clogged Filter Switch . . . . . . . 7-112 AMP . . . . . . . . . . . . . . . . . . . . . . . 7-118
Location . . . . . . . . . . . . . 7-141 to 7-146 Circuit Card . . . . . . . . . . . . . . . . . 6-116
Torque . . . . . . . . . . . . . . . . 7-152, 7-153 Molex . . . . . . . . . . . . . . . . . . . . . . 7-117
Chains Relay/Control Fuse Panel . . . . . . . 6-117
Anchors . . . . . . . . . . . . . . . . . . . . . 7-201 Vehicle Manager . . . . . . . . . . . . . . 6-116
Condition-Cause Chart . . . . . . . . . . 4-25 Contactor Panel . . . . . . . . . . . . . . . . 7-121
Free Lift . . . . . . . . . . . . . . . . . . . . . 7-211 Contactor, Steer . . . . . . . . . . . . . . . . . 7-41
I-2 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section I. Index
Control Handle Secondary . . . . . . . . . . . . . 7-24, 7-28
Filler Cover . . . . . . . . . . . . . . 7-25, 7-28 Fore-Aft Stance Covers . . . . 7-28 to 7-30
Fore-Aft Stance Left Front . . . . . . . . . . . . . . . 7-25, 7-27
Primary . . . . . . . . . . . . . 7-49 to 7-58 Removal Sequence . . . . . . . . . . . . . 7-24
Flex Circuit Assembly . . . 7-50, 7-53 Right Front . . . . . . . . . . . . . . 7-25, 7-27
Horn Button . . . . . . . . . . . . . . 7-53 Right Side . . . . . . . . . . . 7-25, 7-28, 7-31
Lift/Lower Potentiometer (VR2) Side Stance Covers . . . . . . . 7-31 to 7-32
. . . . . . . . . . . . . . . . . . . 7-52, 7-55 Steering . . . . . . . . . . . . 7-25, 7-29, 7-32
Pot Heaters . . . . . . . . . . . . . . . . . . . Top . . . . . . . . . . . 7-26, 7-30, 7-31, 7-32
. . . . . 7-50, 7-52, 7-53, 7-55, 7-56 Cushion, Lift Cylinder Lowering
Reach/Retract Buttons . . . . . . 7-53 Free Lift . . . . . . . . . . . . . 7-176 to 7-178
Shell Assembly . . . . . . . . . . . . 7-57 Main Lift . . . . . . . . . . . . . . . . . . . . 7-176
Shell Disassembly . . . . . . . . . . 7-49 Cutout, Lift, Configuring . . . . . . . . . . . 6-12
ThermaKit Heater . . 7-53, 7-54, 7-56 CV-1 Check Valve
Tilt/Sideshift Card . . . . . . . . . 7-53 Location . . . . . . . . . . . . . 7-141 to 7-146
Travel Potentiometer (VR1) 7-50, 7-56 Torque . . . . . . . . . . . . . . . 7-152, 7-153
Secondary . . . . . . . . . . . 7-70 to 7-74 CV-2 Check Valve
Horn Button . . . . . . . . . . . . . . 7-73 Location . . . . . . . . . . . . . 7-145 to 7-146
ThermaKit Heater . . . . . . . . . . . 7-70 Torque . . . . . . . . . . . . . . . . . . . . . 7-153
Travel Potentiometer (VR3) . . . 7-70 CV-3 Check Valve . . . . . . . . . . . . . . . 7-149
Primary, Cover . . . . . . . . . . . . 7-24, 7-28 Location . . . . . . . . . . . . . . . . . . . . 7-149
Secondary, Cover . . . . . . . . . . 7-24, 7-28 Torque . . . . . . . . . . . . . . . . . . . . . 7-154
Side Stance . . . . . . . . . . . . 7-59 to 7-69 Cylinder
Flex Circuit Assembly . . . . . . . . . 7-64 Free Lift . . . . . . . . . . . . . 7-157 to 7-163
Horn Button . . . . . . . . . . . . . . . . 7-64 Exploded Parts Drawings . . . . . . . . . .
Lift/Lower Potentiometer (VR2) . . . . . . . . . . . . . . . . . . . . . . . 7-161 to 7-163
. . . . . . . . . . . . . . . . . . . . . 7-62, 7-66 Lowering Cushion . . . . 7-176 to 7-178
Pot Heaters . . . . . . . . . . . . . . . . . . . . . Model 7400 . . . . . . . . . . 7-235, 7-242
. . . . . . . 7-60, 7-63, 7-64, 7-66, 7-67 Model 7420 . . . . . . . . . . 7-247, 7-254
Reach/Retract Buttons . . . . . . . . 7-64 Model 7440 . . . . . . . . . . 7-258, 7-264
Shell Assembly . . . . . . . . . . . . . . 7-67 Seal Repacking . . . . . . 7-164 to 7-166
Shell Disassembly . . . . . . . . . . . 7-59 Main Lift . . . . . . . 7-156, 7-167 to 7-173
ThermaKit . . . . . . . . . . . . . 7-64, 7-65 Exploded Parts Drawings . . . . . . . . . .
Tilt/Sideshift Card . . . . . . . . . . . 7-64 . . . . . . . . . . . . . . . . . 7-172 to 7-173
Travel Potentiometer (VR1) . 7-60, 7-67 Lowering Cushion . . . . . . . . . . . 7-176
Controls, Learn . . . . . . . . . . . . . . . . . 6-16 Seal Repacking . . . . . . 7-174 to 7-175
Conversion Reach . . . . . . . . . . . . . . . . . . . . . . 7-179
Decimal to Fraction . . . . . . . . . . . . A-11 Adjustment . . . . . . . . . . . . . . . . 7-181
Fraction to Decimal . . . . . . . . . . . . A-11 Tilt . . . . . . . . . . . . . . . . . . . . . . . . 7-182
Metric to Standard . . . . . . . . . . . . . A-14 Cylinder, Main Lift, Lowering Cushion 7-156
Standard to Metric . . . . . . . . . . . . . A-14 CYL-P Pressure Transducer . . . . . . . 7-132
Corrosion Inhibitor, Cold Storage . . .7-127 Location . . . . . . . . . . . . . 7-141 to 7-146
Counterbalance Valve CB1 & CB2 . . .7-130 Torque . . . . . . . . . . . . . . . 7-152, 7-153
Location . . . . . . . . . . . . . . . . . . . . .7-149
Torque . . . . . . . . . . . . . . . . . . . . . .7-154 D
Cover
Control Handle
DC Motor Tests . . . . . . . . . . . . . 5-8 to 5-9
Filler . . . . . . . . . . . . . . . . . 7-25, 7-28
DC Motor Troubleshooting . . . . . . . . . . 5-8
Primary . . . . . . . . . . . . . . . 7-24, 7-28
Deadman
Pedal Assembly . . . . . . . . . . 7-76, 7-102
Sensor VR4 . . . . . . . . . . . . . 7-76, 7-102
Switch S2 . . . . . . . . . . . . . . . . . . . 7-102
1026304B, 15 July 2007 I-3
Section I. Index Model 7400/7420/7440 Reach-Fork ® Truck
Decals and Plates . . . . . . . . . . 7-33 to 7-37 Disassembly . . . . . . . . . . . . . . . . 7-86
Deceleration Troubleshooting . . . . . . . . . . . . . . . 7-81
Lift, Configuring . . . . . . . . . . . . . . . 6-12 Drive Wheel and Tire . . . . . . . . . . . . . 7-78
Lower, Configuring . . . . . . . . . . . . . 6-12
Decimal to Fraction Conversion . . . . .A-11 E
Deep-Reach
Reach Manifold . . . . . . . . . . . . . . . 7-149
Electric Steering Motor (AC Lift) . . . . . 7-41
Tilt/Sideshift Manifold . . . . . . . . . . 7-151
Electrical Codes
Design, Manual . . . . . . . . . . . . . . . . . . .1-3
See Fault Codes
Diagnostic Mode
Electrical Schematics . . . . . . . A-17 to A-28
See Service Mode
Legend . . . . . . . . . . . . . . . . . . . . . . A-26
Digital Input Tests . . . . . . . . . . . . . . 6-151
Options (All Series) . . . . . . . . . . . . . A-22
Summary List . . . . . . . . . . . . . . . . 6-119
Series AA/BA/DA/EA (DC Lift) . . . . A-20
See Tests, Input for Individual Tests
Series CA/FA (AC Lift) . . . . . . . . . . . A-18
Digital Output Tests . . . . . . 6-183 to 6-203
Electrical Tests . . . . . . . . . 6-119 to 6-206
Summary List . . . . . . . . . . . . . . . . 6-119
Summary List . . . . . . . . . . . . . . . . 6-119
See Tests, Output for Individual Tests
See also Tests Analog, Tests Input,
Display, Operator . . . . . . . . . . . . 3-6, 7-40
and Tests Output
Software Release Changes . . . . . . . . .6-3
Electrical Troubleshooting
Troubleshooting . . . . . . . . . . . . . . . 5-32
Guidelines . . . . . . . . . . . . . . . . . . . . 5-3
Drive Motor . . . . . . . . . . . . . . . . . . . . . 7-77
Symptoms . . . . . . . . . . . . . 5-31 to 5-35
FlashWare for Manufacturer
Electronic Operator Key . . . . 3-7, 6-5, 6-14
Selection . . . . . . . . . . . . . . . . . . . 7-272
Electrostatic Discharge
Power Cable Terminal Nuts . . . . . . 7-122
See Static Precautions
Speed Sensor (Danaher) . . . . . . . . 7-124
Embedded Statistics, Configuring . . . . 6-14
Temperature Sensor TMT . . . . . . . 7-123
Encoder
Drive Unit . . . . . . . . . . . . . . . . 7-79 to 7-94
AC Motor Speed (Danaher) . . . . . . 7-124
Assembly . . . . . . . . . . . . . . . 7-87 to 7-94
Height (HTI/HI) . . . . . . . . . . . . . . . 7-214
Helical Gear . . . . . . . . . . . . . . . . . 7-90
Steering (AC Lift) . . . . . . . . . . . . . . . 7-43
Output Shaft . . . . . . . . . . . . . . . . 7-88
Energy Saving Mode, Configuring . . . . 6-15
Pivot Ring . . . . . . . . . . . . . . . . . . 7-92
English Units, Configuring Display for 6-13
Spiral Pinion . . . . . . . . . . . . . . . . 7-87
Entering a Password or SuperWrd . . . . 6-6
Backlash Measurement . . . . . . . . . . 7-92
EPO Switch . . . . . . . . . . . . . . . . . . . . 7-40
Disassembly . . . . . . . . . . . . 7-83 to 7-87
Error Log . . . . . . . . . . . . . . . . . .6-16, 6-17
Output Shaft . . . . . . . . . . . . . . . . 7-84
Error Messages
Pivot Ring . . . . . . . . . . . . . . . . . . 7-83
Fault Codes
Spiral Pinion . . . . . . . . . . . . . . . . 7-86
See Fault Codes
Exploded Parts Diagram . . . . . . . . . 7-79
Power Amplifier . . . . . . . . . . . . . . . . 6-21
Helical Gear Assembly . . . . . . . . . . . 7-90
Summary List . . . . . . . . . . . . . . . . . 6-19
Installation . . . . . . . . . . . . . . . . . . . 7-94
ES Mode, Configuring . . . . . . . . . . . . 6-15
Output Shaft
ESD
Assembly . . . . . . . . . . . . . . . . . . . 7-88
See Static Precautions
Disassembly . . . . . . . . . . . . . . . . . 7-84
ESD Ground Jack . . . . . . . . . . . . . . . . 2-9
Pivot Ring
ESD Strap . . . . . . . . . . . . . . . . . . . . 7-111
Assembly . . . . . . . . . . . . . . . . . . . 7-92
Disassembly . . . . . . . . . . . . . . . . . 7-83
Removal . . . . . . . . . . . . . . . . . . . . . 7-82 F
Shim Formulas . . . . . . . . . . . . . . . . 7-90
Shim Installation . . . . . . . . . . . . . . . 7-91 Factory Default Configure Settings 6-8, 6-11
Spiral Pinion
Assembly . . . . . . . . . . . . . . . . . . . 7-87
I-4 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section I. Index
Fan
Drive Motor (FAN-T) . . . . . . . . . . . .7-109 Code 59 – CAN Transmission Buffer Error
Lift Motor (FAN-L) . . . . . . . . . . . . .7-109 for BUS_I . . . . . . . . . . . . . . . . . . . 6-45
Traction Power Amplifier (FAN-2) . .7-109 Code 5A – CAN Bus Error/Vehicle Manager
Tractor Compartment Cooling (FAN) 7-109 for BUS_I . . . . . . . . . . . . . . . . . . . 6-46
Fault Codes . . . . . . . . . . . . . .6-21 to 6-113 Code 5B – CAN Receive Bus Error/Vehicle
Code 12 – Bump Detect . . . . . . . . . 6-22 Manager . . . . . . . . . . . . . . . . . . . . 6-47
Code 1H – Traction Power Amplifier Code 5G – No Communications Received
Overheated . . . . . . . . . . . . . . . . . 6-23 from Traction Power Amplifier . . . . 6-48
Code 1T – Battery Low . . . . . . . . . . 6-24 Code 5J – No Communication from Lift Power
Code 1V – Lift Power Amplifier Amplifier Series CA/FA (AC lift) . . . 6-49
Overheated . . . . . . . . . . . . . . . . . 6-25 Code 5M – Traction Power Amplifier CAN
Code 2A – Traction Motor Approaching Watchdog Timeout . . . . . . . . . . . . 6-50
Overtemperature . . . . . . . . . . . . . 6-26 Code 5P – Lift Power Amplifier CAN Watchdog
Code 2C – Traction Power Amplifier Timeout Series CA/FA (AC lift) . . . 6-51
Temperature Sensor Out-of-Range 6-27 Code 5Q – Display Manager
Code 2E – Traction Motor Temperature Not Responding . . . . . . . . . . . . . . 6-52
Sensor Out-of-Range . . . . . . . . . . 6-28 Code 5R – Secondary CAN Bus Error for
Code 2H – Failure Detected in Traction BUS_E . . . . . . . . . . . . . . . . . . . . . 6-53
Motor Feedback Encoder . . . . . . . 6-29 Code 5T – No CAN Message
Code 2M – Traction Power Amplifier From Any Node . . . . . . . . . . . . . . . 6-54
Failed . . . . . . . . . . . . . . . . . . . . . 6-30 Code 61 – Mast Switch #1 Not Crossed 6-55
Code 2P – Traction Power Amplifier Code 62 – Lift Power Amplifier Reverted
Reverted to Default Parameters . . 6-31 to Default Parameters . . . . . . . . . . 6-56
Code 2T – Traction Power Amplifier Code 63 – First and Second Speed Limiting
Current Calibration Error . . . . . . 6-32 Switches Do Not Agree . . . . . . . . . 6-57
Code 2U – Traction Power Amplifier Code 64 – No Pulses Seen from Height
Fault - Overcurrent . . . . . . . . . . . 6-33 Indicator Encoder . . . . . . . . . . . . . 6-58
Code 2V – Traction Power Amplifier Code 66 – Calculated Height Greater Than
Fault - High DC Voltage . . . . . . . . 6-34 Configured Height . . . . . . . . . . . . . 6-60
Code 42 – Lift Contactor Detected Closed Code 67 – Calculated Height Does Not Match
When Commanded Open . . . . . . . 6-35 First Speed Limiting Switch (S12) . 6-61
Code 43 – Lift Contactor Detected Open, Code 6D – Pressure Sensor
Low DC Voltage After Power-Up . . 6-36 Out-of-Range . . . . . . . . . . . . . . . . 6-62
Code 44 – TPC Contactor Detected Closed Code 6F – Lift Motor Overheated . . . 6-63
When Commanded Open . . . . . . . 6-37 Code 6G – Lift Motor Temperature Sensor
Code 45 – TPC Contactor Detected Open, Out-of-Range . . . . . . . . . . . . . . . . 6-64
Low DC Voltage After Power-Up . . 6-38 Code 6S – Lift Power Amplifier Temperature
Code 4B – Steer Contactor Detected Closed Sensor Out-of-Range,
When Commanded Open . . . . . . . 6-39 Series CA/FA (AC lift) . . . . . . . . . . 6-65
Code 4C – Steer Contactor Detected Open Code 6T – Lift Power Amplifier Current
When Commanded Closed . . . . . . 6-40 Calibration Error,
Code 4D – No Charging Traction DC Input Series CA/FA (AC lift) . . . . . . . . . . 6-66
Voltage During Start-Up . . . . . . . 6-41 Code 6U – Excessive Lift Motor Brush Wear,
Code 4E – No Charging Lift DC Input Voltage Series AA/BA/DA/EA (DC lift) . . . 6-67
During Start-Up, Code 6V – Lift Power Amplifier Failure,
Series CA/FA (AC lift) . . . . . . . . . 6-42 Series CA/FA (AC lift) . . . . . . . . . . 6-68
Code 57 – VM Not Responding to Code 6W – Failure Detected in Lift Motor
Operator Display . . . . . . . . . . . . . 6-43 Feedback Encoder,
Code 58 – OCSS CAN Failure . . . . . 6-44 Series CA/FA (AC lift) . . . . . . . . . . 6-69
1026304B, 15 July 2007 I-5
Section I. Index Model 7400/7420/7440 Reach-Fork ® Truck
Code 6X – Lift Power Amplifier Fault - Code F4 – Vehicle Manager COP Time-out
Overcurrent, Series CA/FA (AC lift) 6-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Code 6Y – Lift Power Amplifier Fault - High Code F5 – Bad Op Code . . . . . . . . . 6-97
DC Voltage, Series CA/FA (AC lift) . 6-71 Code F8 – Vehicle Manager COP
Code 6Z – FlashWare Parameters Do Not Not Enabled . . . . . . . . . . . . . . . . . 6-98
Match Stored Values . . . . . . . . . . . 6-72 Code FE – Vehicle Manager
Code 80 – Primary Throttle Potentiometer Not Calibrated . . . . . . . . . . . . . . . 6-99
Out-of-Range . . . . . . . . . . . . . . . . 6-73 Code FG – 5 and/or 12 Volt Power Supply
Code 81 – Lift Potentiometer Out-of-Range . . . . . . . . . . . . . . . 6-100
Out-of-Range . . . . . . . . . . . . . . . . . 6-74 Code FH – Battery Voltage Out-of-Range
Code 83 – Primary Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
Out-of-Neutral-Zone . . . . . . . . . . . 6-75 Code FN – VM Did Not Power Off . . 6-102
Code 84 – Brake inoperable . . . . . . . 6-76 Code FP – VM Hardware Failure . . 6-103
Code 88 – 5-volt Power Supply Code FR – VM Config Item Out-of-Range
Out-of-Range . . . . . . . . . . . . . . . . 6-77 . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104
Code 8A – Operator Compartment Sensor Code FT – VM Internal Software Related
System Failure . . . . . . . . . . . . . . . 6-78 Failure . . . . . . . . . . . . . . . . . . . . 6-105
Code 8C – Deadman Pedal Signals Code FV – Display Internal Software Related
Do Not Agree . . . . . . . . . . . . . . . . . 6-79 Failure . . . . . . . . . . . . . . . . . . . . 6-106
Code 8F – Lift Throttle Out-of-Neutral-Zone Code G0 – Steer Tiller 1 Channel A/B Fault,
. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80 Series CA/FA (AC lift) . . . . . . . . . 6-107
Code 8G – Secondary Throttle Potentiometer Code G3 – Steer Feedback Proximity Sensor
Out-of-Range . . . . . . . . . . . . . . . . 6-81 fault, Series CA/FA (AC lift) . . . . 6-108
Code 8H – Secondary Throttle Potentiometer Code G4 – Open Detected in Steer Control
Out-of-Neutral-Zone . . . . . . . . . . . 6-82 Circuit, Series CA/FA (AC lift) . . . 6-109
Code 8J – Ambient Temperature Sensor Code G5 – Short Detected in Steer Motor
Out-of-Range . . . . . . . . . . . . . . . . 6-83 Encoder Circuit,
Code 8K – Deadman Sensor Out-of-Range Series CA/FA (AC lift) . . . . . . . . . 6-110
. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84 Code G7 – Steer Tiller 2 Channel A/B Fault,
Code 8L – Brake Feedback Current Series CA/FA (AC lift) . . . . . . . . . 6-111
Out-of-Range . . . . . . . . . . . . . . . . 6-85 Code GD – Open Detected in Steer Motor
Code 8M – Internal Handle Heater Failure Encoder Circuit,
. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86 Series CA/FA (AC lift) . . . . . . . . . 6-112
Code 8N – Optional Start Switch Code GE – Steer Encoder Failure . 6-113
Closed at Start-Up . . . . . . . . . . . . . 6-87 Power Amplifier . . . . . . . . . . . . . . . . 6-21
Code A0 – Incorrect Software For Summary List . . . . . . . . . . . . . . . . . 6-19
Proper Lift Truck Operation . . . . . . 6-88 Filter, Clogged Filter Switch CFS-1 . . 7-112
Code AH – Bad Operator Display Location . . . . . . . . . . . . . 7-141 to 7-146
Checksum . . . . . . . . . . . . . . . . . . . 6-89 Torque . . . . . . . . . . . . . . . .7-152, 7-153
Code AJ – Bad VM Flash Memory . . 6-90 Filter, Hydraulic . . . . . . . . . . . . . . . . 7-135
Code AK – Bad VM RAM Memory . . . 6-91 Location . . . . . . . . . . . . . 7-141 to 7-146
Code AL – Bad Battery Backed-Up Torque . . . . . . . . . . . . . . . .7-152, 7-153
VM RAM Memory . . . . . . . . . . . . . 6-92 Firmware
Code AM – Bad Operator Display Flash Displaying Version . . . . . . . . . . 6-4, 6-9
Memory . . . . . . . . . . . . . . . . . . . . . 6-93 FlashWare . . . . . . . . . . . . . . . . . . 7-271
Code AN – Malfunctioning Matching VM and DM . . . . . . . . . . 7-272
Operator Display . . . . . . . . . . . . . . 6-94 Release Changes . . . . . . . . . . . . . . . . 6-2
Code EH – Invalid Interrupt - FlashWare . . . . . . . . . . . . . . . . . . . . 7-271
Operator Display . . . . . . . . . . . . . . 6-95 Flex Circuit Assembly
Fore-Aft Stance . . . . . . . . . . . .7-50, 7-53
Side Stance . . . . . . . . . . . . . . . . . . . 7-64
I-6 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section I. Index
Flow Limiter Horn Button
Free Lift . . . . . . . . . . . . . . . . . . . . .7-185 Fore-Aft Stance
Torque . . . . . . . . . . . . . . . . . . . .7-154 Primary . . . . . . . . . . . . . . . . . . . . 7-53
Main Lift . . . . . . . . . . . . . . . . . . . .7-184 Secondary . . . . . . . . . . . . . . . . . . 7-73
Fork Inspection . . . . . . . . . . . . . . . . .7-213 Side Stance . . . . . . . . . . . . . . . . . . . 7-64
Fraction to Decimal Conversion . . . . . A-11 Hose
Free Lift Cylinder . . . . . . . .7-157 to 7-163 Free Lift . . . . . . . . . . . . . . . . . . . . 7-234
Exploded Parts Drawings .7-161 to 7-163 Installation, Mast
Model 7400 . . . . . . . . . . . . 7-235, 7-242 Model 7400 . . . . . . . . . . . . . . . . 7-242
Model 7420 . . . . . . . . . . . . 7-247, 7-254 Model 7420 . . . . . . . . . . . . . . . . 7-254
Model 7440 . . . . . . . . . . . . 7-258, 7-264 Model 7440 . . . . . . . . . . . . . . . . 7-264
Seal Repacking . . . . . . . .7-164 to 7-166 Main Lift . . . . . . . . . . . . . . . . . . . . 7-219
Fuse Panel . . . . . . . . . . . . . . . . . . . .7-111 Over-the-Mast . . . . . . . . . . 7-189, 7-220
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Removal, Mast
Model 7400 . . . . . . . . . . . . . . . . 7-235
G Model 7420 . . . . . . . . . . . . . . . . 7-247
Model 7440 . . . . . . . . . . . . . . . . 7-258
Hour Meters . . . . . . . . . . . . . . 4-2, 6-4, 6-9
Gates, Battery, Inspection . . . . . . . . .7-108
HTI
Grease Fittings
Belt Replacement . . . . . . . . . . . . . 7-214
See Lubrication Points
Codes and Tests
Ground Jack, ESD . . . . . . . . . . . . . . . 2-9
Code 66 . . . . . . . . . . . . . . . . . . . . 6-60
Grounded DC Motor Test . . . . . . . . . . 5-9
Test I26 . . . . . . . . . . . . . . . . . . . 6-169
Test I42 . . . . . . . . . . . . . . . . . . . 6-176
H Test I86 . . . . . . . . . . . . . . . . . . . 6-182
Guard for Freezer Application . . . . 7-109
Harness Pressure Switch . . . . . . . . . . . . . . 7-111
Inspection . . . . . . . . . . . . . . . . . . .7-116 Location . . . . . . . . . . . 7-141 to 7-146
Repair . . . . . . . . . . . . . . . . . . . . . .7-116 Torque . . . . . . . . . . . . . . 7-152, 7-153
Soldering Procedures . . . . . . . . . . .7-116 Hung-Up Carriage, Lowering . . . . . . . 7-138
Terminology . . . . . . . . . . . . . . . . . .6-115 Hydraulic Filter . . . . . . . . . . . . . . . . 7-135
Heater Location . . . . . . . . . . . . . 7-141 to 7-146
Control Handle Torque . . . . . . . . . . . . . . . 7-152, 7-153
Fore-Aft Stance Hydraulic Fluid Capacity . . . . . . . . . 7-131
Potentiometers . . . . . . . . . . . . . . . . Hydraulic Manifold
. . . . . 7-50, 7-52, 7-53, 7-55, 7-56 See Manifold
ThermaKit . . . . 7-53, 7-54, 7-56, 7-70 Hydraulic Schematics . . . . . . . A-35 to A-41
Side Stance Series AA/BA/DA/EA (DC Lift) . . . . . . .
Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-38 to A-39
. . . . . 7-60, 7-63, 7-64, 7-66, 7-67 Series CA/FA (AC Lift) . . . . . A-36 to A-37
Height Encoder Belt . . . . . . . . . . . . .7-214 Hydraulic Solenoid
Height-Tilt Indicator See Valve
See HTI Hydraulic Steering Motor (DC lift) . . . . 7-40
Helical Gear Assembly, Drive Unit . . . 7-90 Hydraulic System
Horn . . . . . . . . . . . . . . . . . . . . . . . . .7-109 Bleeding . . . . . . . . . . . . . . . . . . . . 7-134
Switch Functional Operation
Fore-Aft Stance See Theory of Operation,
Primary . . . . . . . . . . . . . . . . . . 7-53 Lift/Aux System
Secondary . . . . . . . . . . . . . . . . 7-73 Troubleshooting
Side Stance . . . . . . . . . . . . . . . . 7-64 Guidelines . . . . . . . . . . . . . . . . . . 5-13
Test 018 . . . . . . . . . . . . . . . . . . .6-195 Symptoms . . . . . . . . . . . . 5-19 to 5-28
Test I15 . . . . . . . . . . . . . . . . . . .6-163
1026304B, 15 July 2007 I-7
Section I. Index Model 7400/7420/7440 Reach-Fork ® Truck
I Lift/Lower System
Theory of Operation . . . . . 8-25 to 8-109
Inertial Dampener . . . . . . . . . . 7-78, 7-103 Troubleshooting . . . . . . . . . . . . . . . 5-25
Input Tests . . . . . . . . . . . . . . . . . . . . 6-151 Lift/Lower Valve SOL2
Summary List . . . . . . . . . . . . . . . . 6-119 Location . . . . . . . . . . . . . 7-141 to 7-146
See Tests, Input for Individual Tests Torque . . . . . . . . . . . . . . . .7-152, 7-153
Limit Switch, Steer S11 (AC Lift) . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 7-41, 7-44, 7-111
J Linkage, Steering . . . . . . . . . . . . . . . . 7-48
Load Holding Valve SOL1
Jacking Safety . . . . . . . . . . . . . . . . . . 2-11 Location . . . . . . . . . . . . . 7-141 to 7-146
Torque . . . . . . . . . . . . . . . .7-152, 7-153
L Load Shuttle LS-1
Location . . . . . . . . . . . . . 7-141 to 7-146
Learn Function . . . . . . . . . . .3-7, 6-4, 6-16 Torque . . . . . . . . . . . . . . . .7-152, 7-153
Controls . . . . . . . . . . . . . . . . . . . . . 6-16 Locator Photos
Weight . . . . . . . . . . . . . . . . . . . . . . . 6-16 Components . . . . . . . . . . . . . 7-7 to 7-21
Lift Acceleration, Configuring . . . . . . . 6-12 Lubrication Points . . . . . . . 4-18 to 4-24
Lift Chains Scheduled Maintenance . . . 4-12 to 4-16
See Chains Loctite®
Lift Cutout, Configuring . . . . . . . . . . . 6-12 See Thread Adhesives
Lift Cylinder Loop Back Tests . . . . . . . . . 6-204 to 6-206
Free Lift . . . . . . . . . . . . . . 7-157 to 7-163 Lower Acceleration, Configuring . . . . . 6-12
Exploded Parts Drawings Lower Deceleration, Configuring . . . . . 6-12
. . . . . . . . . . . . . . . . . . 7-161 to 7-163 Lower Function
Model 7400 . . . . . . . . . . 7-235, 7-242 Speed, Configuring . . . . . . . . . . . . . 6-12
Model 7420 . . . . . . . . . . 7-247, 7-254 Theory of Operation
Model 7440 . . . . . . . . . . 7-258, 7-264 Series AA/BA/DA/EA . . . . . . . . . 8-86
Main Lift . . . . . . . 7-156, 7-167 to 7-173 Series CA/FA . . . . . . . . . . . . . . . 8-32
Exploded Parts Drawings . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . 5-27
. . . . . . . . . . . . . . . . . . 7-172 to 7-173 Lowering Carriage Manually . . . . . . . 7-138
Lift Deceleration, Configuring . . . . . . . 6-12 LS-1 Load Shuttle
Lift Function Location . . . . . . . . . . . . . 7-141 to 7-146
Theory of Operation Torque . . . . . . . . . . . . . . . .7-152, 7-153
Series AA/BA/DA/EA . . . . . . . . . 8-75 Lubrication Points . . . . . . . . . 4-18 to 4-24
Series CA/FA . . . . . . . . . . . 8-27, 8-62 Lubrication Specification Chart . . . . . . A-2
Troubleshooting . . . . . . . . . . . . . . . 5-25
Lift Hose . . . . . . . . . . . . . . . . . . . . . . 7-219 M
Lift Limit Cutout, Configuring . . . . . . . 6-12
Lift Motor . . . . . . . . . . . . . . . . . . . . . 7-109 Main Lift Cylinder . .7-156, 7-167 to 7-173
AC Lift Motor Temperature Sensor Exploded Parts Drawings 7-172 to 7-173
LMT . . . . . . . . . . . . . . . . . . . . . . 7-123 Seal Repacking . . . . . . . . 7-174 to 7-175
DC Lift Motor Temperature Sensor 7-112 Main Manifold . . . . . . . . . . . . . . . . . 7-132
Lift Power Amplifier (AC Lift) . . . . . . . 7-110 AC Lift, Model 7400 . . . . . . . . . . . 7-141
Software Release Changes . . . . . . . . .6-3 AC Lift, Model 7420/7440 . . . . . . . 7-143
Lift Pressure Adjustment . . . . . . . . . . 7-137 DC Lift . . . . . . . . . . . . . . . . . . . . . 7-145
Lift Pump . . . . . . . . . . . . . . . . . . . . . 7-131 Maintenance Minder ™ Tool . . . . . . .4-3, 6-14
Lift/Lower Potentiometer (VR2) Maintenance Mode
Fore-Aft Stance . . . . . . . . . . . 7-52, 7-55 See Service Mode
Side Stance . . . . . . . . . . . . . . 7-62, 7-66 Manifold
Auxiliary . . . . . . . . . . . . . . .7-131, 7-147
Main . . . . . . . . . . . . . . . . . . . . . . . 7-132
I-8 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section I. Index
AC Lift, Model 7400 . . . . . . . . . .7-141 Meters, Hour . . . . . . . . . . . . . 4-2, 6-4, 6-9
AC Lift, Model 7420/7440 . . . . .7-143 Metric to Standard Conversion . . . . . . A-14
DC Lift . . . . . . . . . . . . . . . . . . . .7-145 Metric Units, Configuring Display for . 6-13
Reach (DR only) . . . . . . . . . . . . . . .7-149 Modes of Operation . . . . . . 3-76-4 to 6-18
Tilt/Sideshift (DR only) . . . . . . . . .7-151 Overview . . . . . . . . . . . . . . . . . . 3-7, 6-4
Manual Design . . . . . . . . . . . . . . . . . . 1-3 Program . . . . . . . . . . . . . . . 3-7, 6-4, 6-5
Manual Lowering of Carriage . . . . . . .7-138 Configure . . 3-7, 6-4, 6-6, 6-10 to 6-15
Map, Navigating the Manual . . . . . . . . 1-2 Restoring Factory Defaults 6-8, 6-11
Mast Hour Meters . . . . . . . . . . . . . 6-4, 6-9
Model 7400 Serial Number . . . . . . . . . . . . 6-4, 6-9
Assembly . . . . . . . . . . .7-239 to 7-246 Service . . . . . . . . . 3-7, 6-4, 6-16, 6-17
Disassembly . . . . . . . . .7-235 to 7-238 Active . . . . . . . . . . . . . . . 6-16, 6-18
Main Lift Chain Installation . . . .7-240 Error Log . . . . . . . . . . . . 6-16, 6-17
Main Lift Chain Removal . . . . . .7-236 Learn . . . . . . . . . . . . . 3-7, 6-4, 6-16
Mating Tractor to Mast . . . . . . . .7-245 Controls . . . . . . . . . . . . . . . . 6-16
Separation of Telescopics . . . . . .7-237 Weight . . . . . . . . . . . . . . . . . 6-16
Separation of Tractor and Mast .7-235 Static . . . . . . . . . . . . . . . . . . . . 6-17
Model 7420 Version . . . . . . . . . . . . . . . . . 6-4, 6-9
Assembly . . . . . . . . . . .7-252 to 7-257 Run . . . . . . . . . . . . . . . . . . . . . 3-7, 6-4
Disassembly . . . . . . . . .7-247 to 7-251 Tones . . . . . . . . . . . . . . . . . . . . . . 6-5
Main Lift Chain Installation . . . .7-253 Molex Connectors . . . . . . . . . . . . . . . 7-117
Main Lift Chain Removal . . . . . .7-249 Motors . . . . . . . . . . . . . . . . . . . 5-8 to 5-10
Mating Tractor to Mast . . . . . . . .7-257 AC Motor Tests
Separation of Telescopics . . . . . .7-250 Open Winding . . . . . . . . . . . . . . . 5-10
Separation of Tractor and Mast .7-247 Shorted Winding Test . . . . . . . . . 5-10
Model 7440 AC Speed Sensor (Danaher) . . . . . . 7-124
Assembly . . . . . . . . . . .7-262 to 7-269 Auxiliary (DC Lift) . . . . . . . . . . . . . 7-108
Disassembly . . . . . . . . .7-258 to 7-261 Cleaning . . . . . . . . . . . . . . . . . . . . . 4-17
Main Lift Chain Installation . . . .7-263 DC Motor Tests
Main Lift Chain Removal . . . . . .7-259 Grounded Motor Test . . . . . . . . . . . 5-9
Mating Tractor to Mast . . . . . . . .7-269 Open Circuit Test . . . . . . . . . . . . . 5-8
Separation of Telescopics . . . . . .7-259 Drive . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Separation of Tractor and Mast .7-258 Lift . . . . . . . . . . . . . . . . . . . . . . . . 7-109
Shimming . . . . . . . . . . . . . . . . . . .7-194 Power Cable Terminals . . . . . . . . . 7-122
Types . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Steering Electric . . . . . . . . . . . . . . . 7-41
Mast Bearing Shimming Temperature Sensor . . . . . 7-112, 7-123
Carriage to Inner Tele Troubleshooting . . . . . . . . . . . . . . . 5-31
Model 7400 . . . . . . . . . . . . . . . .7-241 AC . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Model 7420 . . . . . . . . . . . . . . . .7-254 DC . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Model 7440 . . . . . . . . . . . . . . . .7-264 Types (AC) . . . . . . . . . . . . . . . . . . . . 5-10
Inner Tele to Outer Tele Types (DC) . . . . . . . . . . . . . . . . . . . . 5-8
Model 7400 . . . . . . . . . . . . . . . .7-240
Model 7420 . . . . . . . . . . . . . . . .7-253 O
Model 7440 . . . . . . . . . . . . . . . .7-263
Outer Tele to Main Frame
OCSS
Model 7400 . . . . . . . . . . . . . . . .7-239
Fault Code 58 CAN Failure . . . . . . . 6-44
Model 7420 . . . . . . . . . . . . . . . .7-252
FlashWare . . . . . . . . . . . . . . . . . . . 7-272
Model 7440 . . . . . . . . . . . . . . . .7-262
Installation and Maintenance
Messages and Codes
Instructions . . . . . . . . . 7-275 to 7-293
Fault Codes
Test I80 – Upper Beam . . . . . . . . . 6-178
See Fault Codes
Test I81 – Lower Beam . . . . . . . . . 6-180
Power Amplifier . . . . . . . . . . . . . . . 6-21
Testing and System Setup . . . . . . . 7-292
1026304B, 15 July 2007 I-9
Section I. Index Model 7400/7420/7440 Reach-Fork ® Truck
Open Circuit DC Motor Test . . . . . . . . .5-8 Side Stance . . . . . . . . . . . . .7-62, 7-66
Open Winding AC Motor Test . . . . . . . 5-10 Travel (VR1)
Operator Compartment Sensor System Fore-Aft Stance . . . . . . . . . .7-50, 7-56
Fault Code 58 CAN Failure . . . . . . . 6-44 Side Stance . . . . . . . . . . . . .7-60, 7-67
Installation and Maintenance Travel (VR3)
Instructions . . . . . . . . . 7-275 to 7-293 Fore-Aft Stance, Secondary . . . . . 7-70
Test I80 – Upper Beam . . . . . . . . . 6-178 Power Amplifier
Test I81 – Lower Beam . . . . . . . . . . 6-180 LED Diagnostics . . . . . . . . . . . . . . . 6-21
Testing and System Setup . . . . . . . 7-292 Lift (AC Lift) . . . . . . . . . . . . . . . . . 7-110
Operator Display . . . . . . . . . . . . . 3-6, 7-40 Software Release Changes . . . . . . . . 6-3
Software Release Changes . . . . . . . . .6-3 Steer (AC Lift) . . . . . . . . . . . . . . . . . 7-41
Troubleshooting . . . . . . . . . . . . . . . 5-32 Traction . . . . . . . . . . . . . . . . . . . . 7-110
Operator Key, Electronic . . . .3-7, 6-5, 6-14 Power Cables, Motor . . . . . . . . . . . . . 7-122
Orbitrol, Steering (DC Lift) . . . . . . . . . 7-42 Power Distribution Diagrams . A-29 to A-33
Output Tests . . . . . . . . . . . . 6-183 to 6-203 Series AA/BA/DA/EA (DC Lift) . . . . A-32
Summary List . . . . . . . . . . . . . . . . 6-119 Series CA/FA (AC Lift) . . . . . . . . . . . A-30
See Tests, Output for Individual Tests Preset Lift Heights, Configuring . . . . . 6-15
Outrigger Pressure Adjustment
See Baseleg Auxiliary . . . . . . . . . . . . . . .7-130, 7-140
Over-the-Mast Hose . . . . . . . . . . . . . 7-189 Lift . . . . . . . . . . . . . . . . . . . . . . . . 7-137
Over-the-Mast Hose/Cable . . . . . . . . 7-220 Pressure Switch, HTI
Cable Only Replacement . . . . . . . . 7-230 Location . . . . . . . . . . . . . 7-141 to 7-146
Conversion for Bulk Cable Use . . . 7-229 Torque . . . . . . . . . . . . . . . .7-152, 7-153
Retainer Upgrade . . . . . . . . . . . . . . 7-227 Pressure Transducer CYL-P . . . . . . . 7-132
Location . . . . . . . . . . . . . 7-141 to 7-146
P Torque . . . . . . . . . . . . . . . .7-152, 7-153
Primary Control Handle . . . . . 7-49 to 7-58
Priority-on-Demand Valve POD-1
Page Revision Record . . . . . . . . . . . . . . . v
Location . . . . . . . . . . . . . 7-141 to 7-144
Passwords
Torque . . . . . . . . . . . . . . . . . . . . . 7-152
Changing Password or SuperWrd . . . .6-6
Product Improvement Notices Included viii
Configuring . . . . . . . . . . . . . . . . . . . 6-14
Program Mode . . . . . . . . . . . . 3-7, 6-4, 6-5
Electronic Operator Key . . .3-7, 6-5, 6-14
Menu Settings . . . . . . . . . . . 6-9 to 6-16
Entering Password or SuperWrd . . . .6-6
See also Individual Parameter Name
Password . . . . . . . . . . . . . .3-7, 6-5, 6-14
Proportional Valve Adjustment . . . . . 7-139
SuperWrd . . . . . . . . . . . . .3-8, 6-5, 6-14
Pulleys, Over-the-Mast . . . . . . . . . . . 7-190
Pin Extraction
Pump
AMP Connectors . . . . . . . . . . . . . . 7-118
Auxiliary (DC Lift) . . . . . . . . . . . . . 7-130
Molex Connectors . . . . . . . . . . . . . 7-117
Lift . . . . . . . . . . . . . . . . . . . . . . . . 7-131
Pin Insertion
AMP Connectors . . . . . . . . . . . . . . 7-119
Molex Connectors . . . . . . . . . . . . . 7-117 R
Pinout Matrix . . . . . . . . . . . 8-113 to 8-134
Pivot Ring, Drive Unit Ram
Assembly . . . . . . . . . . . . . . . . . . . . . 7-92 See Cylinder
Disassembly . . . . . . . . . . . . . . . . . . 7-83 Reach Carriage
POD-1 Priority-on-Demand Valve See Carriage
Location . . . . . . . . . . . . . 7-141 to 7-144 Reach Cylinder . . . . . . . . . . . . . . . . . 7-179
Torque . . . . . . . . . . . . . . . . . . . . . . 7-152 Adjustment . . . . . . . . . . . . . . . . . . 7-181
Potentiometer Reach Function
Lift/Lower (VR2) Configuring Speed . . . . . . . . . . . . . 6-13
Fore-Aft Stance . . . . . . . . . 7-52, 7-55 Theory of Operation
Series AA/BA/DA/EA . . . . . . . . . 8-92
I-10 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section I. Index
Series CA/FA . . . . . . . . . . . . . . . 8-44 S
Troubleshooting . . . . . . . . . . . . . . . 5-23
Reach Manifold (DR) . . . . . . . . . . . . .7-149 Safety
Reach Speed, Configuring . . . . . . . . . 6-13 Battery . . . . . . . . . . . . . . . . . . . . . . . 2-6
Reach Valve Decals . . . . . . . . . . . . . . . . . 7-33 to 7-37
Location Definitions of Warning and Caution . . 2-2
Deep-Reach . . . . . . . . . . . . . . . .7-149 ESD . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Single Reach . . . . . . . . . . . . . . . .7-147 General . . . . . . . . . . . . . . . . . . 2-3 to 2-5
Torque . . . . . . . . . . . . . . . . . . . . . .7-154 Jacking . . . . . . . . . . . . . . . . . . . . . . 2-11
Reach/Retract Buttons Static Precautions . . . . . . . . . . . . . . . 2-9
Fore-Aft Stance . . . . . . . . . . . . . . . 7-53 Tie-Down for Transport . . . . . . . . . . 2-13
Side Stance . . . . . . . . . . . . . . . . . . 7-64 Welding . . . . . . . . . . . . . . . . . . . . . . 2-14
REL-1 Relief Valve (DC Lift) Scheduled Maintenance
Location . . . . . . . . . . . . . .7-145 to 7-146 180 Days . . . . . . . . . . . . . . . . . . . . . 4-6
Torque . . . . . . . . . . . . . . . . . . . . . .7-153 2000 Deadman Hours . . . . . . . . . . . 4-11
REL-2 Relief Valve (AC Lift) 250 Deadman Hours . . . . . . . . . . . . . 4-5
Location . . . . . . . . . . . . . .7-141 to 7-144 360 Days . . . . . . . . . . . . . . . . . . . . 4-11
Torque . . . . . . . . . . . . . . . . . . . . . .7-152 500 Deadman Hours . . . . . . . . . . . . . 4-6
REL-3 Relief Valve (DR) . . . . . . . . . . .7-132 Chains . . . . . . . . . . . . . . . . . . . . . . 4-25
Location . . . . . . . . . . . . . . . . . . . . .7-149 Charts . . . . . . . . . . . . . . . . . 4-2 to 4-11
Torque . . . . . . . . . . . . . . . . . . . . . .7-154 Guidelines . . . . . . . . . . . . . . . . . . . . . 4-2
Relay/Control Fuse Panel . . . . . . . . .7-111 Initial 90 Days . . . . . . . . . . . . . . . . . 4-5
Circuit Card Connectors . . . . . . . .6-117 Lubrication Points . . . . . . . . 4-18 to 4-24
Relays . . . . . . . . . . . . . . . . . . . . . . . .7-111 Maintenance Minder ™ Tool . . . . . . . . . . 4-3
Relief Valve REL-1 (DC lift) Motor Cleaning . . . . . . . . . . . . . . . . 4-17
Location . . . . . . . . . . . . . .7-145 to 7-146 Photos . . . . . . . . . . . . . . . . . 4-12 to 4-16
Torque . . . . . . . . . . . . . . . . . . . . . .7-153 Schematics
Relief Valve REL-2 (AC lift) Electrical . . . . . . . . . . . . . . . A-17 to A-28
Location . . . . . . . . . . . . . .7-141 to 7-144 Legend . . . . . . . . . . . . . . . . . . . . . A-26
Torque . . . . . . . . . . . . . . . . . . . . . .7-152 Options (All Series) . . . . . . . . . . . A-22
Relief Valve REL-3 (DR) . . . . . . . . . . .7-132 Series AA/BA/DA/EA (DC Lift) . . A-20
Location . . . . . . . . . . . . . . . . . . . . .7-149 Series CA/FA (AC Lift) . . . . . . . . . A-18
Torque . . . . . . . . . . . . . . . . . . . . . .7-154 Hydraulic . . . . . . . . . . . . . . A-35 to A-41
Retract Function Series AA/BA/DA/EA (DC Lift)
Configuring Speed . . . . . . . . . . . . . 6-13 . . . . . . . . . . . . . . . . . . . A-38 to A-39
Theory of Operation Series CA/FA (AC Lift) . . . A-36 to A-37
Series CA/FA . . . . . . . . . . . . . . . 8-50 Power Distribution Diagrams A-29 to A-33
Troubleshooting . . . . . . . . . . . . . . . 5-24 Series AA/BA/DA/EA (DC Lift) . . A-32
Retract Speed, Configuring . . . . . . . . 6-13 Series CA/FA (AC Lift) . . . . . . . . . A-30
Run Mode . . . . . . . . . . . . . . . . . . . 3-7, 6-4 Seal Repacking
Tones . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Free Lift Cylinder . . . . . . 7-164 to 7-166
Main Lift Cylinder . . . . . . 7-174 to 7-175
Sealants, Specifications . . . . . . . . . . . . A-3
Secondary Control Handle . . . 7-70 to 7-74
SelfTest . . . . . . . . . . . . . . . . . . . . . . . . 8-8
1026304B, 15 July 2007 I-11
Section I. Index Model 7400/7420/7440 Reach-Fork ® Truck
Sensor Software
AC Motor Speed (Danaher) . . . . . . . 7-124 Displaying Version . . . . . . . . . . 6-4, 6-9
AC Motor Temperature FlashWare . . . . . . . . . . . . . . . . . . 7-271
(LMT or TMT) . . . . . . . . . . . . . . . . 7-123 Matching VM and DM . . . . . . . . . . 7-272
Ambient Temperature . . . . . . . . . . 7-112 Release Changes . . . . . . . . . . . . . . . . 6-2
DC Lift Motor Temperature . . . . . . 7-112 SOL1 Load Holding Valve
Deadman VR4 . . . . . . . . . . . 7-76, 7-102 Location . . . . . . . . . . . . . 7-141 to 7-146
OCSS Torque . . . . . . . . . . . . . . . .7-152, 7-153
Lower Beam Test I81 . . . . . . . . . 6-180 SOL2 Lift/Lower Valve
Upper Beam Test I80 . . . . . . . . . 6-178 Location . . . . . . . . . . . . . 7-141 to 7-146
Serial Number Torque . . . . . . . . . . . . . . . .7-152, 7-153
Displaying from Program Mode . 6-4, 6-9 SOL3 Proportional Main Relief/Dump Valve
Location on Specification Plate . . . . .3-3 Location . . . . . . . . . . . . . 7-141 to 7-144
Service Bulletins Included . . . . . . . . . . 1-vii Torque . . . . . . . . . . . . . . . . . . . . . 7-152
Service Intervals SOL4 2d Pump Valve
See Scheduled Maintenance Charts Location . . . . . . . . . . . . . 7-145 to 7-146
Service Mode . . . . . . . . 3-7, 6-4, 6-16, 6-17 Torque . . . . . . . . . . . . . . . . . . . . . 7-153
Active Service Mode . . . . . . . . . . . . . 6-18 SOL5B/5T Auxiliary Valve
Static Service Mode . . . . . . . . . . . . . 6-17 Location . . . . . . . . . . . . . 7-141 to 7-146
Shimming Torque . . . . . . . . . . . . . . . .7-152, 7-153
Drive Unit . . . . . . . . . . . . . . . . . . . . 7-90 SOL8 Auxiliary Dump Valve
Mast Bearings . . . . . . . . . . . . . . . . 7-194 Location . . . . . . . . . . . . . 7-145 to 7-146
Carriage to Inner Tele Torque . . . . . . . . . . . . . . . . . . . . . 7-153
Model 7400 . . . . . . . . . . . . . . . 7-241 Soldering Procedures . . . . . . . . . . . . 7-116
Model 7420 . . . . . . . . . . . . . . . 7-254 Solenoid
Model 7440 . . . . . . . . . . . . . . . 7-264 See Valve
Inner Tele to Outer Tele Specification Plate . . . . . . . . . . . . . . . . 3-3
Model 7400 . . . . . . . . . . . . . . . 7-240 Speed
Model 7420 . . . . . . . . . . . . . . . 7-253 Limit Switch 1, Configuring . . . . . . 6-11
Model 7440 . . . . . . . . . . . . . . . 7-263 Limit Switch 2, Configuring . . . . . . 6-11
Outer Tele to Main Frame Lowering, Configuring . . . . . . . . . . . 6-12
Model 7400 . . . . . . . . . . . . . . . 7-239 Reach, Configuring . . . . . . . . . . . . . 6-13
Model 7420 . . . . . . . . . . . . . . . 7-252 Retract, Configuring . . . . . . . . . . . . 6-13
Model 7440 . . . . . . . . . . . . . . . 7-262 Sensor, AC Motor (Danaher) . . . . . 7-124
Shock Absorber Travel, Configuring . . . . . . . . . . . . . 6-11
See Inertial Dampener Speed Sensor, AC Motor (Danaher) . . 7-124
Shorted Winding AC Motor Test . . . . . 5-10 Spiral Pinion, Drive Unit
Shorts to Frame Test . . . . . . . . . . . . . .5-5 Assembly . . . . . . . . . . . . . . . . . . . . 7-87
Sideshift Function Disassembly . . . . . . . . . . . . . . . . . . 7-86
Theory of Operation Standard to Metric Conversion . . . . . . A-14
Series AA/BA/DA/EA . . . . . . . . . 8-98 START Page . . . . . . . . . . . . . . . . . . . . . 1-9
Series CA/FA . . . . . . . . . . . . . . . . 8-56 Static Precautions . . . . . . . . . . . . . . . . 2-9
Troubleshooting . . . . . . . . . . . . . . . 5-22 Static Service Mode . . . . . . . . . . . . . . 6-17
Sideshift Valve Static Strap . . . . . . . . . . . . . . . . . . . 7-111
Location Steer Contactor . . . . . . . . . . . . . . . . . 7-41
Deep-Reach . . . . . . . . . . . . . . . . 7-151 Steer Limit Switch S11 (AC lift) . . . . . . . . .
Single Reach . . . . . . . . . . . . . . . 7-147 . . . . . . . . . . . . . . . . . . . 7-41, 7-44, 7-111
Torque . . . . . . . . . . . . . . . . . . . . . . 7-154 Steer Manager (AC) . . . . . . . . . . . . . 7-126
Steer Power Amplifier (AC lift) . . . . . . . 7-41
Steerable Caster . . . . . . . . . . . . . . . . . 7-45
Height Adjustment . . . . . . . . . . . . . 7-46
I-12 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section I. Index
Steering T
Encoder (AC lift) . . . . . . . . . . . . . . . 7-43
Limit Switch S11 (AC Lift) . . . . . . . . . . . Temperature Sensor
. . . . . . . . . . . . . . . . 7-41, 7-44, 7-111 AC Motor (LMT or TMT) . . . . . . . . . 7-123
Linkage . . . . . . . . . . . . . . . . . . . . . 7-48 Ambient (T) . . . . . . . . . . . . . . . . . . 7-112
Motor, Electric (AC lift) . . . . . . . . . . 7-41 DC Lift Motor . . . . . . . . . . . . . . . . 7-112
Motor, Hydraulic (DC Lift) . . . . . . . 7-40 Terminals, Motor Power Cable . . . . . 7-122
Orbitrol (DC Lift) . . . . . . . . . . . . . . 7-42 Tests
Steer Manager (AC) . . . . . . . . . . . .7-126 AC Motors . . . . . . . . . . . . . . . . . . . . 5-10
Steerable Caster . . . . . . . . . . . . . . 7-45 Analog . . . . . . . . . . . . . . 6-121 to 6-150
Height Adjustment . . . . . . . . . . . 7-46 Test A04 – Primary Throttle
Theory of Operation Potentiometer (VR1) Voltage . . . 6-122
Series AA/BA/DA/EA . . . . . . . . . 8-68 Test A05 – Lift/Lower Potentiometer
Series CA/FA . . . . . . . . . . . . . . . 8-20 Voltage . . . . . . . . . . . . . . . . . . 6-123
Troubleshooting . . . . . . . . . . . . . . . 5-24 Test A08 – Traction Motor Temperature
Wheel . . . . . . . . . . . . . . . . . . . . . . 7-42 . . . . . . . . . . . . . . . . . . . . . . . . 6-124
Stops, Carriage . . . . . . . . . . . . . . . . .7-190 Test A09 – Lift Motor Temperature 6-125
SuperWrd . . . . . . . . . . . . . . 3-8, 6-5, 6-14 Test A10 – Traction Power Amplifier
Changing . . . . . . . . . . . . . . . . . . . . . 6-6 Heatsink Temperature . . . . . . . 6-128
Entering . . . . . . . . . . . . . . . . . . . . . 6-6 Test A11 – Traction Motor
Switch Current . . . . . . . . . . . . . . . . . . 6-129
Clogged Filter (CFS-1) S19 . . . . . . .7-112 Test A13 – Pressure Sensor
Location . . . . . . . . . . . .7-141 to 7-146 Voltage . . . . . . . . . . . . . . . . . . 6-129
Torque . . . . . . . . . . . . . . 7-152, 7-153 Test A14 – Power Supply +12V DC 6-131
Deadman S2 . . . . . . . . . . . . . . . . .7-102 Test A15 – Battery Voltage . . . . . 6-132
First Speed Limit, Configuring . . . . 6-11 Test A19 – Lift Power Amplifier
Horn Heatsink Temperature . . . . . . . 6-133
Fore-Aft Stance Test A20 – Lift Motor Current . . 6-134
Primary . . . . . . . . . . . . . . . . . . 7-53 Test A22 – Primary Traction
Secondary . . . . . . . . . . . . . . . . 7-73 Throttle (VR1) Request . . . . . . . 6-135
Side Stance . . . . . . . . . . . . . . . . 7-64 Test A23 – Lift Throttle (VR2) Request
HTI Pressure S18 . . . . . . . . . . . . . .7-111 . . . . . . . . . . . . . . . . . . . . . . . . 6-136
Location . . . . . . . . . . . .7-141 to 7-146 Test A26 – Travel and Lift/Lower +5V DC
Torque . . . . . . . . . . . . . . 7-152, 7-153 Power Supply . . . . . . . . . . . . . 6-137
Second Speed Limiting, Configuring 6-11 Test A28 – Deadman Inductive Sensor
Steer Limit (AC Lift) S11 7-41, 7-44, 7-111 (VR4) . . . . . . . . . . . . . . . . . . . . 6-138
Tilt/Sideshift Test A29 – Secondary Throttle
Series AA/BA/CA . . . . . . . . 7-54, 7-55 Potentiometer (VR3) Voltage . . . 6-139
Series DA/EA/FA . . . . . . . . 7-65, 7-66 Test A30 – Secondary Traction
UnNested, Configuring . . . . . . . . . . 6-11 Throttle (VR3) Request . . . . . . . 6-140
Symbols, List of . . . . . . . . . . . . . . . . . . 1-5 Test A31 – Solenoid 5T (AUX1)
Symptom Tables Current . . . . . . . . . . . . . . . . . . 6-141
Electrical Symptoms . . . . . 5-31 to 5-35 Test A32 – Solenoid 5B (AUX2)
Hydraulic Functions . . . . . 5-19 to 5-28 Current . . . . . . . . . . . . . . . . . . 6-142
Travel Functions . . . . . . . . 5-29 to 5-30 Test A33 – Aux Dump (SOL3)/ Main Relief
System Card Dump (SOL8) Current . . . . . . . 6-143
See Vehicle Manager Test A34 – Solenoid 2 (Lift/Lower)
Current . . . . . . . . . . . . . . . . . . 6-144
Test A35 – Brake Current . . . . . 6-145
Test A36 – Ambient Temperature
Sensor . . . . . . . . . . . . . . . . . . . 6-146
1026304B, 15 July 2007 I-13
Section I. Index Model 7400/7420/7440 Reach-Fork ® Truck
Test A37 – Steer Power Amplifier Test O00 – Toggle the TPC Contactor
Current . . . . . . . . . . . . . . . . . . 6-147 . . . . . . . . . . . . . . . . . . . . . . . . 6-184
Test A39 – Analog Reference Test O01 – Toggle the STR Contactor
Voltage . . . . . . . . . . . . . . . . . . . 6-148 . . . . . . . . . . . . . . . . . . . . . . . . 6-185
Test A40 – Handle Heater Test O02 – Toggle the LPC Contactor
Reference Voltage . . . . . . . . . . . 6-149 . . . . . . . . . . . . . . . . . . . . . . . . 6-186
Test A41 – Emergency Power Off Test O04 – Toggle Aux1 Directional
(EPO) Switch . . . . . . . . . . . . . . 6-150 (SOL5T) Solenoid . . . . . . . . . . . 6-187
DC Motors . . . . . . . . . . . . . . . .5-8 to 5-9 Test O05 – Toggle Aux2 Directional
Input (SOL5B) Solenoid . . . . . . . . . . 6-188
Test I00 – Deadman Switch (S2) . 6-152 Test O06 – Toggle the Reach Solenoid
Test I01 – Nested Switch (S14) . . 6-153 . . . . . . . . . . . . . . . . . . . . . . . . 6-189
Test I02 – First Speed Limiting Test O07 – Toggle the Tilt
Switch (S12) . . . . . . . . . . . . . . 6-154 Solenoid . . . . . . . . . . . . . . . . . 6-190
Test I06 – Reach Switch (S4) . . . 6-156 Test O08 – Toggle the Sideshift
Test I07 – Retract Switch (S5) . . . 6-157 Solenoid . . . . . . . . . . . . . . . . . 6-191
Test I08 – Tilt Up Switch (S6) . . . 6-158 Test O09 – Aux Dump (SOL3)/
Test I09 – Tilt Down Switch (S7) . 6-159 Main Relief
Test I10 – Sideshift Right Dump (SOL8) Current . . . . . . . 6-192
Switch (S9) . . . . . . . . . . . . . . . 6-160 Test O11 – Toggle the Load Hold (SOL1)
Test I11 – Sideshift Left Solenoid . . . . . . . . . . . . . . . . . 6-193
Switch (S8) . . . . . . . . . . . . . . . 6-161 Test O12 – Ramp the Proportional Lower
Test I14 – Steering Fuse (FU1) . . 6-162 (SOL2) Solenoid . . . . . . . . . . . . 6-194
Test I15 – Horn Switch (S3) . . . . 6-163 Test O18 – Toggle the Horn . . . . 6-195
Test I19 – Drive Motor Test O19 – Audible Alarm . . . . . 6-196
Speed Sensor . . . . . . . . . . . . . . 6-164 Test O20 – Travel Alarm Test . . . 6-197
Test I20 – Lift Motor Speed Sensor 6-165 Test O23 – Toggle Fans . . . . . . . 6-198
Test I23 – CAN Bus Test . . . . . . . 6-166 Test O25 – Toggle the 2d Pump (SOL4)
Test I24 – Steer Feedback Solenoid . . . . . . . . . . . . . . . . . 6-199
Proximity Sensor . . . . . . . . . . . 6-167 Test O28 – Ramp the Lift Power Amplifier
Test I25 – Steer Motor Encoder . . 6-168 . . . . . . . . . . . . . . . . . . . . . . . . 6-200
Test I26 – Height Indicator Test O29 – Ramp the Traction Power
Encoder . . . . . . . . . . . . . . . . . . 6-169 Amplifier . . . . . . . . . . . . . . . . . 6-201
Test I27 – Secondary Horn Test O30 – Toggle the Brake Solenoid
Switch (S10) . . . . . . . . . . . . . . 6-170 . . . . . . . . . . . . . . . . . . . . . . . . 6-202
Test I33 – Steer Tiller Encoder 1 Test O32 – Toggle Relays
Connect Detect . . . . . . . . . . . . 6-171 K1, K2, K3, and K4 . . . . . . . . . 6-203
Test I34 – Steer Tiller Encoder 2 Shorts to Frame . . . . . . . . . . . . . . . . 5-5
Connect Detect . . . . . . . . . . . . 6-172 Summary List . . . . . . . . . . . . . . . . 6-119
Test I35 – Steer Tiller Encoder 1 Theory of Operation
(Channel A & B) . . . . . . . . . . . . 6-173 BSOC . . . . . . . . . . . . . . . . . . . . . . . 5-11
Test I36 – Steer Tiller Encoder 2 Cold Storage . . . . . . . . . . . . . . . . . . 8-24
(Channel A & B) . . . . . . . . . . . . 6-174 Electric Brake . . . . . . . . . . . . . . . . 8-110
Test I39 – Neutral Pulses . . . . . . 6-175 Lift/Aux System . . . . . . . . 8-25 to 8-109
Test I42 – Lift Height . . . . . . . . . 6-176 Series AA/BA/DA/EA . . 8-68 to 8-109
Test I60 – Security Start Switch Lift . . . . . . . . . . . . . . . . . . . . . . 8-75
(option) . . . . . . . . . . . . . . . . . . 6-177 Lower . . . . . . . . . . . . . . . . . . . . 8-86
Test I80 – OCSS Upper Beam Test 6-178 Reach . . . . . . . . . . . . . . . . . . . 8-92
Test I81 – OCSS Lower Beam Test 6-180 Sideshift . . . . . . . . . . . . . . . . . 8-98
Test I86 – Lift Height . . . . . . . . . 6-182 System Components . . . .8-74, 8-92
Loop Back . . . . . . . . . . . . 6-204 to 6-206 Tilt . . . . . . . . . . . . . . . . . . . . . 8-104
Output
I-14 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section I. Index
Series CA/FA . . . . . . . . . 8-25 to 8-67 Torque Chart . . . . . . . . . . . . . . A-6 to A-10
Lift with Aux . . . . . . . . . . . . . . 8-62 Face Seal O-Rings . . . . . . . . . . . . . . . A-5
Lift without Aux . . . . . . . . . . . 8-27 Hydraulic Fittings . . . . . . . . . . . . . . . A-4
Lower . . . . . . . . . . . . . . . . . . . 8-32 Metric (Brass) . . . . . . . . . . . . . . . . . . A-9
Reach . . . . . . . . . . . . . . . . . . . 8-44 Metric (Ferrous) . . . . . . . . . . . . . . . . A-8
Retract . . . . . . . . . . . . . . . . . . 8-50 Solenoid Valves . . . . . . . . 7-152 to 7-154
Sideshift . . . . . . . . . . . . . . . . . 8-56 Standard (Brass) . . . . . . . . . . . . . . . A-10
System Components . . . . . . . . 8-25 Standard (Ferrous) . . . . . . . . . . . . . . A-6
Tilt . . . . . . . . . . . . . . . . . . . . . 8-38 Traction Motor
Pinout Matrix . . . . . . . . . .8-113 to 8-134 See Drive Motor
SelfTest . . . . . . . . . . . . . . . . . . . . . . 8-8 Traction Motor Temperature Sensor
Steering System TMT . . . . . . . . . . . . . . . . . . . . . . . . 7-123
Series AA/BA/DA/EA . . . . . . . . . 8-68 Traction Power Amplifier . . . . . . . . . 7-110
Series CA/FA . . . . . . . . . . . . . . . 8-20 LED Diagnostics . . . . . . . . . . . . . . . 6-21
Traction System . . . . . . . . . . 8-3 to 8-24 Traction System Functional Operation
Battery Connected . . . . . . . . . . . . 8-3 See Theory of Operation, Traction System
Deadman Pedal Depressed . . . . . 8-14 Transducer, Pressure CYL-P . . . . . . . 7-132
Key Switch Turned On . . . . . . . . . 8-8 Location . . . . . . . . . . . . . 7-141 to 7-146
Requesting Travel . . . . . . . . . . . . 8-21 Torque . . . . . . . . . . . . . . . 7-152, 7-153
ThermaKit Transmission
Fore-Aft Stance See Drive Unit
Primary . . . . . . 7-49, 7-53, 7-54, 7-56 Transport, Tie-Down for . . . . . . . . . . . 2-13
Side Stance . . . . . 7-59, 7-64, 7-65, 7-67 Travel Acceleration, Configuring . . . . . 6-11
Thread Adhesives, Specifications . . . . . A-3 Travel Alarm, Configuring . . . . . . . . . . 6-11
Tie-Down for Transport . . . . . . . . . . . 2-13 Travel Functions,
Tilt Cylinder . . . . . . . . . . . . . . . . . . .7-182 Troubleshooting . . . . . . . . . . 5-29 to 5-30
Tilt Function Travel Light . . . . . . . . . . . . . . . . . . . 7-112
Theory of Operation Travel Potentiometer
Series AA/BA/DA/EA . . . . . . . . .8-104 Fore-Aft Stance
Series CA/FA . . . . . . . . . . . . . . . 8-38 Primary (VR1) . . . . . . . . . . 7-50, 7-56
Troubleshooting . . . . . . . . . . . . . . . 5-21 Secondary (VR3) . . . . . . . . . . . . . 7-70
Tilt Valve Side Stance (VR1) . . . . . . . . . 7-60, 7-67
Location Travel Speed Limit
Deep-Reach . . . . . . . . . . . . . . . .7-151 Switch 1, Configuring . . . . . . . . . . . 6-11
Single Reach . . . . . . . . . . . . . . . .7-147 Switch 2, Configuring . . . . . . . . . . . 6-11
Torque . . . . . . . . . . . . . . . . . . . . . .7-154 Travel Speed, Configuring . . . . . . . . . . 6-11
Tilt/Sideshift Troubleshooting
Switch Card Auxiliary Functions . . . . . . . . . . . . . 5-19
Series AA/BA/CA . . . . . . . . 7-54, 7-55 Chains . . . . . . . . . . . . . . . . . . . . . . 4-25
Series DA/EA/FA . . . . . . . . 7-65, 7-66 Dead Lift Truck . . . . . . . . . . . . . . . . 5-33
Tilt/Sideshift Card Drive Unit . . . . . . . . . . . . . . . . . . . . 7-81
Fore-Aft Stance . . . . . . . . . . . . . . . 7-53 Electrical
Side Stance . . . . . . . . . . . . . . . . . . 7-64 Guidelines . . . . . . . . . . . . . . . . . . . 5-3
Tilt/Sideshift Manifold (DR only) . . . .7-151 Symptoms . . . . . . . . . . . . 5-31 to 5-35
Tire, Drive . . . . . . . . . . . . . . . . . . . . . 7-78 End Procedure . . . . . . . . . . . . . . . . 5-18
Tones, Run Mode . . . . . . . . . . . . . . . . 6-5 Fuses . . . . . . . . . . . . . . . . . . . . . . . . 5-7
General Procedure . . . . . . . . 5-15, 5-16
How to Use this Chapter . . . . . . . . . . 5-2
Hydraulic
Guidelines . . . . . . . . . . . . . . . . . . 5-13
1026304B, 15 July 2007 I-15
Section I. Index Model 7400/7420/7440 Reach-Fork ® Truck
Symptoms . . . . . . . . . . . . 5-19 to 5-28 Torque . . . . . . . . . . . . . . . . . . . 7-152
Lift Function . . . . . . . . . . . . . . . . . . 5-25 Proportional, Adjustment . . . . . . . 7-139
Lift/Lower Functions . . . . . . . . . . . . 5-25 Reach
Loop Back Tests . . . . . . . 6-204 to 6-206 Location
Lower Function . . . . . . . . . . . . . . . . 5-27 Deep-Reach . . . . . . . . . . . . . . 7-149
Miscellaneous Procedures . . . . . . . . 5-17 Single Reach . . . . . . . . . . . . . 7-147
Motors . . . . . . . . . . . . . . . . . . . . . . . 5-31 Torque . . . . . . . . . . . . . . . . . . . 7-154
AC . . . . . . . . . . . . . . . . . . . . . . . . 5-10 REL-1 Relief (DC Lift)
DC . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Location . . . . . . . . . . . 7-145 to 7-146
Operator Display . . . . . . . . . . . . . . . 5-32 Torque . . . . . . . . . . . . . . . . . . . 7-153
Pinout Matrix . . . . . . . . . 8-113 to 8-134 REL-2 Relief (AC Lift)
Reach Function . . . . . . . . . . . . . . . . 5-23 Location . . . . . . . . . . . 7-141 to 7-144
Retract Function . . . . . . . . . . . . . . . 5-24 Torque . . . . . . . . . . . . . . . . . . . 7-152
Shorts to Frame Test . . . . . . . . . . . . .5-5 REL-3 Relief (DR) . . . . . . . . . . . . . 7-132
Sideshift Function . . . . . . . . . . . . . . 5-22 Location . . . . . . . . . . . . . . . . . . 7-149
Steering Function . . . . . . . . . . . . . . 5-24 Torque . . . . . . . . . . . . . . . . . . . 7-154
Symptom Tables . . . . . . . . . 5-19 to 5-35 Sideshift
Tilt Function . . . . . . . . . . . . . . . . . . 5-21 Location
Travel Functions . . . . . . . . . 5-29 to 5-30 Deep-Reach . . . . . . . . . . . . . . 7-151
Vantage Point . . . . . . . . . . . 5-34, 7-311 Single Reach . . . . . . . . . . . . . 7-147
Truck Utilization System, Configuring Torque . . . . . . . . . . . . . . . . . . . 7-154
See Embedded Statistics SOL1 Load Holding
Location . . . . . . . . . . . 7-141 to 7-146
U Torque . . . . . . . . . . . . . .7-152, 7-153
SOL2 Lift/Lower
Location . . . . . . . . . . . 7-141 to 7-146
Units, Configuring Display . . . . . . . . . 6-13
Torque . . . . . . . . . . . . . .7-152, 7-153
UnNested Switch, Configuring . . . . . . . 6-11
SOL3 Proportional Main Relief/Dump
Location . . . . . . . . . . . 7-141 to 7-144
V Torque . . . . . . . . . . . . . . . . . . . 7-152
SOL4 2d Pump
Valve . . . . . . . . . . . . . . . . . . 7-152 to 7-154 Location . . . . . . . . . . . 7-145 to 7-146
CB1 & CB2 Counterbalance . . . . . 7-130 Torque . . . . . . . . . . . . . . . . . . . 7-153
Location . . . . . . . . . . . . . . . . . . . 7-149 SOL5B/5T Auxiliary
Torque . . . . . . . . . . . . . . . . . . . . 7-154 Location . . . . . . . . . . . 7-141 to 7-146
CE1 Compensating Element (DC lift) Torque . . . . . . . . . . . . . .7-152, 7-153
Location . . . . . . . . . . . . 7-145 to 7-146 SOL8 Auxiliary Dump
Torque . . . . . . . . . . . . . . . . . . . . 7-153 Location . . . . . . . . . . . 7-145 to 7-146
CV-1 Check Valve Torque . . . . . . . . . . . . . . . . . . . 7-153
Location . . . . . . . . . . . . 7-141 to 7-146 Steering Orbitrol (DC Lift) . . . . . . . . 7-42
Torque . . . . . . . . . . . . . . 7-152, 7-153 Tilt
CV-2 Check Valve Location
Location . . . . . . . . . . . . 7-145 to 7-146 Deep-Reach . . . . . . . . . . . . . . 7-151
Torque . . . . . . . . . . . . . . . . . . . . 7-153 Single Reach . . . . . . . . . . . . . 7-147
CV-3 Check Valve . . . . . . . . . . . . . 7-149 Torque . . . . . . . . . . . . . . . . . . . 7-154
Location . . . . . . . . . . . . . . . . . . . 7-149 Torque Chart . . . . . . . . . 7-152 to 7-154
Torque . . . . . . . . . . . . . . . . . . . . 7-154 Vantage Point
LS-1 Load Shuttle Adjusting the Monitor . . . 7-308 to 7-310
Location . . . . . . . . . . . . 7-141 to 7-146 Electrical Schematic . . . . . . . . . . . . A-25
Torque . . . . . . . . . . . . . . 7-152, 7-153 FlashWare . . . . . . . . . . . . . . . . . . 7-272
POD-1 Priority-on-Demand
Location . . . . . . . . . . . . 7-141 to 7-144
I-16 1026304B, 15 July 2007
Model 7400/7420/7440 Reach-Fork ® Truck Section I. Index
Installation and Maintenance
Instructions . . . . . . . . . .7-294 to 7-311
Testing and System Setup 7-306 to 7-310
Troubleshooting . . . . . . . . . . 5-34, 7-311
Vehicle Manager . . . . . . . . . . . . . . . .7-112
Circuit Card Connectors . . . . . . . .6-116
Software Release Changes . . . . . . . . 6-2
Version, Displaying Software . . . . . 6-4, 6-9
Vertical Hold
FlashWare . . . . . . . . . . . . . . . . . . .7-272
Vertical Hold, Configuring . . . . . . . . . 6-15
VR4 Deadman Sensor . . . . . . . 7-76, 7-102
Warning, Definition . . . . . . . . . . . . . . . 2-2
Weight, Learn . . . . . . . . . . . . . . . . . . 6-16
Welding Safety . . . . . . . . . . . . . . . . . . 2-14
Wheel, Steering . . . . . . . . . . . . . . . . . 7-42
WHLD
Display Format, Configuring . . . . . 6-15
FlashWare . . . . . . . . . . . . . . . . . . .7-272
Weight-Height Configuration Table . . 6-9
Wiring
General . . . . . . . . . . . . . . . . . . . . .7-116
Harness Terminology . . . . . . . . . . .6-115
Inspection . . . . . . . . . . . . . . . . . . .7-116
Repair . . . . . . . . . . . . . . . . . . . . . .7-116
Soldering Procedures . . . . . . . . . . .7-116
Wrist strap, ESD . . . . . . . . . . . . . . . . . 2-9
1026304B, 15 July 2007 I-17
Section I. Index Model 7400/7420/7440 Reach-Fork ® Truck
I-18 1026304B, 15 July 2007
!1026304B!
1026304B
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