Maintenance Manual

Models 7500/7520 Reach-Fork ® Trucks With

The ACR System™

Model Serial Numbers

7500 31,001 and Up
7520

1112860A Issued: 15 Feb 2012

This publication, 1112860A, applies to the Models 7500/7520 Reach-Fork ® Lift Trucks, S/N 31,001
and up, and to all subsequent releases of this product until otherwise indicated in new editions or
bulletins. Changes occur periodically to the information in this publication.

For revision information, see “Document Revision History” on page iii.

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.

©2012 The Raymond Corporation.

The following terms are trademarks of The Raymond Corporation: Raymond, Auto Power Off,
Deep-Reach, Maintenance Minder, Reach-Fork, ThermaKit, iPort, iAlert, iControl, iWarehouse, The
ACR System, and Vantage Point. All other brand and product names are trademarks or registered
trademarks of their respective companies.
Models 7500/7520 Reach-Fork ® Trucks Table of Contents

Table of Contents

Document Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Service Information List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Interactive Electronic Technical Manuals . . . . . . . . . . . . . . . . . . . . . . 1-3
Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Tie-Down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Model Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Truck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
FlashWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Minder ™ Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial 90 Day/250 Deadman Hours (HD) Maintenance . . . . . . . . . . . 4-5
Every 180 Days or 500 HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Every 360 Days or 2000 HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Contactor Tip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Chain Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-15
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . 5-16
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . 5-26
Messages, Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Power Amp LED Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Analog Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Output Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

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Table of Contents Models 7500/7520 Reach-Fork ® Trucks

Special Tools, Decals, and Chassis . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Steering and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
Hydraulic Components, Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 7-107
Mast, Chain, Hose, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Traction System Functional Operation . . . . . . . . . . . . . . . . . . . . . . . 8-2
Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Hydraulic System Functional Operation (AC Lift
Without Regen Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Hydraulic System Functional Operation (AC Lift
With Regen Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Hydraulic System Functional Operation (DC Lift) . . . . . . . . . . . . . . 8-17
Electric Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Component Specific Service/Torque Chart . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Torque Chart - Straight Thread Face Seal O-Rings . . . . . . . . . . . . . . A-8
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Torque Chart - Metric (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

ii Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks

Document Revision History

Revision Date Description of Changes

1112860A 15 Feb 2012 Initial Release

Publication: 1112860, Issued: 15 Feb 2012 iii

 Models 7500/7520 Reach-Fork ® Trucks

Service Information List

The following Service Information documents have been incorporated into this manual.

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

Document Number Subject Date

iv Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 1. How to Use This Manual

Section 1. How to Use This Manual

Publication: 1112860, Issued: 15 Feb 2012 1-1

Section 1. How to Use This Manual Models 7500/7520 Reach-Fork ® Trucks

Manual Design

Manual Design • 7. Component Procedures gives

step-by-step procedures for testing,
removal, installation, and adjustment of
This manual is designed with the following individual truck components. Components
objectives in mind: are grouped by lift truck system.
• provide technical coverage for expected
levels of user expertise To find a component procedure, you may
use one of three methods:
• anticipate your needs and simplify your
decisions regarding maintenance • Look up the component name in the
List of Component Procedures.
• reduce page flipping through a “one-stop
shopping” approach • Find the component in the Component
Locator Photos.
The two-line running page header at the top of • Look up the component name in the
each page tells you: Index.
• Name of the manual (Models 7500/7520 • 8. Theory of Operation explains signal
Reach-Fork ® Trucks) flow within the electrical and hydraulic
• Current chapter title (for example, this systems for various conditions of lift truck
page How to Use This Manual) operation. This section also contains a
detailed connection point table (Pinout
• Current topic (for example, this page
Matrix) designed to assist in testing and
Design of the Manual)
troubleshooting the truck.
This manual consists of the following sections: • Appendix contains reference information
such as torque values, lubricants, and
• 1. How to Use This Manual explains the
standard/metric conversions.
manual format and design as well as
abbreviations and symbols used. • Index lists subjects alphabetically.
• 2. Safety explains warning and caution
notes, general safety rules, and safety
rules for batteries, static electricity,
jacking, and welding.
• 3. Systems Overview includes general lift
truck specifications, programming
instructions, and configuration menu.
• 4. Scheduled Maintenance outlines the
recommended schedule of preventive
services to keep your lift truck working
most efficiently.
• 5. Troubleshooting guides the user from
fault symptoms to a specific sequence of
tests in order to isolate a failing
component.
• 6. Messages, Codes, and Tests lists
operator messages, fault codes and
procedures for running diagnostic tests.

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Models 7500/7520 Reach-Fork ® Trucks Section 1. How to Use This Manual

Interactive Electronic Technical Manuals

Interactive Electronic
Technical Manuals
The electronic version of this document is an
Interactive Electronic Technical Manual (IETM).
IETMs put service and parts information at
your fingertips; no searching for and opening a
second file, or searching for the corresponding
printed manual. IETMs come in sets
(Maintenance and Parts) and are available on
iManuals or from your local authorized
Raymond Sales and Service Center.

To use IETMs:
• Place both PDF files (Maintenance Manual
and Parts Manual) in the same
directory/folder.
• Do NOT rename the files.

Important:
• IETM file names must remain exactly as
they are downloaded, and must reside in
the same folder. Any changes to the file
names, or failure to have the associated
IETM PDF files in the same folder will
disable the interactive capability of the
manuals.
• IETMs require Adobe Reader 9.0 or higher.

Blue colored text in the Maintenance Manual is

“linked” to locations within the same manual.
Clicking on a blue link automatically takes you
to the linked location.

Green colored text in the Maintenance Manual

is “linked” to a specific location in the
corresponding Parts Manual. Clicking on a
green link automatically opens the
corresponding Parts Manual to the appropriate
page.

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Section 1. How to Use This Manual Models 7500/7520 Reach-Fork ® Trucks

Abbreviations and Symbols

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

Term/Symbol Definition Term/Symbol Definition

A Ampere E UL Electric Truck Type

AC Alternating Current Certification Rating with
AGND Analog Ground safeguards against inherent
amp Ampere or amplifier fire and electrical shock
ANSI American National hazards
Standards Institute
EE UL Electric Truck Type
API American Petroleum
Certification Rating where
Institute
electrical equipment is
approx. approximately
completely enclosed
assy assembly
EPO Emergency Power Off
aux auxiliary
ESD Electrostatic Discharge
AWG American Wire Gauge
ESDS Electrostatic Discharge
BSOC Battery State-of-Charge Sensitive

C Celsius or Centigrade F Fahrenheit

CAN Controller Area Network FF Forks-First
CB Counterbalance valve Fork Ld Forks Leading (FF)
CCW Counterclockwise Fork Trl Forks Trailing (TF)
CD Coil Driver ft. foot or feet
CE Compensating Element ft. lb. foot pound(s)
(valve) FR Flow Regulator
cfg configuration FRC Fuse/Relay Card
cm centimeter FU Fuse
COP Computer Operating
GA gauge
Program
gal. gallon or gallons
CS Cold Storage
gm gram(s)
CV Check Valve
Gnd ground
CW Clockwise
HOI Height Only Indicator
DC Direct Current
HTI Height-Tilt Indicator
DdManH Deadman Pedal Hours
HTR Heater
DGND Digital Ground
diam. diameter in. inch or inches
DMM Digital Multi-Meter in. lb. inch pound(s)
DOT US Department of
Transportation JP jack and pin connector
DVM Digital Volt-Meter

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Models 7500/7520 Reach-Fork ® Trucks Section 1. How to Use This Manual

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

K thousand OACH Overall Collapsed Height

KeyH hours with key switch ON OCSS Operator Compartment
kg kilogram(s) Sensor System
kg/cm2 kilograms per square OD Operator Display
centimeter OSHA Occupational Safety and
km/h kilometers per hour Health Association
kPa kiloPascal(s) OTM over-the-mast
oz. ounce(s)
l liter(s)
lb. pound or pounds P pump or lift contactor
LPA Lift Power Amplifier POD Priority On Demand valve
LED Light Emitting Diode pot potentiometer
Lift H Lift Hours psi pounds per square inch
L/H load holding PWM Pulse Width Modulation
L/L lift/lower P/N Part Number
LM Lift Motor
LME Lift Motor Encoder qt. quart
LMT Lift Motor Temp sensor
RAM Random Access Memory
LPA Lift Power Amplifier
Regen regenerative lowering
LPC Lift Power Contactor
REL relief
LR LPA precharge resistor
RF Radio Frequency
LS load shuttle
ROM Read Only Memory
m meter(s) rpm revolutions per minute
mA milliampere R/R reach/retract
mm millimeter
S Switch
MM Maintenance Minder ™
SA Steer Amplifier
mph miles per hour
SAE Society of Automotive
MS steer motor
Engineers
N/A Not Applicable or Not S/N Serial Number
Available SOL Solenoid
N/C Normally Closed spec specification
NLGI National Lubricating Grease SPL Splice
Institute s/s Sideshift
Nm Newton Meter SSL Sideshift Left
N/O Normally Open SSR Standard
Std Sideshift Right
STR Steer Contactor
SWM Supplier Wireless Module

Publication: 1112860, Issued: 15 Feb 2012 1-5

Section 1. How to Use This Manual Models 7500/7520 Reach-Fork ® Trucks

Abbreviations and Symbols

Term/Symbol Definition

temp temperature
TF Tractor-First
TM Traction Motor
TME Traction Motor Encoder
TMT Traction Motor Temp
sensor
TOTAL D Total Distance Traveled
TP Tie Point
TPA Traction Power Amplifier
TPC Traction Power Contactor
TRAC D Traction Distance
TRAC H Traction Hours
TS Terminal Strip
T/S Troubleshoot

UL Underwriters Laboratories
UNC Unified Coarse thread
UNF Unified Fine thread

V Volts
VDC Volts Direct Current
ver. version
VM Vehicle Manager
VR variable resistor

WHLD Weight Height Limit Display

WMM Warehouse Management
Module
wrt with respect to

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

1-6 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 2. Safety

Section 2. Safety

Publication: 1112860, Issued: 15 Feb 2012 2-1

Section 2. Safety Models 7500/7520 Reach-Fork ® Trucks

Definitions

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

Warning means a potentially hazardous

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

Caution means a potentially hazardous

situation exists, which, if not avoided,
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.

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Models 7500/7520 Reach-Fork ® Trucks Section 2. Safety

General Safety

General Safety Operate this lift truck only from the operator’s
position.
6173_002.eps

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.
8b15004d.eps

Before working on this lift truck, always turn

the key switch OFF and disconnect the lift
truck’s battery connector (unless this manual
tells you otherwise).
6173_005.eps

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

6173_003.eps

Do not wear watches, rings, or jewelry when

working on this lift truck.
jewelry.eps

Do not operate this lift truck if it needs repair or

if it is in any way unsafe.
6173_004.eps

Follow the scheduled lubrication, maintenance,

and inspection steps.
schedmnt.eps

Publication: 1112860, Issued: 15 Feb 2012 2-3

Section 2. Safety Models 7500/7520 Reach-Fork ® Trucks

General Safety

Follow exactly the safety and repair instructions Always operate and park this lift truck indoors.
in this manual. Do not take “shortcuts.” 6173_008.eps

8b15008d.eps

Do not wash this lift truck with a hose.

Do not use an open flame near the lift truck. 6173_009.eps

6173_006.eps

Do not add to or modify this lift truck until you

Do not use gasoline or other flammable liquids contact your local Raymond Sales and Service
for cleaning parts. Center to receive written manufacturer
6173_007.eps

approval.
6173_010.eps

Clean up any hydraulic fluid, oil, or grease that

has leaked or spilled on the floor. Do not park this lift truck in a cold storage area
spills.eps

overnight.

2-4 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 2. Safety

Battery Safety

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

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

As a battery is being charged, an

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

serious damage or injury.

Battery electrolyte is a solution of

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

manuals.
25l6s014.eps

Keep the charging area well-ventilated to avoid

hydrogen gas concentration.
Wear personal protective equipment to protect 04g6s058.eps

eyes, face, and skin when checking, handling,

or filling batteries. This equipment includes

Publication: 1112860, Issued: 15 Feb 2012 2-5

Section 2. Safety Models 7500/7520 Reach-Fork ® Trucks

Battery Safety

Turn the key switch OFF before disconnecting when water is added to the cells, or when the
the battery from the lift truck at the battery specific gravity is checked.
connector. Do not break live circuits at the
battery terminals. A spark often occurs at the Make sure the vent holes in the filler plugs are
point where a live circuit is broken. open to allow the gas to escape from the cells.
6173_005.eps 09g6s047.tif

Vent
Hole

Do not lay tools or metal objects on top of the

battery. A short circuit or explosion could
result.
04g6s057.eps

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.
6173_011.eps

Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.

Keep plugs, terminals, cables and receptacles in

good condition to avoid shorts and sparks.
27y7s013.tif

Never plug a battery charger into the lift truck’s

battery connector. Plug the battery charger only
into the battery connector from the battery.
6173_012.eps

Keep filler plugs firmly in place at all times

except when the electrolyte level is checked,

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Models 7500/7520 Reach-Fork ® Trucks Section 2. Safety

Static Precautions

Static Precautions • If you are removing or installing

static-sensitive components, place them
on a correctly grounded anti-static mat.
Electronic circuit boards can contain
• To transport static sensitive components,
Electrostatic Discharge Sensitive (ESDS)
including failed components being
devices.
returned, place the components in an
anti-static bag or box (available from your
Static charges can accumulate from normal
local authorized Raymond dealer).
operation of the lift truck as well as movement
or contact between non-conductive materials
Test the wrist strap and related accessories
(plastic bags, synthetic clothing, synthetic soles
before each use to make sure they are working
on shoes, styrofoam coffee cups, and so forth.)
correctly.
Accumulated static electricity can be
Figure 2-2 shows the components of the
discharged to a circuit board or component by
Raymond anti-static field service kit,
touching the parts. Electrostatic Discharge
P/N 1-187-059. The kit includes a wrist strap,
(ESD) is also possible through the air when a
ground cord and static-dissipative work surface
charged object is placed close to another
(mat). Follow the instructions packaged with
surface at a different electrical potential. Static
the kit.
discharge can occur without seeing or feeling it.
Figure 2-2. Anti-Static Kit with Wrist Strap and Mat
Whenever working on or near ESDS devices, 2mat2.tif

follow these precautions.

• Wear an ESD wrist strap. The wrist strap
should be equipped with a 1 megohm
resistor to dissipate static charges slowly.
• Connect the wrist strap plug to the ground
jack on the lift truck. See Figure 2-1. If
you cannot use the ground jack, connect
the ground clip to an unpainted, grounded
surface on the lift truck frame.

Figure 2-1. ESD Ground Jack Location

7074_004.tif

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

in quantities of 25.

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

available.

Contact your local Raymond dealer for

information.
ESD Ground Jack

• Handle circuit boards by the edges only.

Avoid touching the edge connectors.

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Section 2. Safety Models 7500/7520 Reach-Fork ® Trucks

Jacking Safety

Jacking Safety
Some maintenance procedures require the lift Use extreme care when the lift truck is
truck to be jacked up. To safely jack the truck: jacked up. Never block the lift truck
1. Lower the forks completely. Remove any between the telescopic and the floor.
load. Attach a chain to the top of the mast and
2. Place all controls in neutral. an overhead hoist to stabilize the mast if
jacking more than described in this
3. Block the wheels to prevent movement of procedure. Keep hands and feet clear
the vehicle. while jacking the lift truck. After the lift
4. Turn the key switch OFF and disconnect truck is jacked, place solid blocks or jack
the battery connector. stands beneath it to support it. Do not
5. If possible, stabilize the top of the mast rely on the jack alone to support the lift
with an overhead chain hoist. truck.
6. Before jacking the lift truck, examine the Figure 2-4. Correct Jacking Locations
A-frame down-travel adjustment bolt. See toyrch_t.eps

Figure 2-3. If the bolt is missing, or the Jack only in

hole that it passes through is excessively these areas
worn, the A-frame will not be held in place
when the lift truck is jacked up; the
A-frame could pivot down and allow the
springs to fall out.

Figure 2-3. A-frame Down-Travel Adjustment Bolt

13y7s001.tif
No Jack Area

A-frame Springs

A-frame
To elevate the rear of the lift
Down-Travel truck:
Adjustment Bolt
1. Place the jack in the specified jacking
position. See Figure 2-4.
7. Place the jack under the designated
jacking points. See Figure 2-4. 2. Jack the rear of the lift truck so that the
drive tire is off the floor no more than 2 in.
(50 mm). If you must elevate the drive tire
more than 2 in., attach a suitable capacity
hoist to the lift truck at the overhead
guard.
3. Block the lift truck in place.

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Models 7500/7520 Reach-Fork ® Trucks Section 2. Safety

Jacking Safety

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 in.
(13 mm).
3. Block the lift truck in place.
NOTE: After working on a vehicle, test all
controls and functions to make sure
they operate correctly.

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Section 2. Safety Models 7500/7520 Reach-Fork ® Trucks

Tie-Down for Transport

Tie-Down for Transport

To transport your Raymond Models 7500/7520
Reach-Fork trucks 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 2-5.
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 secures the lift truck to the vehicle
bed and prevents tip-over and forward
or backward movement.
6. Secure the battery according to the battery
manufacturer’s instructions.

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Models 7500/7520 Reach-Fork ® Trucks Section 2. Safety

Welding Safety

Welding Safety
Disconnect the battery before you
attempt to inspect, service, or repair the
lift truck.
Flame cutting or welding on painted 6173_005.eps

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 • Test for shorts to frame as described in

mechanical methods, chemical methods, “Shorts to Frame” on page 5-2. If you find
or a combination of methods. Do flame any shorts, correct them before you weld.
cutting and/or welding only in well
• Clean the area to be welded.
ventilated areas using local exhaust if
necessary. • Protect all lift truck components from
heat, weld spatter, and debris.
04g6s059.eps

• 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.
• Do not weld near electrical components.
• If you must weld near the battery
compartment, remove the battery from the
lift truck.
Before working on this lift truck, make sure
that: • When you are finished welding, re-install
connectors on circuit cards and do all
• Fire protection equipment is nearby. ground tests and electrical inspections
• You know where the nearest eyewash before operating the lift truck.
station is.

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Section 2. Safety Models 7500/7520 Reach-Fork ® Trucks

Welding Safety

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Models 7500/7520 Reach-Fork ® Trucks Section 3. Systems Overview

Section 3. Systems Overview

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Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks

Introduction

Introduction
This manual provides information for
maintenance and repair of Models 7500/7520
Reach-Fork ® trucks by Raymond.

This manual contains the most current and

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

For the latest information on your Raymond lift

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

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Models 7500/7520 Reach-Fork ® Trucks 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.

Figure 3-1. Lift Truck Specification Plate on Tractor

412-843_B.eps

Raymond model Serial number (see Note) Nominal battery voltage

Approximate weight
of lift truck with
Power rating of
heaviest battery
battery
installed, minus load
and operator
Maximum battery
Approximate weight weight for this lift
of lift truck minus truck
battery, load, and
operator Minimum battery
weight for this lift
Load center truck
dimensions

Maximum load Battery weight must

capacity for this lift be between the
truck minimum and
maximum weight

Attachment
information

NOTE: The lift truck serial number can also

also be found:
• on the mast specification plate on the
lower right mast upright
• stamped on the top edge of the rear
bumper, to the left of center

Load Capacity
Always refer to the specification plate on your
lift truck for the correct ratings for your truck.

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Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks

Model Designations

Model Designations
Mast Series
The model number includes the model and the
mast series designation.

Table 3-1. Mast Series Designation

Max Load
Model(s) Mast Forks Carriage
Lowered
3500 lb.
7500 R35TT
(1587 kg)
Standard
4500 lb.
R45TT
7500 (2041 kg)
7520 3200 lbs.
DR32TT Deep-Reach ®
(1451 kg)

Serial Number
The serial number consists of a three-digit
model abbreviation, two-digit year of
manufacture, two letter configuration code, and
five-digit serial number.

The first letter of the configuration code

indicates operator stance:
A = Fore/Aft B = Dockstance C = Sit/Stand

The second letter of the configuration code

indicates type of lift system:
A = DC Lift B = Enhanced DC Lift C = AC Lift
D = AC Lift with High Speed Lift and
Regenerative (Regen) Lower

Table 3-2. Tractor Series Designation

Model Tractor
Lift System Stance
(abbrev.) Series
AA DC motor with single pump
Fore/Aft
AB DC motor with dual pump
BA DC motor with single pump
Dock
BB DC motor with dual pump
750
AC Fore/Aft
AC motor - standard lift
BC Dock
AD Fore/Aft
BD AC motor - high speed lift and Dock
AD regenerative lower Fore/Aft
752
BD Dock

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Models 7500/7520 Reach-Fork ® Trucks Section 3. Systems Overview

Battery Specifications

Battery Specifications
Table 3-3. 36V Battery Specifications
Weight Max
Width (in.) lb. (kg) Hours Amp
Min Max Hours

2000 2300
16.5 930
(908) (1044)

2300 2600
18.5 6 1085
(1044) (1180)

2600 2900
21.5 1240
(1180) (1315)

UL note 583 specifies that a battery should

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

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Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks

Truck Installation

Truck Installation 4. Slowly raise each hoist until there is no

slack in the chains.

Installation procedures must be performed by a

Raymond Certified Dealer Technician to ensure
warranty coverage. While performing step 5, make sure the
hoist attached to the baselegs does not
During installation, a visual and functional lift the cradle off the floor. Also, do not
inspection must be performed. let the chain become slack as this will
allow the truck to drop.
Installation Procedure 5. Continue to slowly lift the hoist attached
NOTE: Two technicians are required for the to the mast and lower the hoist attached to
installation/assembly of this truck. the baselegs until the center of gravity
shifts, causing the weight of the truck to
shift to the hoist attached to the baselegs.
6. Lower the truck with the hoist attached to
the baselegs until it is standing upright on
Place the cradled truck in an open area
the floor.
where it is safe to work.
7. Remove the chain from the baselegs.
• The truck components are heavy, 8. Remove the chain from the upper crosstie
unstable, and difficult to handle. Use of the mast and attach it to the upper
caution when lifting and assembling cross-piece of the cradle.
this truck.
9. Loosen and remove the nuts holding the
• Personnel involved in the installation wooden cradle cross-piece to the mast,
and assembly of this truck should wear then remove the wooden cross-piece.
gloves, safety glasses, steel toe boots,
10. Remove the bolts from the bottom cradle
and a safety helmet.
cross-piece attached to the truck’s rear
• Do NOT remove any banding that bumper.
secures the truck to the cradle or
11. Lift the cradle up and away from the truck
prevents the carriage and telescopics
and lower it to the floor.
from moving until the truck is upright.
12. Carefully remove the strapping securing
the telescopics and carriage.
Uprighting a Cradled Truck
13. Remove the shipping cap and screws on
top of the hydraulic fluid reservoir. Install
Two Hoist Method the breather cap and screen.
NOTE: This procedure requires two chain 14. Check the fluid level of the hydraulic
hoists of suitable weight capacity. reservoir.
1. Position the cradled truck directly beneath 15. Remove the plug from the drive unit and
and parallel to the chain hoist rail. Remove install the dipstick.
the forks from the cradle.
2. Attach one hoist to the upper crosstie of
the mast main frame.
NOTE: Place blocks between the crossties to
avoid bending them.
3. Attach the second hoist to the baselegs.

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Models 7500/7520 Reach-Fork ® Trucks Section 3. Systems Overview

Truck Installation

Hoist and Lift Truck Method 13. Remove the shipping cap and screws on
top of the hydraulic fluid reservoir. Install
This procedure requires a lift truck and a chain the breather cap and screen.
hoist of suitable weight capacity. 14. Check the fluid level of the hydraulic
NOTE: Use this procedure when only one chain reservoir.
hoist is available. 15. Remove the plug from the drive unit and
install the dip stick.
1. Position the cradled truck directly beneath
and parallel to the chain hoist rail. Remove
the forks from the cradle. Functional Inspection
2. Position the forks of the lift truck under
Before a truck can be put into service, a
the upper cross-piece of the cradle. Secure
Raymond Installation Report must be
the cradle and truck to the carriage of the
completed.
truck lifting the cradle.
3. Attach the chain hoist to the baselegs of
Vehicle Operation
the truck.
4. Slowly raise the hoist until there is no Refer to the Owner and Operator Manuals for
slack in the chain. truck function information.

Warranty
While performing this procedure, make
sure the hoist attached to the baselegs The Installation Report activates the Raymond
does not lift the cradle off the floor. Also, warranty on the truck. Failure to correctly
do not let the chain become slack as this complete the Installation Report can void the
will allow the truck to drop. warranty on the truck.

5. Raise the upper end of the cradle with the

forks of the lift truck while lowering the
chain hoist.
6. Continue to slowly lift the cradle until the
center of gravity shifts, causing the weight
of the truck to shift to the hoist.
7. Lower the truck with the hoist until it is
standing upright on the floor.
8. Remove the chain from the baselegs and
attach it to the upper cross-piece of the
cradle.
9. Loosen and remove the nuts holding the
wooden cradle cross-piece to the mast,
then remove the wooden cross-piece.
10. Remove the bolts from the bottom cradle
cross-piece attached to the truck’s rear
bumper.
11. Lift the cradle up and away from the truck
and lower it to the floor.
12. Carefully remove the strapping securing
the telescopics and carriage.

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Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks

FlashWare

FlashWare key switch OFF, connect cable

P/N 610-809/210 to a USB port on the PC
and the P3 connector on the Vehicle
Overview Manager. See Figure 3-2.
• Serial to Serial - this method requires a
FlashWare allows you to update software, view surge protector (P/N 154-010-801) to be
and configure options on the lift truck through connected in series with the cable to
the following features: protect the PC. With the key switch OFF,
• Update Vehicle Manager software connect a standard 9-pin serial cable to a
serial port on the PC and the J9 connector
• Clear Primary Memory on the Vehicle Manager. See Figure 3-2.
• Clear Vehicle Manager
Figure 3-2. Truck FlashWare Connections
• Reset factory default settings 1750_026.tif

• Update Display software Serial connector (J9) USB connector (P3)

• Update Power Amplifier Software

For more detailed FlashWare information, click

on Help and select Help Topics from the menu
bar.

FlashWare can be installed on any

IBM-compatible PC. The PC communicates with
the truck software via a serial (9 pin) or USB
port.

Installing FlashWare on PC
If you are a customer service technician, obtain
FlashWare from your Raymond Sales and Starting FlashWare
Service Center 1. With the key switch ON, double-click the
FlashWare icon on the main desktop
If you are a Raymond Sales and Service Center screen or navigate via Start > Programs >
technician, obtain FlashWare from the iNet FlashWare. The truck opening screen
software download site. appears. See Figure 3-3.
To install FlashWare on the PC, double-click the Figure 3-3. Truck Opening Screen
installation file and follow the instructions on 9600FW_3-15.jpg

the screen. The software package is a

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

Connecting PC to Truck
There are two methods available to connect the
PC to the Vehicle Manager:
• USB to USB - this method requires the
correct drivers to be installed on the PC.
Typically, this type of connection is much
faster than a serial connection. With the

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Models 7500/7520 Reach-Fork ® Trucks Section 3. Systems Overview

FlashWare

NOTE: When entering or using FlashWare, it is

normal for a 50 series code to display.
2. From the menu bar, click
“Communications”, then select the
applicable connection type:
• COMx (9-pin Serial)
• COMx (USB)
NOTE: “x” numbers will vary depending on the
computer configuration.
3. From the menu bar, click “Connect to
Truck”, then select “All Other Trucks”. The
Truck Setup screen is displayed. If the PC
is connected to a correctly functioning
Vehicle Manager, the Truck Setup screen
is displayed.
NOTE: Refer to FlashWare Help for specific
FlashWare related topics.

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Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks

Operator Display

Operator Display
Figure 3-4. Operator Display
R1009195-A1.cgm

8
Up Button
4
Right Button

Enter Button
5
Left Down
1 6 7 Button Button

1. Battery Discharge Indicator

2. Lift Limit (optional)
3. Service Required
4. Traction/Lift Motor or Power Panel Overtemperature
5. Lift Truck Speed
6. SelfTest, Hour Meters, BSOC, Load Weight, Clock/Calendar, and
Status Messages
7. Display Dialog Buttons
8. Dashboard Selection and Optional Feature Buttons

Selecting Display Format • Lift H: Total hours spent lifting

• Trac D: Total distance traveled (miles or
The Operator Display shows date, time, BSOC, kilometers, depending on Units specified
weight on forks, information/status messages, in Config)
and ambient temperature (optional). Use the • Trac H: Total hours spent traveling
dashboard buttons 1 thru 8 to select the
desired layout of these items on the display. Graphic icons alert 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 3-24. • Lift Limit
• Service Required
Use the display dialog buttons (up, down, left,
right, and enter) to navigate through display • Overtemperature
menus and to select values for parameters. • Lift Truck Speed

Dashboard button 0 displays hour meters:

• Key H: Total hours key switch is turned
ON
• DdMan H: Total hours on deadman

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Models 7500/7520 Reach-Fork ® Trucks Section 3. Systems Overview

Modes of Operation

Modes of Operation Hour Meters and Distance Indicator

The Operator Display shows the following

Overview of Modes accumulated totals:
• Key H: Total hours the key switch has
This lift truck has two modes of operation: Run been turned ON
Mode and Program Mode. Run Mode is the
• DdMan H: Total hours on deadman
normal operating mode. Program Mode permits
configuration, calibration, and diagnostic • Lift H: Total hours spent lifting
testing (service). • Trac D: Total distance traveled (miles or
kilometers, depending on Units specified
Run Mode in Config)
• Trac H: Total hours spent traveling
At power on, the truck software performs a
number of internal checks (SelfTest) and enters These accumulated totals cannot be changed
the default mode of operation, Run Mode. In from Program Mode.
Run Mode, the Operator Display can show date,
time, BSOC, weight on forks, and (optionally) You can also display hour meters and distance
ambient temperature. For information on the indicator in Run Mode by pressing dashboard
Operator Display, see “Operator Display” on button 0 on the Operator Display panel.
page 3-10.
Configure Mode
Run Mode is also entered when the lift truck
exits Program Mode. Use Configure Mode to adjust various lift truck
performance parameters to specific customer
Program Mode requirements. To enter Configure Mode, you
must enter either the Password or Superword
Use Program Mode for configuration, for the lift truck.
calibration, and diagnostic testing of the lift
truck. A password is required to enter Program Some items in Configure Mode appear only if
Mode. See “Passwords”. the Superword is entered.

Program Mode is divided into several categories: For detailed description, see “Using Configure
Mode” on page 3-13.
• Serial Number
• Version
Service Mode
• WHLD (Weight Height Limit Display)
• Hour Meters Use Service Mode to calibrate, test, cycle, and
troubleshoot individual electrical circuits.
• Configure Mode
Service Mode tests are divided into two
• Service Mode categories: static and active.

Serial Number Use the Learn Function to calibrate the lift

truck for correct operation. You can select the
The serial number recorded in firmware must following categories for calibration:
match the serial number on the lift truck • Controls (travel, lift/lower)
tractor and mast specification plates. This field
• Weight
cannot be changed from Program Mode.
• Lower (Std AC Lift only)

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Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks

Modes of Operation

To enter Learn Function, you must enter Run Mode Tones

Service Mode. To enter Service Mode, you must
enter the Superword. The lift truck signals various situations by
using different tone patterns.
For a detailed description, see “Using Service
1. A single tone (chirp) occurs when the
Mode” on page 3-23.
enter button is used to enter a value in a
Program Mode.
Passwords 2. A double tone (high/low) indicates the
system has detected a fault condition. One
For detailed description of how to enter of the PC contactors may be de-energized
passwords, see “Entering an Electronic Key, (open). Travel, lift/lower, and auxiliary
Password, or Superword” on page 3-13. functions are disabled.
3. A triple tone (high/medium/low) indicates
Electronic Operator Key one of the following:

Electronic Operator Key is a configurable • Travel performance limitation: The lift

software feature that allows the customer to set truck is limited to a maximum travel
an operator electronic key or operator speed of 1 mph (1.6 km/h). Lift, lower,
password. When the operator turns the key auxiliary functions, steering, and horn
switch ON, the operator is prompted to enter all operate normally.
the electronic key. Run Mode cannot be entered • Traction system shutdown: The lift
unless the correct electronic key is entered. Up truck is disabled for travel. Lift, lower,
to 20 different electronic keys can be set. auxiliary functions, steering, and horn
all operate normally.
Password • Lift system shutdown: The lift truck is
not permitted to lift. Lower, travel,
Password permits access to Configure Mode steering, and auxiliary functions all
only. It is intended for customer use in setting operate normally.
performance parameters within those features 4. A descending “arcade” tone indicates an
purchased with the lift truck. incorrect password or electronic key was
entered.
Superword

Superword permits access to all Program

Entering Program Mode
Modes. Superword is intended to limit service
To enter Program Mode:
access to qualified and trained service
technicians.
From Run Mode, press the enter button on the
Operator Display.
It is strongly recommended that, during
installation, you change the Superword from
An eight character password prompt field
the factory default to a code known only to the
appears, displaying underscores:
dealer and/or owner so that access to Service
Mode is limited to approved personnel. Record
________
the new Superword in a safe place. If this code
is lost or forgotten, a technician must reset the
Enter the Password or Superword for the lift
lift truck to factory default settings. This
truck. (Refer to “Entering a Password or
requires the reconfiguration of all variable
Superword” in the following paragraphs).
settings.

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Models 7500/7520 Reach-Fork ® Trucks Section 3. Systems Overview

Modes of Operation

Entering an Electronic Key,

Invalid, Try Again
Password, or Superword
7. If you make a mistake while entering a
An Electronic Key, Password, or Superword character, repeat steps 2 thru 5.
may be from one to eight characters in length,
having any combination of letters, numbers, When you have entered the correct Password or
and/or spaces (indicated by an underscore). A Superword, the following is displayed:
password of all spaces is not permitted. Serial #
NOTE: No two passwords (Electronic Key, Version
Password, Superword) may be set to the Hr Mtrs
same value. If you try to do so, the
second password is treated as an invalid Config
code and an error message is displayed.
Each password must be set to a unique To change Password or
value. Superword
1. When the password prompt displays, an
1. Enter the Configure Mode using the
eight character field of underscores
current Password or Superword. See
appears. Initially, the left-most character
“Using Configure Mode” on page 3-13. If
position is flashing, showing it is the
Password is entered, Password is available
currently selected position.
for change, but Superword is not.
2. Use the left/right buttons to select a
2. Use the up/down buttons to scroll to
different character position. The selected
Password. Press the right button.
position flashes.
3. Use the up/down buttons to scroll to the
NOTE: After approx. 3 seconds, the display Password or Superword item.
prompt automatically increments to the
next position to the right. 4. With Password or Superword selected,
press the right button. (If Password was
3. Once you select the character position, entered in step 1 above, Password is
use the up/down buttons to select the available for change, but Superword is
number, letter, or space you want. The not.)
character set wraps between “0” and “-”
5. Enter the new password as specified under
(space). In other words, to go quickly from
“Entering an Electronic Key, Password, or
the number “0” to the letter “z,” press the
Superword”.
up button twice.
6. With the new password displayed, press
0123456789
the enter button.
abcdefghijklmnopqrstuvwyz-
7. Save the new password as specified under
NOTE: To enter numerical values, you can also “To Save New Values” on page 3-14.
use the dashboard keys 1 thru 0 on the
Operator Display panel.
4. Repeat steps 2 and 3 for the remaining Using Configure Mode
characters in the Password or Superword.
5. When you have completed entering all of Use Configure Mode to adjust various lift truck
the characters in the Password or performance parameters to specific customer
Superword, press the enter button once. requirements. To enter Configure Mode, you
must enter either the Password or Superword
6. If you enter an invalid Password or for the lift truck.
Superword, a descending “arcade” tone
sounds and the following message appears Some items in Configure Mode appear only if
on the Operator Display: the Superword is entered.

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Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks

Modes of Operation

“Program Mode Menu” on page 3-16 lists all NOTE: Changes are not saved until you exit
possible lift truck configurations and options. If Configure Mode and reply Save to the
your lift truck does not have one or more of the Restore/Save prompt.
listed options, those options do not appear in
the Operator Display. To Configure Additional Items

To Place the Lift Truck in Configure After configuring the first item, press the left
Mode button. Navigate to the next item as specified
under “To configure an item.”
1. Enter Program Mode as described on
page 3-12.
If You Make a Mistake
2. Enter Password or Superword as
described on page 3-13. If you make a mistake in configuring an item,
3. The Operator Display shows: simply navigate back to that item and configure
it again.
Serial #
Version
To Save New Values
Hr Mtrs
Config Changes to configuration values are not saved
4. Press the down button until Config is until you exit Configuration Mode. If you have
displayed. Press the right button. The made changes to configured values:
Operator Display shows: 1. Use the left button to back out of the
Default # menus.
2. The Operator Display shows:
Travel
Lift Restore
BSOC
Save
To Configure an Item 3. Use the down button to select Save. Press
the enter button. Your new values are
1. Use the up/down buttons to move to the saved.
item you want. An up or down arrow in
front of an item indicates there are more NOTE: You cannot exit to the main menu until
items above or below that item. you have selected either Restore or Save
and pressed the enter button.
2. To configure the selected item, press the
right button. Follow the directions on the 4. Press the left button to back out to the
Operator Display. Use up/down buttons main menu.
to select among specified values or to enter Serial #
a numerical value. Use right/left buttons
to move to lower/higher menu levels. Version
Hr Mtrs
NOTE: To enter numerical values, you can also
use the dashboard keys 1 thru 0 on the Config
Operator Display panel. 5. Press the left button to exit to Run Mode.
The lift truck enters the Run Mode.
When you have entered the values you want via SelfTest is not re-run.
the up/down buttons, press the enter button.
The values are accepted and the Operator
Display shows the name of the item you last
selected.

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Models 7500/7520 Reach-Fork ® Trucks Section 3. Systems Overview

Modes of Operation

If You Change Your Mind About To Reinstate Factory Default Settings

Making Changes 1. Enter Configure Mode and use the down
button to select Default. Press the right
Changes to configuration values are not saved button. The Operator Display shows:
until you exit Configuration Mode. If you made
configuration changes, but do not wish to keep Def No
the changes:
1. Use the left button to back out of the Def Yes
menus.
2. Use the up/down buttons to select Def
2. The Operator Display shows: Yes. Press the enter button.
Factory default values are restored for all
Restore items except:
Save • Password
3. With Restore selected, press the enter • Superword
button. Your new values are discarded. • Electronic Key
NOTE: You cannot exit to the main menu until • Error Log
you have selected either Restore or Save • Switch 2H
and pressed the enter button.
• Lft Lmt
4. Press the left button to back out to the • Maximum Reach and Retract Speeds
main menu.
The following factory default values are
Serial #
restored only if menu was entered from
Version Superword:
Hr Mtrs • BSOC
Config • Lift Cutout
5. Press the left button to exit to Run Mode. • Travel Alarm
The lift truck enters the Run Mode. The following functions are disabled:
SelfTest is not re-run.
• Mnt Mind
• Auto Off
3. Press the left button twice to select the
main menu.
4. Press the left button to exit Program Mode
and enter Run Mode.

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Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks

Modes of Operation

Program Mode Menu

Program Mode Menu

Note: Upper case value in Values column is the Factory Default.

Among values displayed on Operator Display, the item with an asterisk (*) is the currently selected value.

Group Item Values Description

Serial # SN _ _ _ _ _ Lift truck serial number.

Version Programmable device software versions.

VM xx.x Vehicle Manager
VMBoot xx.x VM Boot Block
DM xx.x Display Manager
TPA Traction Power Amplifier
TPASW xx.x TPA Software
TPABoot xx.x TPA Boot Block
TPAVCL xx.x TPA Version Control Language
TPAPar xx.x TPA Parameter Block
LPA Lift Power Amplifier (AC Lift only)
LPASW xx.x LPA Software
LPABoot xx.x LPA Boot Block
LPAVCL xx.x LPA Version Control Language
LPAPar xx.x LPA Parameter Block

WHLD Cfg (option) 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
...
Weight 6 xxxx lb
Height 6 xxx in

Hr Mtrs Display hour meters.

Key H Key Switch Hours
DdMan H Deadman Hours
Lift H Lift Hours
Trac D Traction Distance (mi./km)
Trac H Traction Hours
Note: You can also display hour meters by
pressing the number 0 dashboard button on the
Operator Display.

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Models 7500/7520 Reach-Fork ® Trucks Section 3. Systems Overview

Modes of Operation

Program Mode Menu

Note: Upper case value in Values column is the Factory Default.

Among values displayed on Operator Display, the item with an asterisk (*) is the currently selected value.

Group Item Values Description

Config Mode Menu

Default Def No Do not restore factory default settings.

Def Yes Restores factory values to all settings except:
Password and Superword
Electronic Key
Error Log, Lft Lmt Height,
Max Reach & Retract Speeds
Switch 2H
Disable:
Mnt Mind and Auto Power Off
Restores factory values only if menu was entered
from Superword:
BSOC, Lift Cutout
Travel Alarm

Travel Speed Max Travel Speed

Fork Ld 8.0 mph [default] 0.0 to 8.0 mph (0.0 to 12.8 km/h)
Fork Trl 8.0 mph [default]

T Accel Soft Travel Acceleration

MEDIUM
Hard

Coast LONG Coast Distance after releasing directional/speed

Medium control
Short

Switch1 3.5 [default] Travel Speed Limit at Height 1

0 to 3.5 mph (0 to 5.6 km/h)

Switch2 (option) 1.8 [default] Travel Speed Limit at Height 2

0 to 1.8 mph (0 to 2.9 km/h)

Switch2H (option) OACH [default] Height at which speed is reduced to Switch 2

(Superword only) 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)

Alarm T (option) Status Travel Alarm enabled for:

(Superword only) None
Fork Ld
Fork Trl
BOTH
X.X MPH Set Travel Alarm activation speed
1.0 mph 0.0 to 8.0 mph (0.0 to 12.8 km/h)

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Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks

Modes of Operation

Program Mode Menu

Note: Upper case value in Values column is the Factory Default.

Among values displayed on Operator Display, the item with an asterisk (*) is the currently selected value.

Group Item Values Description

Lift L Accel Soft Lift Acceleration

Medium
HARD

L Decel Soft Lift Deceleration at end of lift

Medium
HARD

Lwr Acc Soft Lower Acceleration

Medium
HARD

Lwr Dec Soft Lower Deceleration at end of lower

Medium
HARD

Lift Byp Std Byp To bypass limit or continue past limit, press and
(Superword only) hold Up arrow on Operator Display.
Alt Byp To bypass or continue past limit, press and
release Up arrow on Operator Display.
No bypass even if Up arrow is pressed.
No Byp Height at which limit cuts out. See Lift Lim.

Lift Lim Lim Hgt1 Height at which lift cuts out. To bypass limit or
(Superword only) Lim Hgt2 continue past limit, press and hold Up arrow on
Operator Display.
Range = overall collapsed height to maximum
elevated height
Default = overall collapsed height

L/LoffDM NO Lift and lower enabled when the deadman pedal

(Superword only) Yes is not depressed.

BSOC Reset by Config Default only when invoked from

(Superword Superword. Cannot be reset by FlashWare.
only)
BSOC 75% [default] The percentage of charge that a new battery
must exceed in order for the BSOC display to
reset to the new battery. For an explanation of
how BSOC is calculated, see “Battery
State-of-Charge” on page 5-5. 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%

Units ENGLISH Measurement units used in display

Metric

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Models 7500/7520 Reach-Fork ® Trucks Section 3. Systems Overview

Modes of Operation

Program Mode Menu

Note: Upper case value in Values column is the Factory Default.

Among values displayed on Operator Display, the item with an asterisk (*) is the currently selected value.

Group Item Values Description

Carriage Reach 1-Spd Reach Speed

2-SPD

MaxHiRch DC Lift: Maximum High Reach Speed Value

(Superword only) 72% [default] 0% to 100%
AC Lift:
100% [default]

MaxHiRtr DC Lift: Maximum High Retract Speed Value

(Superword only) 74% [default] 0% to 100%
AC Lift:
100% [default]

HiRchSw1 100% [default] Maximum High Speed Reach Value above

(Superword only) Switch 1: 0% to 100%

MaxLoRch DC Lift: Maximum Low Reach Speed Value

(Superword only) 56 0% to 100%
AC Lift:
66% [default]

HiRtrSw1 100% [default] Maximum High Speed Retract Value above

(Superword only) Switch 1: 0% to 100%

MaxLoRtr DC Lift: Maximum Low Retract Speed Value

(Superword only) 60% [default] 0% to 100%
AC Lift:
63% [default]

Rch Spd Reach Speed

Hi Spd
100% [default]
HiSpdSw1
65% [default]
Lo Spd
100% [default]

Rtr Spd Retract Speed

Hi Spd
100% [default]
HiSpdSw1
65% [default]
Lo Spd
100% [default]

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Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks

Modes of Operation

Program Mode Menu

Note: Upper case value in Values column is the Factory Default.

Among values displayed on Operator Display, the item with an asterisk (*) is the currently selected value.

Group Item Values Description

Password Note: No two passwords (Electronic Key, Password, or Superword) may be set to the same
value. If you try to do so, the second password is treated as an invalid code and an error
message is displayed. Each password must be set to a unique value.

Password 1_______ Change Password.

SuperWrd 2_______ Change Superword.

(Superword only)

Elec Key (option) 3_______ Electronic Key prompt. Up to 20 different keys

(Superword only) permitted.

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
No hours (restarts the countdown)
Yes
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 to 500 hours on
250 Hrs deadman pedal, in 1 hour increments.
Default is 250.
Note: Action and Interval cannot be reset by
Config Default or by FlashWare.
See “Maintenance Minder ™ Tool” on page 4-3.

Auto Off Set Auto Power Off time

0 min 0 (Disabled), 1, 2, 3, 4, 5, 10 minutes
Note: Auto Power Off shuts down truck only
when truck is in Run Mode.

Clock Set Time and Date

Time hh:mm a/p Note: Holding Up or Down button changes value
Date mm/dd/yy faster.
24-Hour DISABLE 12-hour format (1 PM = 01:00)
Enable 24-hour format (1 PM = 13:00)

Cust Int Customer Interlock Input - enabled in

(Superword FlashWare
only) CI Trav DISABLE
CI Speed Enable
CI Lift 3.5 mph 0.1 mph increments
Std Byps
Alt Byps This option can limit or disable travel and/or lift
No Byps based on the state of the input to the VM.
DISABLED

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Models 7500/7520 Reach-Fork ® Trucks Section 3. Systems Overview

Modes of Operation

Program Mode Menu

Note: Upper case value in Values column is the Factory Default.

Among values displayed on Operator Display, the item with an asterisk (*) is the currently selected value.

Group Item Values Description

WHLD Weight Height Limit Display format

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 xxx nnn Vertical Hold Configuration

1- to 3-character alphanumeric label, followed
by 3-character numeric height (minimum is
OACH plus 12 in. or 30 cm)

iP Spd
(option)
Refer to iPort ™ Kit Installation and Maintenance Instructions P/N 1089339.
iP Lim
(option)

Quit Cfg Restore Quit Config Mode without saving changes.

Save Quit Configuration Mode after saving changes.

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Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks

Modes of Operation

Service Mode Menu

Service Mode (Superword only)

Note: Upper case value in Values column is the Factory Default.

Among values displayed on Operator Display, the item with an asterisk (*) is the currently selected value.

Group Item Values Description

Learn Controls Operator Display message scrolls:

“Learning”
“Return Handle Controls to Neutral, Press Enter
Button.”
“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.”
“Lower Carriage to Floor, Press Horn Button
When Done.”
“Done”

Lower Operator Display message scrolls:

(Std AC Lift only) “Crack lower control when carriage starts to
slightly move, press Horn button...”
“Done”

Analog A04 Tra Pot x.xx V Use Up and Down buttons to scroll through list
... ... of Analog Tests. Test shows real time value.
A100 BSM Comm xx%

Input I00 Dman Sw Up/Down Use Up and Down buttons to scroll through list
... ... of Input Tests. Test shows real time value.
I92 iP Err Unknown

Output O00 TPC Tgl On/Off Operator Display message scrolls:

... ... “Jack up the truck, then press ENTER.”
O34 Htr En On/Off Use Up and Down buttons to scroll through 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.
NO Do not clear active service tests.
Yes Clear active service tests.

Log No errors in log Log holds up to 20 errors in order of occurrence.

BSOC is normalized to Lift Cutout = 0%.
Date Time Code
BSOC

Clr Log NO Retain error log entries.

Yes Clear error log entries.

Clr OCSS NO Retain OCSS log entries.

Yes Clear OCSS log entries.

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Models 7500/7520 Reach-Fork ® Trucks Section 3. Systems Overview

Modes of Operation

Using Service Mode 4. You can select the following from Service
Mode:
Service Mode is divided into two categories: Learn
static and active. Analog
Input
Static Service Mode
Output
Static Service Mode permits testing of Clr Act (only if tests are selected for Active
individual circuits while the lift truck is Service)
standing still. You can use Static Service Mode Log
for most analog and digital input and digital
Clr Log
output tests.
Use the up/down buttons to select the
test category desired, then press the right
button.
By entering Static Service Mode, you are 5. If you select Output tests, the Operator
disabling the safety circuits. Therefore, Display scrolls this warning:
you must take extra precautions while
in Static Service Mode. Follow all WARNING: Jack Up The Drive Wheel,
instructions in this manual for each test. Press Enter When Ready...
If you are unsure how to conduct a test
while in Service Mode, Stop: Do Not After you jack up and block the lift truck,
Proceed with the test. Contact an respond to the Ready prompt by pressing
authorized Raymond dealer. the enter button.
6. Within a test category, test numbers are
While in Static Service Mode, elevate the displayed in numerical sequence. Use the
drive tire off the floor. See “Jacking up/down buttons to move to the test you
Safety” on page 2-8. want.
7. Analog and Input test results are
To Place the Lift Truck in Static Service displayed to the right of the test number
Mode as soon as you select the test. For
example, Test A04 might show:
1. Press the enter button to enter Program
Mode.
A04 Tra Pot 1.10 V
2. Enter the Superword and press enter.
8. You must explicitly start output tests.
3. Use the up/down buttons to select Select the test number you want by
Service, then press the right button. scrolling and highlighting the test.

O01 STR Tgl Off

Press the enter button. The Operator

Display shows the test results to the right
of the test number.

O01 STR Tgl On

Use the enter button to toggle the test.

O01 STR Tgl Off

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Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks

Modes of Operation

the current category and select the other

To exit output test, press the left button. category from the Service menu. Use the
9. The Error Log stores the last twenty error up/down buttons and remaining
codes recorded on the lift truck. Entries dashboard buttons to select more tests
are stored in order of occurrence, with the from that category.
most recent error first. 5. Quit Service Mode and Program Mode. Let
10. To access the Error Log, use the up/down the lift truck enter Run Mode.
buttons to select Log, then press the right 6. To display Active Service tests while in
button. Run Mode, press dashboard button 9.
11. If no errors are stored, the message “No Four tests are displayed at a time. Use the
Errors in Log” appears in the display. up/down buttons to scroll through the list
of selected tests.
12. If errors have been logged, use the
up/down buttons to scroll through the
list. To Clear All Active Maintenance Tests
At Once
13. To clear the log, use the up/down buttons
to scroll to Clr Log. Press the right button. 1. Go to Program Mode.
Scroll to Clr Yes and press the enter
2. Use the up/down buttons to select
button.
Service, then press the right button.
3. Use the up/down buttons to select
Active Service Mode Clr Act. This item only appears if you have
selected one or more tests for Active
Active Service Mode permits testing circuits Service.
while the lift truck is enabled for normal
4. Press the enter button. Active service tests
operation. You can use Active Service Mode for
are cleared. Exit Service Mode and
all analog and digital input tests.
Program Mode.
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 thru 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

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Models 7500/7520 Reach-Fork ® Trucks Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance

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Section 4. Scheduled Maintenance Models 7500/7520 Reach-Fork ® Trucks

Maintenance Guidelines

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

Scheduled maintenance includes:

• Lubrication
• Cleaning
• Inspection
• Service

Perform all the scheduled inspections and

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

When operating under severe or extreme

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

Table 4-1. Maintenance Frequency

Operating Service
Working Environment
Conditions Frequency

180 days or 500

Light to
An eight hour day of basic material handling hours, whichever
Moderate
comes first

• Extended heavy duty operation

• Freezer operation
Severe 250 hours
• Sudden temperature changes such as going from freezer to room
temperature

• All UL Type EE rated lift trucks

• Dusty or sandy conditions such as in cement plants, lumber or flour
mills, coal dust or stone-crushing areas
Extreme 100 hours
• High temperature areas such as in steel mills, foundries, enclosed
(Type EE) applications
• Corrosive atmosphere such as chlorine or salt-sea air environments

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Models 7500/7520 Reach-Fork ® Trucks Section 4. Scheduled Maintenance

Maintenance Minder ™ Tool

Maintenance Minder ™ NOTE: For instructions on selecting Modes of

Operation, see “Modes of Operation” on
Tool page 3-11.

With Configuration Mode selected, use the

Maintenance Minder Tool is a feature that down button to display the “Mnt Mind” item.
permits prompting of a customer when the lift Press the right button. With “Status”
truck is due for scheduled maintenance. highlighted, press the right button. Use the
down button to select “Enable.” Press the enter
Maintenance Minder, when configured and button. Maintenance Minder is enabled with the
enabled, monitors the Hours on Deadman (HD) last stored time interval and action option.
meter. When the time interval for scheduled
maintenance is exceeded, the operator is Exit Program Mode as described under “Exiting
informed in the following ways: Program Mode” on page 4-4.
• One of two messages appears on the
Operator Display following the “Daily
Checklist” message.
Setting or Changing Time
Interval and Action Option
• “Scheduled Maintenance Due”
• “Lift Cutout, Scheduled Maintenance With Configuration Mode selected, use the
Due” down button to display the “Mnt Mind” item.
• A wrench icon flashes Press the right button. Use the down button to
select “Setup.” Press the right button.
• The audible alarm sounds the high-low
tone for approx. 5 seconds.
Use the up/down buttons to scroll to “Interval.”
Press the right button. The first time you enter
Lift Cutout, when active, will not disable the lift
the time interval menu, the Operator Display
function until power to the control circuits is
shows the Factory Suggested setting.
cycled (key switch OFF or battery
Afterwards, when you enter the time interval
disconnected). When control circuit power is
menu, the Operator Display shows the last
cycled, lift is disabled until Maintenance Minder
used setting. Values from 50 to 500 deadman
is reset or disabled, or the lift cutout option is
pedal hours are available. Press the right
turned OFF.
button. Use the up/down buttons to scroll to
the desired time interval. With the selected
Factory Configuration value displayed, press the enter button. Press
the left button to return to the Setup menu.
For field installations, this feature must be
added to the configuration options via the Use the up/down buttons to select “Action.”
FlashWare program. The factory default is Then press the right button. The following
Disable. options are available:
• “Msg Only” causes the Operator Display to
Maintenance Minder settings are not changed show “Scheduled Maintenance Due” when
by resetting Defaults in the Config menu. the scheduled maintenance time interval
is exceeded.
Enabling • “L Cut Out” causes the Operator Display
to show “Lift Cut Out, Scheduled
Once installed, Maintenance Minder appears in Maintenance Due” when the scheduled
the Configure Mode menu. The initial factory maintenance time interval is exceeded. Lift
setting is “Disable.” To enable the feature, enter is disabled the next time the power circuits
Configure Mode. are cycled.

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Section 4. Scheduled Maintenance Models 7500/7520 Reach-Fork ® Trucks

Maintenance Minder ™ Tool

Use the up/down buttons to select the option NOTE: You will not be able to exit to the main
you want, then press the enter button. menu until you have selected either
Restore or Save and pressed the enter
Exit Program Mode as described under “Exiting button.
Program Mode”.
4. Press the left button to back out to the
main menu.
Resetting Maintenance Minder Serial #

If you want to reset the reminder prompt when Version

Maintenance Minder is active and you have done Hr Mtrs
scheduled maintenance, enter Configure Mode. Config

With Configuration Mode selected, use the Press the left button to exit to Run Mode.
down button to display the “Mnt Mind” item. The lift truck enters the Run Mode.
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.

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Models 7500/7520 Reach-Fork ® Trucks Section 4. Scheduled Maintenance

Initial 90 Day/250 Deadman Hours (HD) Maintenance

Initial 90 Day/250 Deadman Hours (HD)

Maintenance
4

Perform the following maintenance tasks 90 days after the lift truck is put into service or at 250 HD,
whichever comes first.

Component Task

Break free, reapply thread-locking compound (P/N 990-544), and re-torque mounting
Drive Unit
bolts to 150 ft. lb. (204 Nm). Change fluid.

Hydraulic
Change fluid and filter(s). Refer to “Hydraulic Filter” on page 7-89 and “Lubrication
Reservoir and
Specification Chart” on page A-2.
Manifold

Break mast to tractor mounting bolts free. Clean threads and reapply thread-locking
Mast compound (P/N 990-544). Re-torque mounting bolts. Refer to “Mating Mast to Tractor” on
page 7-159 or page 7-172.

Power
Re-torque power cable terminal nuts to 11 ft. lb. (15 Nm).
Amplifiers

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Section 4. Scheduled Maintenance Models 7500/7520 Reach-Fork ® Trucks

Every 180 Days or 500 HD

Every 180 Days or 500 HD

NOTE: For Severe or Extreme operating condition service intervals, refer to Table 4-1, “Maintenance
Frequency,” on page 4-2.

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

Component Task

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

In a open area, measure stopping distance. Traveling at 2 to 3 mph (3.2 to 4.8 km/h)
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 approx. one and one-half truck lengths. Stopping distance depends on
Brake the load, floor, and tire conditions.
Examine for signs of oil on the pads or rotor. If oil is present, disassemble brake, clean
rotor, and replace pads.
Measure for correct air gap between armature and armature plate: 0.040 in. (1 mm) max.
See “Brake” on page 7-61.

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
Contactors
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.

Verify lift/lower function is smooth and controllable. Verify travel function is smooth and
Control responsive through full range of motion. Check for play in the center position of lift or
Handle(s) travel control; repair/replace control handle if necessary. Verify no codes on display.
Verify function of all switches. Make sure nylon insert is in the lift knob set screw hole.

Check free lift cylinder piston position. With forks completely lowered, make sure one
Cylinders
piston is not higher than the other.

The deadman pedal must operate smoothly with no binding. Check for correct activation
Deadman Pedal and deactivation of the deadman switch under the pedal. Refer to “Deadman Pedal” on
page 7-63.

Drain Holes Make sure the drain holes in the battery compartment are free of any debris.

Check oil level. Inspect for leaks. Make sure O-ring is present on the dipstick. Check
Drive Unit drive axle for play. Examine for drive unit radial ring wear. See “Radial Ring Inspection”
on page 7-48.

Inspect all power cables for nicks or cuts. Give special attention to those cables that are
not stationary, for example, cables to the Traction Motor. Replace any cable that is
damaged or shows signs of excessive heat. Failure to do so causes intermittent system
Electrical
shutdowns and/or electronic failures. Check the tension of the over-the-mast cables. Set
Cables
the tension on the spring at the carriage by sliding the cable grip to produce a length of
1.75 ±0.12 in. (44.5 ±3.0 mm) across the coils. Do not over tension. Tighten the cable tie
on the cable grip.

Fans Check for correct operation. Run “Test O23 - Toggle Fans” on page 6-119.

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Models 7500/7520 Reach-Fork ® Trucks Section 4. Scheduled Maintenance

Every 180 Days or 500 HD

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

Component Task

Forks Perform fork inspection per page 4-13.

Frame and Perform a visual inspection of structural members for cracks, including but not limited to
Baselegs baselegs, main frame, and tractor.

Check bolt torque of major components (motors, pumps, brake, drive unit,
mast-to-tractor mounting bolts, overhead guard).
Hardware
Tighten any loose hardware. Replace any broken or missing hardware. Refer to torque
charts in “Appendix”.

Horn Make sure horn sounds correctly when activated.

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

Hydraulic
Check fluid level.
Reservoir

Check adjustment. Inspect for excessive stretch or wear (Tool P/N 950-350/CG).
Lift Chains
Lubricate. See “Chain Maintenance” on page 4-12.

Lubrication Lubricate all grease points. Refer to “Lubrication Points” on page 4-10.

Wipe old grease off mast uprights and apply new grease.
Inspect anti-rattle pads and anti-bow pads (7500 only). Correct anti-rattle pad gap is 0.00
to 0.03 in. (0.00 to 0.8 mm). Anti-bow pad minimum thickness is 0.187 in. (4.75 mm) and
correct gap is 0.03 to 0.09 in. (0.8 to 2.3 mm).
Examine mast bearings.
Mast
Inspect 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 in. (3 mm).

AC - Check the cable lugs to make sure they are tight to the terminal studs. Both the
inside and outside nut should be torqued to the values listed in Table A-3, “Component
Specific Service/Torque Chart,” on page A-4. Replace any cable that shows signs of
excessive heat. Check sensor wires for sound connection and condition. Blow out the
inside of the motor with compressed air.

DC - Inspect brushes for excessive heat (discoloration of the pigtails). If excessive heat is
evident, inspect the armature circuit for loose connections. Check condition of
commutator per photos on page 5-11. Inspect the brushes for even wear over the full
Motors surface of the brush. If a brush is not contacting the complete surface, replace the
brushes. Inspect the brush rigging for damage or loose brush holders. Make sure that the
connections on the brush leads are tight. Check brush length and spring tension. Refer to
“DC Motor Service” on page 7-81. Blow out the inside of the motor with compressed air.
Blow out impeller and cooling fins. Check the cable lugs to make sure they are tight to
the terminal studs. Torque both the inside and outside nut to the values listed in
Table A-3, “Component Specific Service/Torque Chart,” on page A-4. Replace any cable
that shows signs of excessive heat. Check sensor wires for sound connection and
condition.

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Section 4. Scheduled Maintenance Models 7500/7520 Reach-Fork ® Trucks

Every 180 Days or 500 HD

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

Component Task

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

Power Make sure power amplifier heatsink fins are free of debris and that air flows freely
Amplifiers through them. Check torque of power cable hardware.

Check for electrical shorts to frame. See “Shorts to Frame” on page 5-2. Wipe
Shorts to Frame
compartments clean.

Make sure static straps are not worn or broken. Clean debris from straps. Check
resistance of resistor in standoff. Resistance must measure >10K and <1.2 megohms. EE
Static Straps
trucks require a phosphor bronze static strap; do not use steel braided cable on EE
trucks.

Check that steering system function is smooth and responsive. 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. See “Steerable Caster” on page 7-28.
Steering Lubricate the steer axle assembly.
Adjust steering snubber if necessary. Refer to “Steer Tiller Encoder (AC Lift)” on
page 7-26.
Check the gap on the steer limit switch (S11). Refer to “Steer Limit Switch (S11)” on
page 7-27.

Check all switches for correct operation and adjust as needed. Refer to “Component
Switches
Specific Service/Torque Chart” on page A-4.

Ventilation
Make sure ventilation slots in the tractor frame are open, with no obstructions or debris.
Slots

Warning Decals Replace any illegible or damaged decals.

Warning Lights Check for correct operation.

Examine for bond failure, chunking, and excessive or uneven wear.

Wheels/Tires Inspect load wheel bearings for binding or excessive play.
Inspect traction wheel axle and steerable caster wheel axle for excessive play.

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Models 7500/7520 Reach-Fork ® Trucks Section 4. Scheduled Maintenance

Every 360 Days or 2000 HD

Every 360 Days or 2000 HD

4

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

Component Task

Drive Unit Change fluid.

Hydraulic
Reservoir and Change hydraulic fluid and filter. See “Hydraulic Filter” on page 7-89.
Manifold

Lift Pump Separate pump and motor. Apply molybdenum anti-seize compound (P/N 990-638) to the
Coupling splines.

Steer Motor
Separate motor and gearbox. Apply molybdenum anti-seize compound (P/N 990-638) to
Coupling
the splines.
(Electric Steer)

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Section 4. Scheduled Maintenance Models 7500/7520 Reach-Fork ® Trucks

Lubrication Points

Lubrication Points
Click on arrow to launch video.

Standard Reach

Deep-Reach

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Models 7500/7520 Reach-Fork ® Trucks Section 4. Scheduled Maintenance

Contactor Tip Inspection

Contactor Tip Inspection

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

Figure 4-1. Severely Pitted Contactor

48A21032S.TIF

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Section 4. Scheduled Maintenance Models 7500/7520 Reach-Fork ® Trucks

Chain Maintenance

Chain Maintenance Figure 4-2. Chain Gauge

4Ma0634.eps

Lift Chain Inspection

A
A
Chain
Wear
Make sure chains are not damaged. Check the Scale
chain for wear using a Chain Gauge
(P/N 950-350/CG). See Figure 4-2.

A
A
MA0634.ill

Chain OK Replace Chain

Replace chains with genuine Raymond spare

parts. See “Lift Chains” on page 7-137.

Condition-Cause Chart
4

Condition Cause Maintenance Procedure

Use a chain gauge or lay the chain on a flat surface

and push it together. Measure and mark a 12 in.
Chain Elongation Wear (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.

Steam cleaning or degreasing

Rust and corrosion Lubricate chain frequently.
new truck chains

Infrequent Oiling

Rust
Cracked Plates Replace the chain.
Corrosion

Chain Fatigue

Bent pins or plates Replace the chain.

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

Chain side wear Chain misalignment Replace the chain.

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Models 7500/7520 Reach-Fork ® Trucks Section 4. Scheduled Maintenance

Fork Inspection

Fork Inspection 2. Multiply these numbers by 0.5%. The

smallest number is your maximum
deviation.
The following tools are required to perform fork
• Length of blade _____ x 0.5% = ______
inspection:
• Height of shank _____ x 0.5% = ______
• Fork Wear Caliper (P/N 922-369)
3. Place a 24 in. framing square on the blade
• Tape Measure or ruler
of the fork, 2 in. away from the heel of the
• 24 in. Framing Square fork. See Figure 4-4.
• 4 ft. Level 4. At 21 in., measure the distance between
the face of the shank and the framing
Do the following when performing Scheduled square. See Figure 4-4.
Maintenance.
Figure 4-4. Fork Measurement with Framing Square
4forkstraight.svg

Surface Inspection 9

Remove the forks from the carriage. Visually

inspect all fork surfaces for signs of damage,
including, but not limited to:
• cracks
• excessive wear
• excessive heat
• deformation
v
• unauthorized modifications

Pay special attention to the heel and welds

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

Straightness of Blade and v

Shank 5. Compare this measurement, minus 2 in.,
to the smallest maximum deviation
NOTE: This measurement can be done with the
number determined in step 2.
forks on or removed from the carriage.
6. If the maximum deviation number is
1. Measure the length of the blade and the exceeded, remove the fork from service.
height of the shank. See Figure 4-3.

Figure 4-3. Measuring Fork Blade and Shank Fork Angle

4forkFacts1.svg

NOTE: This measurement can be done with the

forks on or removed from the carriage.
1. Place the fork caliper on the blade. Make
sure that the two extruded points are
Shank touching the blade of the fork. See
Figure 4-5.

Blade 2. Now open and move the caliper so the two

extruded points are touching the shank.
See Figure 4-5.

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Section 4. Scheduled Maintenance Models 7500/7520 Reach-Fork ® Trucks

Fork Inspection
Figure 4-5. Fork Angle 4. Raise one end of the level to make it level.
4ForkArmWearCaliperGuide_2.svg
See Figure 4-6.
5. Measure the distance from the tip of the
Shank fork. See Figure 4-6.

Figure 4-6. Measuring Fork Tip Height

4Fork Inspection.jpg

Forks

Indicator
Lines
Distance
Blade
from tip
Level of fork

3. When all four extruded points are in

contact with the fork, gently remove the
caliper and note the reading on the Tips
indicator line, located right above the 6. Compare this measurement to the
hinge pin. See Figure 4-5. maximum deviation.
4. If the deviation is greater than 3° of the 7. If the maximum deviation number is
original angle, remove the fork from exceeded, remove the fork from service.
service.
NOTE: Most forks are manufactured with a 90° Positioning Locks (if applicable)
angle; therefore, a reading greater than
93° or less than 87° is unacceptable. 1. With the forks on the carriage, visually
However, there are some forks that are inspect the positioning locks for damage.
purposely manufactured to angles 2. Test the positioning locks to verify they
greater than or less than 90°. work correctly.
3. If the positioning locks are damaged or do
Fork Tip Height not work correctly, remove the fork from
service.
1. With forks on the carriage, measure the
length of the blade. See Figure 4-3.
• For forks 42 in. (106.7 cm) or less, max. Wear
deviation is 0.25 in. (6.3 mm).
• If length of fork is >42 in. (106.7 cm), Fork Blade and Shank
multiply length of blade by 3%. 1. Remove the forks from the carriage.
Blade length _____in. x 3% = _____in.
2. Approx. half way up the shank, set the
This is the maximum deviation.
front teeth of the jaws of the caliper on the
2. Elevate forks approx. 4 ft. (1.2 m) off the shank. Make sure the caliper is held
floor. square across the shank to get an
3. Place a 4 ft. level across the tips of the accurate reading. The caliper is now set to
forks. See Figure 4-6. measure fork blade wear. Carefully remove
the caliper from the shank. See Figure 4-7.

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Models 7500/7520 Reach-Fork ® Trucks Section 4. Scheduled Maintenance

Fork Inspection
Figure 4-7. Measuring Fork Shank
4Fork Inspection.jpg

If there is greater than 10% wear of the

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

NOTE: The caliper is designed to measure forks

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

3. Measure 2 in. (50 mm) out from the heel of Fork Hooks
the fork.
4. Place the caliper over the flanks of the fork 1. Remove the forks from the carriage.
arm blade at this 2 in. (50 mm) point. See 2. Determine the fork mounting class.
Figure 4-8. a. Measure the height of the carriage or
the distance between the hooks. See
Figure 4-8. Measuring Fork Blade Wear
4Fork Inspection.jpg
Figure 4-9.

Figure 4-9. Determining Fork Mounting Class

4Fork Inspection.jpg

Distance between hooks

Carriage Height
b. Compare this measurement to the table
below.

Fork Distance Carriage

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

1 12.05 (306) 13 (331)

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

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Section 4. Scheduled Maintenance Models 7500/7520 Reach-Fork ® Trucks

Fork Inspection

3. Locate the correct extruded edge on the

caliper for the fork mounting class. See
Figure 4-10.
4. Slide the extruded edge up into the hook
pocket. See Figure 4-10.
5. If the caliper’s extruded edge completely
slides up into the fork pocket, remove the
fork from service. See Figure 4-10.

Figure 4-10. Fork Hook Inspection

4Fork Inspection.jpg

Fork Pocket

Fork Mounting Class

designation

Markings

Make sure the fork’s marking (individual load

rating) is legible (typically located on side of
fork). If fork marking is not legible, remove the
fork from service.

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Section 5. Troubleshooting

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Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Electrical Troubleshooting

Electrical • Whenever measuring resistance, turn the

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

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Electrical Troubleshooting

• Circuit card mounts a serious short. Do not continue until this

condition is corrected. The meter may be
Shorts to Frame Test damaged if you proceed before correcting
this condition.
1. Turn the key switch OFF and disconnect
a. To identify the cause of the short to
the battery connector.
frame, disconnect circuit components
2. To test the battery for shorts to case, until the low resistance condition
connect a 12V test light to the battery case disappears. Do not reconnect
from battery B+, and then to the battery components one at a time, but leave
case from battery B–. If the light them disconnected until the low
illuminates at all, even momentarily, there resistance reading disappears. Prevent
is a serious problem with the battery, disconnected terminals or connectors
either external contamination or internal from touching the lift truck frame or
damage. Do not continue until this other conductive surfaces.
condition is corrected. The meter may be
b. The most likely areas to check are:
damaged if you proceed before correcting
this condition. • Motors
• Heatsinks
Install another battery in the truck and
• Power cables
repeat this procedure from Step 1.
• Power circuit components
If the test light does not illuminate, • Control circuit components
continue to the next step.
c. Repair or replace the component
3. Use a DMM set on the ampere function to causing the low resistance condition.
measure the current leakage from the Repeat Step 4.
battery case to battery B+ and from the
battery case to battery B–. Begin d. Reconnect all other components
measuring at the highest ampere scale previously disconnected, one at a time,
and work toward the lowest. A reading of measuring resistance between steps. If
more than 0.001A (1mA) indicates a a reading is <1000 ohms when
serious short. Do not continue until this reconnecting a component, that
condition is corrected. The meter may be component or its wiring is faulty; repair
damaged if you proceed before correcting or replace as appropriate.
this condition. e. When, after all components are
reconnected, you get readings
Install another battery in the lift truck and >1000 ohms, continue with the next
repeat this procedure from Step 1. step.
5. Reconnect the battery connector and turn
If the current is <0.0002A (0.2mA), go to
the key switch ON. If the battery was
Step 4. If the current is >0.0002A (0.2mA)
previously removed, make sure the battery
and <0.001A (1mA), remove the battery
case does not touch the lift truck frame.
from the truck, then continue with Step 4.
Make sure the battery case does not touch NOTE: The functions being checked must be
the truck frame during the remaining energized. Example: to check for shorts
tests. to frame in the travel circuit, travel must
4. With the battery disconnected (or removed be requested.
and disconnected) from the truck, use a 6. Use a DVM set to the current function to
DMM to measure the resistance from lift measure current leakage to the truck
truck frame to truck B+, to truck B– (not frame from B+, B–, and all fuses and
battery B+ and B–), and to all fuses and motor terminals. Begin measuring at the
motors. A reading of <1000 ohms indicates highest ampere scale and work toward the

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Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Electrical Troubleshooting

lowest. If the current is <0.001A (1mA), go

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

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Electrical Troubleshooting

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

below 95% charge will not change the
Battery State-of-Charge (BSOC) is a feature that Operator Display. Older batteries or
monitors and remembers the charge level of the applications providing inadequate
battery connected to the lift truck and helps to charging time could require a lower
prevent excessive discharging of that battery. configured value for BSOC since older
Operating a lift truck using a discharged batteries might be unable to reach a
battery can damage both the battery and the higher percent charge. Therefore, some
electrical components of the lift truck. batteries could require BSOC configured
as low as 55% before lift cutout resets and
At power-up, BSOC tests the battery voltage to the Operator Display shows the charge of
determine if it is the same as it was at the replacement battery.
power-down. If the voltage is the same, BSOC
assumes it is the same battery and continues to Setting Battery State-of-Charge
monitor the battery for discharge and updates Cutout
the Operator Display as required.
1. Fill, charge, and install a battery that is
If a different battery voltage is detected, BSOC typical of the batteries normally used in
assumes a different battery is installed and this application.
tests to determine the state-of-charge of the 2. Have a customer operator use the lift
replacement battery. The replacement battery truck in normal application until cutout
must meet one of the following criteria before occurs.
the display resets and lift is restored.
3. Allow the battery to cool and stabilize for
• The replacement battery must have a at least two hours.
charge level at least 50% different from the
4. Before filling the battery, either take
previously installed battery,
specific gravity readings or measure open
• The charge value of the replacement circuit voltage of the battery cells.
battery must be greater than the
5. Compare the measurements with the
configured BSOC setting.
battery manufacturer’s recommendations
for maximum discharge.
The criteria are determined in this way:
6. Adjust the cutout value as needed and
• BSOC compares the charge of the battery
repeat the previous steps until battery
that was connected to the lift truck with
cutout occurs at the desired discharge
the replacement battery’s charge. A charge
level.
difference of at least 50% between the two
batteries resets BSOC to show the
state-of-charge of the replacement battery,
that is, the measured state-of-charge of
the replacement battery minus the
remembered state-of-charge of the old
battery must equal or exceed 50%. This
reset can be higher or lower than the old
battery.
• BSOC looks at the configured reset point.
BSOC reset is programmable from 55% to
100% of total battery charge and can be
changed by entering the Configure Mode
using the Superword. The replacement
battery must be greater than the
configured percent of charge before BSOC
changes. Example - BSOC configured at

Publication: 1112860, Issued: 15 Feb 2012 5-5

Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Electrical Troubleshooting

Fuses
Test/Inspection

Examine the fuse for signs of overheating,

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

To test a fuse, remove it from the lift truck. The

resistance should be <1 ohm.

Table 5-1. Fuse Chart

Fuse Amps Location Function

FU1 150 Contactor/Fuse Panel Power fuse for steering
FU2 500 Contactor/Fuse Panel Power fuse for travel
FU3 675 Contactor/Fuse Panel Power fuse for lift
FU4 100 Contactor/Fuse Panel Power fuse for Aux
FU5 15 Fuse/Relay Card Control fuse for Vehicle Manager (B+)
FU6 15 Fuse/Relay Card Control fuse for Vehicle Manager (B–)
FU7 5 Fuse/Relay Card Control fuse for aux power (B+)
FU8 5 Fuse/Relay Card Control fuse for aux power (B–)
FU9 10 Travel alarm Control fuse for travel alarm
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
FU15 2 TS2 Control fuse for optional Fork-Laser Module (B+)
FU16 2 In-line harness near TP1 Control fuse for optional Fork-Laser Module (B–)
FU17 2 In-line harness near TP4 Control fuse for OCSS Heater option
FU18 2 In-line harness near JPS14 Control fuse for Vantage Point option
FU35 2 In-line harness near TP1 Control fuse for optional iPort (B+)

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Electrical Troubleshooting

Electrical Connections
Terminology
Figure 5-1. Molex Jack and Pin Connector
8c04013s.tif

Pin Identifier Lines

(black lines added for clarity)

Jack Pins

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 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 5-1.

Electrical Connector Locator Chart

Refer to legend on electrical schematic.

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Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Electrical Troubleshooting

Circuit Card Connectors

Vehicle Manager

Figure 5-2. Vehicle Manager Connectors

R1019283_B.cgm

PC22 PC10 PC6 PC24 JC9 PC3

PC14 PC18 PC20 PC12 PC4

PC22 PC10 PC6 PC24 JC9 PC3

PC14 PC18 PC20 PC12 PC4

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Electrical Troubleshooting

Fuse/Relay Card

Figure 5-3. Fuse/Relay Card Connectors

R1022159_A.cgm

Publication: 1112860, Issued: 15 Feb 2012 5-9

Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Electrical Troubleshooting

DC Motors If the commutator appears rough, pitted, or has

signs of burning or heavy arcing between the
commutator bars, remove the motor for
Types of DC Motors servicing.
There are two primary types of DC Motors (refer
to Figure 5-4): Servicing
• A series-wound motor has only two
If the commutator requires service, you must
external connections because the
remove the armature from the motor.
armature and field windings are connected
internally.
Do not use a stone to even out high and low
• A permanent magnet motor has two spots on the commutator.
external connections. The field is produced
by an internal magnet. Servicing a motor for an abnormal commutator
NOTE: Field connections may be labeled A or S. surface condition and high mica or mica
undercutting requires special equipment at a
Series wound motor field connections
motor rebuilding facility.
may be labeled D.

Figure 5-4. Motor Circuits

5motor-series.eps,motor-pmagnet.eps

Series-Wound Motor Permanent Magnet

S/D Motor
A2
MS+

MS

MP
A1
MS–

Inspection

Inspect commutator for surface condition and

high mica. Most armatures have the mica
undercut. If the armature on your motor does
not, do not attempt to cut it.

The commutator must be smooth and clean to

provide maximum brush wear. When
commutators are not correctly maintained,
carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
the armature.

Good commutation is indicated by a dark

brown polished commutator and an evenly
polished brush wearing surface. See Table 5-2,
“Commutator Surfaces.”

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Electrical Troubleshooting
Table 5-2. Commutator Surfaces
Condition Probable Cause Commutator Surface

Uniform coloring indicates satisfactory operation

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

This is not a good condition but in our experience

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

Frequently due to under-loaded operation,

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

Patchy colors of varying densities and shape. Due

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

These areas can be isolated or regular.

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

Unsatisfactory Bars are low on entry and leaving edges giving

Condition-Example of Poor rise to the brushes riding on the middle of the
Commutator Machining bars.

Bars are low in the middle giving rise to the

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

This is a further development of the third

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

Publication: 1112860, Issued: 15 Feb 2012 5-11

Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Electrical Troubleshooting

Condition Probable Cause Commutator Surface

Unsatisfactory Darkening of commutator in sequences two pole

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

Storage of machines, for lengthy periods, with

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

Unsatisfactory Illustration shows high mica in every slot. Same

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

Related to overloaded machines and low brush

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

Open Circuit Motor Test 3. Observe the following measurements:

An open circuit is an electrical circuit within the

DC Motor Probe Points Resistance
motor that is broken. This can be caused by:
A to S <1 ohm
• bad brushes or brush springs Lift
A to Frame
• a broken wire in the field or armature
winding Auxiliary A1 or A2 to
Frame >100,000 ohms
• loose or bad connections
MS+ or MS– to
Steer
Frame
Refer to Figure 5-4 on page 5-10 while
performing the following procedure:
1. Isolate the motor from the lift truck circuit 4. If the meter indicates high resistance in
by removing the power cables. Use two the armature, check the condition of the
wrenches to avoid twisting the terminal brushes before replacing the motor.
stud. 5. If you find an open circuit in a
2. With the motor at room temperature, series-wound motor, the motor must be
connect the leads of a digital ohmmeter disassembled by a motor rebuilding facility
between the individual circuits in the to isolate the problem to the field or
motor. 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.

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Electrical Troubleshooting

The ground may be caused by: Testing a motor for short circuited windings
• insulation breakdown requires special equipment at a motor
rebuilding facility.
• 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

<100,000 ohms, the motor is grounded. Clean,
repair, or replace the motor as necessary.

Short Circuited Armature or Field

Winding

A short circuited winding is one that the

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

A shorted motor may be indicated by:

• Slow or sluggish operation
• Running faster than usual (suggests a
short in the field)
• Overheating
• Blowing a power fuse
• Burning of brush wires
• Severe burning or discoloration on
armature coil
• Severe burning or discoloration on one or
two commutator segments every 90° of
rotation.

These symptoms can be caused by problems

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

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Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Electrical Troubleshooting

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

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

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

Figure 5-5. Traction Motor Circuits

5motor_AC3phaseA.eps,motor_AC3phaseB.eps

AC
3φ

V W

Open Winding

If the AC motor fails with an open winding, the

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

Using a clamping ammeter, measure current in

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

Shorted Winding

If the AC motor fails with a shorted winding, the

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

Using a clamping ammeter, measure current in

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

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Hydraulic Troubleshooting Guidelines

Hydraulic
Troubleshooting
Guidelines

After elevating or reaching the carriage

for troubleshooting, 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.

Publication: 1112860, Issued: 15 Feb 2012 5-15

Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Symptom Tables: Hydraulic Functions

Symptom Tables:
Hydraulic Functions
Refer to electrical/hydraulic schematics.
NOTE: If a component fails due to hydraulic
fluid contamination, replace the failed
component, flush, fill, and bleed the
hydraulic system. Refer to “Hydraulic
System Bleeding” on page 7-88.

Auxiliary Functions
No Auxiliary Functions Work (Reach/Retract, Tilt, Sideshift) - 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 Run Test O04 - Toggle Aux1 Directional (SOL5T) Solenoid
(valve or wiring) (Page 6-108) or Test O05 - Toggle Aux2 Directional (SOL5B)
Solenoid (Page 6-109).

Bad pump Operate lift and aux function. If aux works, replace pump.

Bad POD-1 valve Replace POD-1 valve.

Bad RV-4 Replace RV-4.

No Auxiliary Functions Work (Reach/Retract, Tilt, Sideshift) - AC Lift with

Regen Lower
Possible Cause Action

Bad RV-4 Replace RV-4.

Bad aux directional solenoid Run Test O04 - Toggle Aux1 Directional (SOL5T) Solenoid
(Page 6-108) or Test O05 - Toggle Aux2 Directional (SOL5B)
Solenoid (Page 6-109).

Bad EP-1 valve Replace EP-1.

Bad pump Replace pump.

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Symptom Tables: Hydraulic Functions

No Auxiliary Functions Work (Reach/Retract, Tilt, Sideshift) - DC Lift

Possible Cause Action

Bad K2 relay circuit Troubleshoot K2 relay circuit.

Bad SOL8 (valve or wiring) Run Test O09 - Aux Dump (SOL6 or SOL8)/Main Relief Dump
(SOL3) (Page 6-113).

Bad CE1 valve Repair/replace CE1 valve.

Bad LS1 shuttle Repair/replace LS1.

Bad aux directional solenoid 5B or 5T Run Test O04 - Toggle Aux1 Directional (SOL5T) Solenoid
(valve or wiring) (Page 6-108) or Test O05 - Toggle Aux2 Directional (SOL5B)
Solenoid (Page 6-109).

All Auxiliary Functions are Slow - AC Lift

Possible Cause Action

Incorrect hydraulic fluid for Replace hydraulic fluid with correct fluid. See “Lubrication
application 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 7-95.

Bad LS1 shuttle Replace LS1.

Bad pump Operate lift and aux function. If aux works, replace pump.

All Auxiliary Functions are Slow - AC Lift with Regen Lower

Possible Cause Action

Bad or mis-adjusted RV-4 Adjust or replace RV-4.

Bad EP-1 valve Replace EP-1.

Bad pump Measure pressure.

Bad aux motor Measure current draw.

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Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Symptom Tables: Hydraulic Functions

All Auxiliary Functions are Slow - DC Lift

Possible Cause Action

Incorrect hydraulic fluid for Replace hydraulic fluid with correct fluid. See “Lubrication
application 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 7-95. 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.

No Tilt or Tilt One Direction Only; Other Aux Functions OK

Possible Cause Action

Bad tilt switch (S6 and/or S7) Run Test I08 - Tilt Up Switch (S6) (Page 6-69) or Test I09 - Tilt
Down Switch (S7) (Page 6-70).

Bad tilt solenoid valve or coil, or Run Test O07 - Toggle Tilt Solenoid (Page 6-111). If contamination
wiring. Check for 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 Measure pressure; normal operation should be below bypass
carriage pressure. See “Auxiliary Pressure Adjustment” on page 7-95.
Binding produces higher pressures. Repair/replace cylinder or
other binding components.

Tilt cylinder leaking internally Measure pressure.

Slow Tilt; Other Aux Functions OK

Possible Cause Action

Mechanical binding in tilt cylinder or Measure pressure; normal operation should be below bypass
carriage pressure. See “Auxiliary Pressure Adjustment” on page 7-95.
Binding produces 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.

No Sideshift or One Direction Only; Other Aux Functions OK

Possible Cause Action

Bad sideshift switch (S8 and/or S9) Run Test I10 - Sideshift Right Switch (S9) (Page 6-71) or Test
I11 - Sideshift Left Switch (S8) (Page 6-72).

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Symptom Tables: Hydraulic Functions

Possible Cause Action

Bad sideshift solenoid or wiring Run Test O08 - Toggle the Sideshift Solenoid (Page 6-112). Swap
hoses with tilt to check valve and cylinder.

Mechanical binding in sideshift Measure pressure; normal operation should be below bypass
cylinder or carriage pressure. See “Auxiliary Pressure Adjustment” on page 7-95.
Binding produces higher pressures. Repair/replace cylinder or
other binding components.

Sideshift cylinder leaking internally Measure pressure.

Slow Sideshift; Other Aux Functions OK

Possible Cause Action

Mechanical binding in sideshift Measure pressure; normal operation should be below bypass
cylinder or carriage pressure. See “Auxiliary Pressure Adjustment” on page 7-95.
Binding produces higher pressures. Repair/replace cylinder or
other binding components.

Bad sideshift solenoid valve Repair/replace sideshift solenoid valve.

Sideshift cylinder leaking internally Measure pressure.

Reach and Retract Do Not Work or are Slow; Other Functions OK

Possible Cause Action

Bad reach solenoid (valve or wiring) Run Test I06 - Reach Switch (S4) (Page 6-67). 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 7-95. Binding produces 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 7-95. Binding produces higher pressures. Repair/replace
cylinder or other binding components.

Switches S4 and S5 both bad (or Run Test I06 - Reach Switch (S4) (Page 6-67) and Test I07 - Retract
wiring) Switch (S5) (Page 6-68).

Reach cylinder leaking internally Measure pressure.

RV-1 bad Replace RV-1.

Reach Does Not Work; Other Functions OK

Possible Cause Action

Bad reach switch (S4) Run Test I06 - Reach Switch (S4) (Page 6-67).

RV-2 bad Replace RV-2.

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Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Symptom Tables: Hydraulic Functions

Retract Does Not Work; Other Functions OK

Possible Cause Action

Bad retract switch (S5) Run Test I07 - Retract Switch (S5) (Page 6-68).

Steering Does Not Work; Other Functions OK - 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 - 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 Replace orbitrol.

steering orbitrol

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Symptom Tables: Hydraulic Functions

Lift/Lower System
No Lift - Motor Runs - AC Lift
Possible Cause Action

Bad POD-1 valve Replace POD-1 valve.

SOL3 main relief dump valve pressure Run Test O09 - Aux Dump (SOL6 or SOL8)/Main Relief Dump
too low (SOL3) (Page 6-113). Replace SOL3.

SOL2 lift/lower valve open Run Test O12 - Ramp the Proportional Lower (SOL2) Solenoid
(Page 6-115).

No Lift - Motor Runs - AC Lift with Regen Lower

Measure pressure at Main Manifold
Action
Port G1.

If no pressure... Replace CV-1 in pump manifold. If still no pressure, replace lift

pump.

If pressure is at bypass... Inspect mast and cylinders for binding.

If pressure is less than 1500 psi but Make sure Emergency Lower Valve is closed. Adjust or replace
greater than 0 psi... RV-5 in main manifold. If still no lift, replace CV-5 in main
manifold. If still no lift, replace lift pump.

No Lift - Motor Runs - DC Lift

Measure pressure at Main Manifold
Action
Port G1.

If pressure is less than 1500 psi but Disconnect coil wire to SOL2. If lift works, run Test O12. If still no
greater than 0 psi... lift, adjust or replace Main Relief REL-1. If still no lift, replace
Lift/Lower solenoid SOL2. If still no lift, replace lift pump.

If no pressure... Replace Load Hold solenoid (SOL1). If still no pressure, replace

CV-1. If still no pressure, replace lift pump.

If pressure is at bypass... Inspect mast and cylinders for binding.

No Lift - Motor Does Not Run - AC Lift

Possible Cause Action

Battery below BSOC cutout setting Check battery voltage and BSOC settings.

Maintenance Minder ™ interval Display config settings for Maintenance Minder.

exceeded with LCutout specified

Bad Lift Cutout Switch Run Test I22 - Lift Cutout Switch (S27) (Page 6-77).

Third party device not functioning Test per third party device documentation.
correctly.

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Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Symptom Tables: Hydraulic Functions

No Lift - Motor Does Not Run - DC Lift

Possible Cause Action

Battery below BSOC cutout setting Check battery voltage and BSOC settings.

Maintenance Minder ™ interval Display config settings for Maintenance Minder.

exceeded with LCutout specified

Open in Lift Motor circuit Run Test O28 - Ramp Lift Motor (AC Lift) (Page 6-121).

Bad Lift Cutout Switch Run Test I22 - Lift Cutout Switch (S27) (Page 6-77).

Third party device not functioning Test per third party device documentation.
correctly.

Slow Lift with No Load - AC Lift

Measure pressure at Main Manifold
Action
Ports G1 and PP.

If pressure at G3 is in bypass and Replace POD-1 valve. If readings remain the same, replace CV-1.
pressure is low at G1...

If pressure at G3 and G1 are in Inspect mast and cylinders for binding or bad flow limiter.
bypass...

If pressure at G3 and G1 is less than Run Test O09 - Aux Dump (SOL6 or SOL8)/Main Relief Dump
1500 psi... (SOL3) (Page 6-113). If OK, replace SOL3. If still slow lift, replace
lift pump.

Slow Lift with No Load - AC Lift with Regen Lower

Measure pressure at Main Manifold
Action
Port G1.

If pressure is at bypass... Inspect mast and cylinders for binding or bad flow limiter.

If pressure is less than 1500 psi... Make sure Emergency Lower Valve is closed. Adjust or replace
RV-5 in main manifold. If still no lift, replace CV-5 in main
manifold. If still no lift, replace CV-6 in main manifold. If still no
lift, replace lift pump.

Slow Lift with No Load - DC Lift

Measure pressure at Main Manifold
Action
Port G1.

If pressure is less than 1500 psi but Disconnect coil wire to SOL2. If lift works, run Test O12 - Ramp
greater than 0 psi... the Proportional Lower (SOL2) Solenoid (Page 6-115). If still slow
lift, adjust or replace Main Relief REL-1. If still slow lift, replace
SOL2. If still slow lift, replace Load Hold Solenoid (SOL1). If still
slow lift, replace CV-1. If still slow lift, test lift motor. If OK, replace
lift pump.

If pressure is at bypass... Inspect mast and cylinders for binding or bad flow limiter.

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Symptom Tables: Hydraulic Functions

Unable to Pick Up a Load - AC Lift

Possible Cause Action

Bad SOL3 Run Test O09 - Aux Dump (SOL6 or SOL8)/Main Relief Dump
(SOL3) (Page 6-113).

Bad lift pump Check pressures. Replace pump.

Unable to Pick Up a Load - AC Lift with Regen Lower

Possible Cause Action

Bad Relief Valve RV-5 Adjust or replace RV-5.

Bad lift pump Replace lift pump.

Unable to Pick Up a Load - 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.

Slow Lower
Possible Cause Action

Clogged hydraulic filter Replace hydraulic filter.

Mechanical binding in bearings or Adjust or replace bearings. Check shimming.

telescopics

Bad lift/lower proportional solenoid Run Test O12 - Ramp the Proportional Lower (SOL2) Solenoid
valve SOL2 (Page 6-115).

Contamination in load holding Inspect load holding solenoid SOL1 for contamination.
solenoid valve SOL1

Plugged or malfunctioning flow limiter Replace flow limiters.

Bad CV-2 (Regen Lower) Replace CV-2.

Bad CV-8 (Regen Lower) Replace CV-8.

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Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Symptom Tables: Hydraulic Functions

Intermittent Lower
Possible Cause Action

Bad SOL2 solenoid (valve or wiring) Perform Learn Lower. Run Test O12 - Ramp the Proportional Lower
(SOL2) Solenoid (Page 6-115). Check wiring. Replace SOL2.

Bad SOL1 load holding solenoid (valve Run Test O11 - Toggle the Load Hold (SOL1) Solenoid (Page 6-114).
or wiring) Check wiring. Replace SOL1.

Plugged or malfunctioning flow limiter Replace flow limiters.

valves

Load Drifting/Settling
Possible Cause Action

Load too large for lift truck capacity Check load weight.

DC Lift: Incorrect lift pressure Check and adjust lift pressure setting.
adjustment

DC Lift: Contaminated or bad relief Replace relief valve REL1. If contamination is present, flush, fill,
valve REL1 and bleed the hydraulic system.

AC Lift with Regen Lower: Leaking Replace CV-6.

CV-6

Leaking or contaminated load holding Replace SOL1.

solenoid SOL1

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Symptom Tables: Travel Functions

Symptom Tables: Travel

Functions
Slow or Sluggish Acceleration
Possible Cause Action

Configuration:

Accel set to “soft” Set accel to “medium” or “hard.” See “Using Configure Mode” on
page 3-13.

Mechanical:

Worn load wheel or idler wheel assy Replace load wheel/idler assembly as required.

Debris in load wheel axle or idler Remove debris.

Dragging brake Inspect brake for correct operation.

Binding drive unit Inspect for wear.

Electrical: Measure current draw.

Current is limited due to high Check temperature and temperature sensors for traction motor
temperature and power amplifier. Run Test A08 - Traction Motor Temperature
(Page 6-30) and Test A10 - TPA Temperature (Page 6-33).

Slow Travel
Possible Cause Action

Mechanical:

Binding drive unit Check for excessive current draw in Traction Motor.

Dragging brake Inspect brake for correct operation.

Electrical:

Incorrect configuration of speed Reconfigure the lift truck. See “Using Configure Mode” on
page 3-13.

If equipped with nested switch option, Run Test I01 - Nested Switch (S14) (Page 6-65).
bad S14 switch

Bad height encoder (causing false Run Test I26 - Height Indicator Encoder (Page 6-82).
speed limiting)

Bad Speed Limit 1 Switch S12 Run Test I02 - 1st Speed Limiting Switch (S12) (Page 6-66).

Bad High Speed Travel Switch S25 Run Test I63 - High Speed Travel Switch (S25) (Page 6-90).

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Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Symptom Tables: Electrical Symptoms

Symptom Tables:
Electrical Symptoms
NOTE: Reference electrical schematics.

Motor Overheating
Possible Cause Action

Especially DC Lift: Application exceeds Contact Dealer Service Manager to make sure of application.
designed workload -- 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 Check motor brushes.

brushes or springs (lift and aux motor Check brush spring tension.
only)

Cable, terminal, or wiring problems. Replace wiring or cables as needed. Make sure motor cables are
Look for loose or discolored terminals, torqued correctly.
loose or damaged crimps.

High motor current due to binding Inspect gearbox or pump for binding. Check brake for correct
gearbox, pump, or dragging brake operation.

Cooling fans not functioning correctly. Run Test O23 - Toggle Fans (Page 6-119).

Note: See also “DC Motors” on page 5-10 and “AC Motors” on page 5-14.

Scrambled or Intermittent Display

Possible Cause Action

Electrostatic discharge resulting from Clean or replace static straps as needed.

dirty, worn, or wrong type static
straps

Loose display harness or card Reseat cards and harness connections. Test for continuity while
connectors; intermittent wires or flexing harness. If no continuity is found, replace wiring harness.
connectors in harness See “Wiring and Harness Connectors” on page 7-71.

Short to frame See “Shorts to Frame” on page 5-2.

Mismatched Vehicle Manager and Install matching Vehicle Manager and Display Manager software.
Display Manager software VM and DM versions may not have the same version number. See
“FlashWare” on page 3-8.

Incorrect installation of options or Verify correct installation of options.

unauthorized parts

Bad Operator Display card Replace Operator Display card.

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Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting

Symptom Tables: Electrical Symptoms

Display is Dark; Lift Truck is Not Operational

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 Troubleshoot B+ to B+KEY circuits from battery to VM.
B+ to Vehicle Manager or bad Vehicle
Manager

Problem with +12V power supply Troubleshoot +12V supply at VM. Run Test A14 - +12VDC Power
Supply (Page 6-36).

Bad Operator Display Replace Operator Display.

Publication: 1112860, Issued: 15 Feb 2012 5-27

Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks

Symptom Tables: Electrical Symptoms

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Section 6. Messages, Codes, and Tests

Publication: 1112860, Issued: 15 Feb 2012 6-1

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Power Amp LED Diagnostics

Power Amp LED

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

The power amps also contain a Light Emitting

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

6-2 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Messages and Codes Summary List

Section 6. Messages, Codes, and Tests

Code 1H - TPA Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Code 1V - LPA Overheated (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Code 2A - Traction Motor Approaching Overtemp . . . . . . . . . . . . . . . . 6-5
Code 2E - Traction Motor Temp Sensor Out-of-Range . . . . . . . . . . . . 6-5
Code 2G - Phase Open on Traction Motor . . . . . . . . . . . . . . . . . . . . . 6-6
Code 2H - Traction Motor Speed Sensor Failure . . . . . . . . . . . . . . . . . 6-6
Code 2T - TPA Current Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Code 2U - TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . 6-6
Code 2V - TPA High DC Bus Voltage . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Code 2X - TPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . 6-7
Code 42 - LPC Detected Closed When Commanded Open . . . . . . . . . . 6-7
Code 43 - LPC Detected Open When Commanded Closed . . . . . . . . . . 6-7
Code 44 - PC Detected Closed When Commanded Open . . . . . . . . . . . 6-7
Code 45 - PC Detected Open When Commanded Closed . . . . . . . . . . . 6-7
Code 49 - Aux Contactor Detected Closed When Commanded Open . . 6-8
Code 4A - Aux Contactor Detected Open When Commanded Closed . . 6-8
Code 4B - Steer Contactor Detected Closed
When Commanded Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Code 4C - Steer Contactor Detected Open
When Commanded Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Code 4D - No Pre-Charge Traction DC Input Voltage
During Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Code 4E - No Pre-Charge Lift DC Input Voltage
During Start-Up (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Code 55 - Vantage Point CAN Timeout . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Code 57- VM Not Responding to Operator Display . . . . . . . . . . . . . . . 6-9
Code 58 - OCSS CAN Communication Error . . . . . . . . . . . . . . . . . . 6-10
Code 59 - CAN Transmission Buffer Error . . . . . . . . . . . . . . . . . . . . 6-10
Code 5A - CAN Bus Error/VM for BUS_I . . . . . . . . . . . . . . . . . . . . . 6-10
Code 5B - CAN Receive Bus Error/VM . . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 5G - No Communications Received from TPA . . . . . . . . . . . . . 6-10
Code 5J - No Communications Received from LPA (AC Lift) . . . . . . . 6-11
Code 5M - TPA CAN Watchdog Timeout . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 5P - LPA CAN Watchdog Timeout (AC Lift) . . . . . . . . . . . . . . . . 6-11
Code 5Q - Display Manager Not Responding . . . . . . . . . . . . . . . . . . 6-11
Code 61 - Mast Switch #1 Not Crossed . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 63 - HS Travel and 1st Speed Limiting Switches
Do Not Agree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 64 - No Pulses Seen from Height Indicator Encoder . . . . . . . . . 6-12
Code 66 - Calculated Height Greater Than Configured Height . . . . . 6-12
Code 67 - Calculated Height Does Not Match
1st Speed Limiting Switch (S12) . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 6D - Pressure Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . 6-13
Code 6F - Lift Motor Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 6G - Lift Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . . 6-13
Code 6T - LPA Current Sensor Error (AC Lift) . . . . . . . . . . . . . . . . . . 6-13
Code 6U - Excessive Lift Motor Brush Wear (DC Lift) . . . . . . . . . . . . 6-14

Publication: 1112860, Issued: 15 Feb 2012 6-3

Messages and Codes Summary List Models 7500/7520 Reach-Fork ® Trucks

Code 6W - Failure Detected in Lift Motor Speed Sensor (AC Lift) . . . 6-14
Code 6X - LPA Fault: Overcurrent (AC Lift) . . . . . . . . . . . . . . . . . . . 6-14
Code 6Y - LPA Fault: High DC Voltage (AC Lift) . . . . . . . . . . . . . . . . 6-14
Code 6Z - FlashWare Parameters Do Not Match Stored Values . . . . 6-14
Code 7G - Lift Motor Phase Open . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 7X - LPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . 6-15
Code 80 - Primary Throttle Pot Out-of-Range . . . . . . . . . . . . . . . . . . 6-15
Code 81 - Lift/Lower Pot Out-of-Range . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 83 - Primary Throttle Pot Out-of-Neutral . . . . . . . . . . . . . . . . . 6-15
Code 84 - Brake - Not Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 88 - +5VDC Power Supply Out-of-Range . . . . . . . . . . . . . . . . . 6-16
Code 8A - OCSS Photo Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 8F - Lift/Lower Pot Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . 6-16
Code 8G - Secondary Throttle Pot Out-of-Range . . . . . . . . . . . . . . . 6-16
Code 8H - Secondary Throttle Pot Out-of-Neutral . . . . . . . . . . . . . . 6-17
Code 8J - Ambient Air Temp Sensor Out-of-Range . . . . . . . . . . . . . 6-17
Code 8L - Brake Feedback Current Out-of-Range . . . . . . . . . . . . . . 6-17
Code 8M - Internal Handle Heater Failure . . . . . . . . . . . . . . . . . . . . 6-17
Code 8N - Optional Start Switch Closed at Start-Up . . . . . . . . . . . . 6-17
Code A0 - Incorrect VM Software Version . . . . . . . . . . . . . . . . . . . . 6-18
Code AH - Bad Display Card Checksum . . . . . . . . . . . . . . . . . . . . . 6-18
Code AV - Primary Memory Mismatch . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code F4 - VM COP Time-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code F5 - Bad Op Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code F8 - VM COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code FE - VM Not Calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code FG - 5 and/or 12V Power Supply Out-of-Range . . . . . . . . . . . 6-20
Code FH - Battery Voltage Out-of-Range . . . . . . . . . . . . . . . . . . . . . 6-20
Code FN - Relays Did Not Open at Power Off . . . . . . . . . . . . . . . . . . 6-20
Code FP - VM Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code FR - VM Config Item Out-of-Range . . . . . . . . . . . . . . . . . . . . . 6-20
Code FT - VM Internal Software Error . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code FV - Display Internal Software Error . . . . . . . . . . . . . . . . . . . . 6-21
Code G0 - Steer Tiller 1 Channel A/B Fault (AC Lift) . . . . . . . . . . . . 6-21
Code G3 - Steer Feedback Prox Sensor Fault (AC Lift) . . . . . . . . . . . 6-21
Code G4 - Open Detected in Steer Control Circuit (AC Lift) . . . . . . . 6-22
Code G5 - Short Detected in Steer Motor Encoder Circuit (AC Lift) . . 6-22
Code G7 - Steer Tiller 2 Channel A/B Fault (AC Lift) . . . . . . . . . . . . 6-22
Code GD - Open Detected in Steer Motor Encoder Circuit (AC Lift) . 6-22
Code GE - Steer Encoder Failure (AC Lift) . . . . . . . . . . . . . . . . . . . . 6-23
Code T0 - SOL5T Current Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code T1 - SOL5B Current Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code T2 - SOL3 Current Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code T3 - SOL2 Current Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code X4 - Switch Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Messages and Codes

Messages and Codes

Section 6. Messages, Codes, and Tests

Code 1H Overheated. Allow Time to Cool

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

Code 1H - TPA Overheated Test A10 - TPA Travel is disabled. Cycle key
The TPA has reported its internal Temperature switch to clear after TPA has
temperature is >239°F (115°C). (Page 6-33) cooled.
Test O23 - Toggle Fans Note: The VM cannot cause this
(Page 6-119) code.

Lift Cut-Out Pending...Low Battery

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

Battery Low None Change battery. Self resetting.

Lift cutout point configured for
BSOC has been reached.

Code 1V Overheated, Allow Time to Cool

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

Code 1V - LPA Overheated Test A19 - LPA Temp Lift is disabled. Cycle key switch
(AC Lift) (AC Lift) (Page 6-38) to clear after LPA has cooled.
The LPA has reported its internal Test O23 - Toggle Fans Note: The VM cannot cause this
temperature is >239°F (115°C). (Page 6-119) code.

Code 2A Overheated, Allow Time to Cool

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

Code 2A - Traction Motor Test A08 - Traction Traction performance is limited.

Approaching Overtemp Motor Temperature Self resetting after motor has
The TPA senses the Traction Motor (Page 6-30) cooled.
is approaching overtemperature. Note: The VM cannot cause this
code.

Code 2E Inform Service

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

Code 2E - Traction Motor Temp Test A08 - Traction Traction performance is limited.
Sensor Out-of-Range Motor Temperature Self resetting.
The Traction Motor temperature (Page 6-30) Note: The VM cannot cause this
sensor is open or shorted. code.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Code 2G - Phase Open on Traction Motor

Code 2G Inform Service

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

Code 2G - Phase Open on Test O29 - Ramp Cycle key switch to clear.
Traction Motor Traction Motor Note: The VM cannot cause this
The TPA detects no current draw in (Page 6-122) code.
one of the three phases of the
motor.

Code 2H Inform Service

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

Code 2H - Traction Motor Speed Test I19 - Traction Traction performance is limited.
Sensor Failure Motor Speed Sensor Self resetting.
The Traction Motor speed sensor (Page 6-75) Note: The VM cannot cause this
circuit is inoperative. code.

Code 2T Inform Service

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

Code 2T - TPA Current Sensor None Traction performance is limited.

Error Cycle key switch to clear. If code
The TPA has detected a current does not clear, replace TPA.
calibration error. Note: The VM cannot cause this
code.

Code 2U Inform Service

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

Code 2U - TPA Overcurrent or Test A11 - Traction Traction is disabled. Cycle key
Short Circuit Motor Current switch to clear.
The TPA has sensed current in (Page 6-34) Note: The VM cannot cause this
excess of 540A. Note: This code may be code.
caused by a shorted
TPC diode.

Code 2V Inform Service

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

Code 2V - TPA High DC Bus None Traction is disabled. Cycle key

Voltage switch to clear. If code occurs
The TPA has detected >50VDC at during plugging, replace all
TPA+. battery cables and connections
that show signs of heat or
corrosion. Install a battery that is
in good condition. If code persists,
replace the TPA.
Note: The VM cannot cause this
code.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Code 2X - TPA Power Supply Out-of-Range

Code 2X Inform Service

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

Code 2X - TPA Power Supply None Cycle key switch to clear.

Out-of-Range Disconnect +wire to temperature
The power supply output in the and speed sensors. Cycle key
TPA is <4.5V, >5.5V, or too much switch. If code changes, trouble-
current is being drawn by an shoot wires and sensors. If code
external component. does not change, replace TPA.
Note: The VM cannot cause this
code.

Code 42 Inform Service

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

Code 42 - LPC Detected Closed Test O02 - Toggle LPC Cycle key switch to clear.
When Commanded Open Contactor (Page 6-106) Note: Low battery voltage can
The VM detected >10VDC at contribute to burnt tips. If
JPC22-20 (FU3 Sense) after the contactor tips are welded or
LPC was commanded open. burnt, check the BSOC setting in
Config Mode menu.

Code 43 Inform Service

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

Code 43 - LPC Detected Open Test O02 - Toggle LPC Cycle key switch to clear.
When Commanded Closed Contactor (Page 6-106) Note: The VM cannot cause this
The VM detected <18VDC at code on trucks with AC Lift.
JPC22-20 after the LPC coil was
energized.

Code 44 Inform Service

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

Code 44 - PC Detected Closed Test O00 - Toggle TPC Cycle key switch to clear.
When Commanded Open or MPC Contactor Note: Low battery voltage can
The VM detected an incorrect (Page 6-104) contribute to burnt tips. If
voltage at JPC24-21 during contactor tips are welded or
SelfTest. burnt, check the BSOC setting in
Config Mode menu.

Code 45 Inform Service

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

Code 45 - PC Detected Open Test O00 - Toggle TPC Cycle key switch to clear.
When Commanded Closed or MPC Contactor
The VM detected <12VDC at (Page 6-104)
JPC24-21 after the TPC coil was
energized.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Code 49 - Aux Contactor Detected Closed When Commanded Open

Code 49 Inform Service

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

Code 49 - Aux Contactor Test O03 - Toggle AUX Cycle key switch to clear.
Detected Closed When Contactor (Page 6-107)
Commanded Open
The VM detected >10VDC at
JPC22-20 when the AUX coil was
de-energized.

Code 4A Inform Service

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

Code 4A - Aux Contactor Test O03 - Toggle AUX Cycle key switch to clear.
Detected Open When Contactor (Page 6-107)
Commanded Closed
The VM detected <10VDC at
JPC22-20 when the AUX coil was
energized.

Table 6-1. Code 4B Inform Service

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

Code 4B - Steer Contactor Test O01 - Toggle STR Cycle key switch to clear.
Detected Closed When Contactor (Page 6-105)
Commanded Open If open, run Test
The VM detected >10VDC at I14 - Steering Fuse
JPC22-19 when the STR coil was (FU1) (Page 6-73).
de-energized.

Code 4C Inform Service

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

Code 4C - Steer Contactor If contactor closes, run Cycle key switch to clear.
Detected Open When Test I14 - Steering Fuse
Commanded Closed (FU1) (Page 6-73).
The VM detected <10VDC at If contactor does not
JPC22-19 when the STR coil was close, run Test
energized. O01 - Toggle STR
Contactor (Page 6-105).

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Code 4D - No Pre-Charge Traction DC Input Voltage During Start-Up

Code 4D Inform Service

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

Code 4D - No Pre-Charge None Cycle key switch to clear.

Traction DC Input Voltage Check components, connections,
During Start-Up and wiring between JPF1-5 and
The TPA detected an incorrect TPA+ for correct resistance and
pre-charge voltage (<25VDC) at continuity.
TPA+. TPA Pre-Charge Resistor (TR) =
12 ohms.
Thermistor on Fuse/Relay Card =
6 to 12 ohms at room temp
(70°F/21°C).

Code 4E Inform Service

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

Code 4E - No Pre-Charge Lift DC None Cycle key switch to clear.

Input Voltage During Start-Up Check components, connections,
(AC Lift) and wiring between JPF1-3 and
The LPA detected an incorrect LPA+ for correct resistance and
pre-charge voltage (<25VDC) at continuity.
LPA+. LPA Pre-Charge Resistor (LR) =
12 ohms.
Thermistor on Fuse/Relay Card =
6 to 12 ohms at room temp
(70°F/21°C).

Code 55 Inform Service

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

Code 55 - Vantage Point CAN None This code is only displayed if the
Timeout Vantage Point option is enabled.
Communication from the Vantage Check the wires to JPVS1 from
Point system is not functioning. the VM for opens or shorts. If
none are found, replace the
Vantage Point module.

Code 57 Inform Service

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

Code 57- VM Not Responding to Test I23 - CAN Bus Self resetting.
Operator Display Test (Page 6-78) Note: This code is not normally
The Operator Display has lost recorded in the error log since the
communication with the VM over log resides in the VM.
the CAN bus. This code is initiated A code 5Q is often recorded in the
by the Operator Display. error log when a code 57 is on the
Operator Display.

Publication: 1112860, Issued: 15 Feb 2012 6-9

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Code 58 - OCSS CAN Communication Error

Code 58 Inform Service

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

Code 58 - OCSS CAN None Cycle key switch to clear.

Communication Error Check for +12V at JPX1-1 and 0V
No communication received from at JPX1-4 on the OCSS CAN I/O
the OCSS controller. Expander Module.

Code 59 Inform Service

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

Code 59 - CAN Transmission Test I23 - CAN Bus Cycle key switch to clear.
Buffer Error Test (Page 6-78) Check for shorts to frame, static,
The VM has detected a CAN and electrical leakage from
transmission buffer error. battery.

Code 5A Inform Service

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

Code 5A - CAN Bus Error/VM for Test I23 - CAN Bus Cycle key switch to clear.
BUS_I Test (Page 6-78) Check for shorts to frame, static,
The VM detected an error in the and electrical leakage from
CAN Bus. battery.
Note: This code cannot be caused
by an error on the secondary bus
BUS_E.

Code 5B Inform Service

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

Code 5B - CAN Receive Bus Test I23 - CAN Bus Cycle key switch to clear.
Error/VM Test (Page 6-78) Check for shorts to frame, static,
CAN Receive Bus error in VM for and electrical leakage from
BUS_I. battery.
Note: This code cannot be caused
by an error on the secondary bus
BUS_E.

Code 5G Inform Service

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

Code 5G - No Communications Test I23 - CAN Bus Cycle key switch to clear.
Received from TPA Test (Page 6-78) Check for shorts to frame, static,
The VM has received no and electrical leakage from
communication from the TPA. battery.
Note: This code can be caused by
bad K3 relay tips. Check LEDs on
both power amplifiers. If both are
not illuminated, check the K3
relay.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Code 5J - No Communications Received from LPA (AC Lift)

Code 5J Inform Service

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

Code 5J - No Communications Test I23 - CAN Bus Cycle key switch to clear.
Received from LPA (AC Lift) Test (Page 6-78) Check for shorts to frame, static,
The VM has received no and electrical leakage from
communication from the LPA. battery.

Code 5M Inform Service

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

Code 5M - TPA CAN Watchdog Test I23 - CAN Bus Cycle key switch to clear.
Timeout Test (Page 6-78) This code is generated by the TPA.
CAN watchdog circuit timeout This fault can be caused by a
detected by TPA. source external to the amplifier.
Check for shorts to frame, static,
electrical leakage from battery,
bad power amp cables or wiring,
and CAN Bus.

Code 5P Inform Service

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

Code 5P - LPA CAN Watchdog Test I23 - CAN Bus Cycle key switch to clear.
Timeout (AC Lift) Test (Page 6-78) This code is generated by the LPA.
The CAN watchdog circuit has not This fault can be caused by a
received communication from other source external to the amplifier.
amplifier circuits. Check for shorts to frame, static,
electrical leakage from battery,
bad power amp cables or wiring,
and CAN Bus.

Code 5Q Inform Service

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

Code 5Q - Display Manager Not Test I23 - CAN Bus Self resetting.
Responding Test (Page 6-78) Note: Code 5Q is recorded in the
The VM is not receiving error log. The Operator Display
communication from the Display will most likely display Code 57.
Manager. This code appears in the
error log but not usually on the
Operator Display.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Code 61 - Mast Switch #1 Not Crossed

Code 61 Inform Service

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

Code 61 - Mast Switch #1 Not Test I02 - 1st Speed Cross mast switch #1.
Crossed Limiting Switch (S12)
AC Lift: Too many height encoder (Page 6-66)
pulses were seen without detecting
mast switch #1 opening.
DC Lift: Too much time has elapsed
without crossing mast switch #1
while a lift request is above a
certain threshold.

Code 63 Inform Service

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

Code 63 - HS Travel and 1st Test I02 - 1st Speed Cross the 1st speed limiting
Speed Limiting Switches Do Limiting Switch (S12) switch several times.
Not Agree (Page 6-66) Note: Check the error log to see if
The VM reads the 1st speed Test I63 - High Speed a Code 64 or 67 preceded the
limiting switch as closed when the Travel Switch (S25) Code 63. If so, troubleshoot per
HS travel switch or Switch 2 reads (Page 6-90) that code.
open. Note: Switch 2 must be turned
ON in FlashWare for trucks with
an elevated height above 331 in.

Code 64 Inform Service

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

Code 64 - No Pulses Seen from Test I02 - 1st Speed Lower the carriage, then lift past
Height Indicator Encoder Limiting Switch (S12) the first mast switch.
With the lift pump running or (Page 6-66) Troubleshoot HTI system. Code
SOL2 energized, the first mast limit Test I86 - Lift Height clears when pulses are detected.
switch is open, but the VM (Page 6-98) Cycle key switch.
detected no pulses from the Height If code is intermittent, cause
Indicator encoder. could be proportional valve.
Adjust valve - see “Proportional
Valve Adjustment” on page 7-94.

Code 66 Inform Service

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

Code 66 - Calculated Height Test I86 - Lift Height Lower the carriage below the
Greater Than Configured (Page 6-98) configured maximum height to
Height clear.
The carriage height calculated by Check actual mast height against
the VM, from information from the configured height.
Height Indicator, is more than 6 in. Check actual fork height against
(15 cm) greater than the configured indicated fork height when HTI
height of the lift truck. counting begins.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Code 67 - Calculated Height Does Not Match 1st Speed Limiting Switch (S12)

Code 67 Inform Service

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

Code 67 - Calculated Height Does Test I02 - 1st Speed Lift the carriage through the 1st
Not Match 1st Speed Limiting Limiting Switch (S12) speed limiting switch height or
Switch (S12) (Page 6-66) cycle the key switch to clear.
The VM detected S12 closed at an
incorrect calculated height when
lowering.

Code 6D Inform Service

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

Code 6D - Pressure Sensor Test A13 - Pressure Cycle key switch to clear.
Out-of-Range Sensor Voltage
Voltage is <0.7V (indicating (Page 6-35)
<300 psi) or >5.0V (indicating
>3999 psi).

Code 6F Overheated. Allow time to cool

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

Code 6F - Lift Motor Overtemp Test A09 - Lift Motor Allow time to cool. Self resetting.
AC Lift: The LPA has detected the Temperature
Lift Motor is overheated (Page 6-31)
(>300°F/149°C).
DC Lift: The VM has detected the
Lift Motor is overheated
(>279°F/137°C).

Code 6G Inform Service

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

Code 6G - Lift Motor Temp Test A09 - Lift Motor Self resetting.
Sensor Out-of-Range Temperature Note: The VM cannot cause this
Lift motor temperature sensor is (Page 6-31) code.
out-of-range.

Code 6T Inform Service

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

Code 6T - LPA Current Sensor None Cycle key switch to clear.

Error (AC Lift) Replace the LPA.
The LPA has detected an internal Note: The VM cannot cause this
fault. code.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Code 6U - Excessive Lift Motor Brush Wear (DC Lift)

Code 6U Inform Service

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

Code 6U - Excessive Lift Motor None Cycle key switch to clear.

Brush Wear (DC Lift) Replace brushes.
The VM has detected more than
+10VDC at JPC22-15
(BrushWear1) or JPC22-16
(BrushWear2).

Code 6W Inform Service

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

Code 6W - Failure Detected in Test I20 - Lift Motor Self resetting.

Lift Motor Speed Sensor Speed Sensor (AC Lift) Note: The VM cannot cause this
(AC Lift) (Page 6-76) code.
The lift feedback circuit, as seen by
the LPA, is not functioning.

Code 6X Inform Service

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

Code 6X - LPA Fault: Overcurrent Test A20 - Lift Motor Cycle key switch to clear.
(AC Lift) Current (AC Lift) Note: The VM cannot cause this
The LPA has detected >675A or a (Page 6-39) code.
shorted output.

Code 6Y Inform Service

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

Code 6Y - LPA Fault: High DC None Cycle key switch to clear.

Voltage (AC Lift) Install good battery. Replace TPA.
The LPA has detected a DC input
voltage exceeding 50V at LPA (+).

Code 6Z Inform Service

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

Code 6Z - FlashWare Parameters None Cycle key switch to clear.

Do Not Match Stored Values Verify programmed height is
Fork height, as calculated by the correct in FlashWare.
display, is at least 6 in. higher than
the maximum elevated height
programmed in the truck’s
memory.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Code 7G - Lift Motor Phase Open

Code 7G Inform Service

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

Code 7G - Lift Motor Phase Open Test O28 - Ramp Lift Cycle key switch to clear.
The LPA detects no current draw in Motor (AC Lift) Note: The VM cannot cause this
one of the three phases of the (Page 6-121) code.
motor.

Code 7X Inform Service

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

Code 7X - LPA Power Supply None Cycle key switch to clear.

Out-of-Range Disconnect +wire to LPA
The power supply output in the temperature and speed sensors. If
LPA is <4.5V, >5.5V, or too much code changes, troubleshoot wires
current is being drawn by an and sensors. If code does not
external component. change, replace LPA.

Code 80 Inform Service

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

Code 80 - Primary Throttle Pot Test A04 - Primary Cycle key switch to clear.
Out-of-Range Throttle Pot (VR1)
The VM detects <0.15V or >2.1V at Voltage (Page 6-28)
JPC12-3. Test A26 - +5VDC
Power Supply
(Page 6-42)

Code 81 Inform Service

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

Code 81 - Lift/Lower Pot Test A05 - Lift/Lower Cycle key switch to clear.
Out-of-Range Pot Voltage (Page 6-29)
The VM detected <0.15V or >2.1V Test A26 - +5VDC
at JPC12-2. Power Supply
(Page 6-42)

Code 83 Inform Service

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

Code 83 - Primary Throttle Pot Test A04 - Primary Travel is disabled.

Out-of-Neutral Throttle Pot (VR1) Return control handle to neutral.
Primary throttle pot (VR1) out of Voltage (Page 6-28) Cycle key switch to clear.
learned neutral value. Test A26 - +5VDC
Power Supply
(Page 6-42)

Publication: 1112860, Issued: 15 Feb 2012 6-15

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Code 84 - Brake - Not Applied

Code 84 Inform Service

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

Code 84 - Brake - Not Applied Test I19 - Traction Cycle key switch to clear.
The Traction Motor speed sensor Motor Speed Sensor Check brake. See “Inspection” on
indicated movement during (Page 6-75) page 7-61.
SelfTest.

Code 88 Inform Service

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

Code 88 - +5VDC Power Supply Test A26 - +5VDC Cycle key switch to clear.
Out-of-Range Power Supply
Control Handle +5VDC power (Page 6-42)
supply (located on the VM) is
out-of-range.

Code 8A Inform Service

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

Code 8A - OCSS Photo Sensor Test I80 - OCSS Upper Cycle key switch to clear.
Fault Beam (Page 6-91)
The VM senses the beams are ON Test I81 - OCSS Lower
with the deadman pedal UP. Beam (Page 6-93)

Code 8F Inform Service

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

Code 8F - Lift/Lower Pot Test A05 - Lift/Lower Lift/lower disabled. Return

Out-of-Neutral Pot Voltage (Page 6-29) control handle to neutral.
Lift/Lower pot (VR2) out of learned Cycle key switch to clear.
neutral value.

Code 8G Inform Service

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

Code 8G - Secondary Throttle Test A26 - +5VDC Return control handle to neutral.
Pot Out-of-Range Power Supply Cycle key switch to clear.
The VM detected <0.1V or >2.2V at (Page 6-42)
JPC4-4. Test A29 - Secondary
Traction Throttle Pot
(VR3) Voltage (optional)
(Page 6-43)

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Code 8H - Secondary Throttle Pot Out-of-Neutral

Code 8H Inform Service

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

Code 8H - Secondary Throttle Test A26 - +5VDC Return control handle to neutral.
Pot Out-of-Neutral Power Supply Cycle key switch to clear.
Secondary throttle pot (VR3) out of (Page 6-42)
learned neutral value. Test A29 - Secondary
Traction Throttle Pot
(VR3) Voltage (optional)
(Page 6-43)

Code 8J Inform Service

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

Code 8J - Ambient Air Temp Test A36 - Ambient Air Cycle key switch to clear.
Sensor Out-of-Range Temp Sensor Note: Control handle heaters are
The voltage measured from the (Page 6-50) off when this code is present.
ambient air temp sensor is outside
the reference range.

Code 8L Inform Service

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

Code 8L - Brake Feedback Test A35 - Brake Cycle key switch to clear.
Current Out-of-Range Armature (Page 6-49) Note: The brake is either fully
The current measured in the brake engaged or fully disengaged when
feedback circuit is zero, or outside this code is present.
the reference range.

Code 8M Inform Service

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

Code 8M - Internal Handle Test A40 - Handle Self resetting.

Heater Failure Heater Reference
The internal heater in the control Voltage (optional)
handle has malfunctioned. (Page 6-53)

Code 8N Inform Service

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

Code 8N - Optional Start Switch Test I60 - Security Open, then close the optional
Closed at Start-Up Start Switch (S23) start switch.
The VM senses switch (S23) closed. (optional) (Page 6-89)

Publication: 1112860, Issued: 15 Feb 2012 6-17

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Code A0 - Incorrect VM Software Version

Code A0 Inform Service

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

Code A0 - Incorrect VM Software None Cycle key switch to clear. Re-flash

Version the VM with correct software. See
The Display Card and VM software “FlashWare” on page 3-8.
versions incompatible.

Code AH Inform Service

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

Code AH - Bad Display Card None Cycle key switch to clear.

Checksum 1. If the problem is
The Display Card and VM software intermittent, check for
checksums do not match. shorts to frame. See “Shorts
to Frame” on page 5-2.
2. Re-flash the software. See
“FlashWare” on page 3-8.
3. Replace the VM.
4. If the correct software
version appears on the
Operator Display, replace the
Display Card.

Code AP Inform Service

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

Code AP - TPA Software Fault None Cycle key switch to clear. If code
does not clear, upgrade TPA
software via FlashWare.

Code AT Inform Service

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

Code AT - LPA Software Fault None Cycle key switch to clear. If code
does not clear, upgrade LPA
software via FlashWare.

Code AV Inform Service

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

Code AV - Primary Memory None Cycle key switch to clear.

Mismatch Install a preprogrammed Operator
The three primary memory Display and a preprogrammed
locations do not agree. VM.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Code F4 - VM COP Time-out

Code F4 Inform Service

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

Code F4 - VM COP Time-out None Cycle key switch to clear.

The COP circuit has timed out 1. If the problem is
before a reset was generated. intermittent, check for
shorts to frame. See “Shorts
to Frame” on page 5-2.
2. Re-flash the software. See
“FlashWare” on page 3-8.
3. Replace the VM.

Code F5 Inform Service

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

Code F5 - Bad Op Code None Cycle key switch to clear.

Bad code was detected during 1. If the problem is
SelfTest. Results in total intermittent, check for
shutdown. shorts to frame. See “Shorts
to Frame” on page 5-2.
2. Re-flash the software. See
“FlashWare” on page 3-8.
3. Replace the VM.

Code F8 Inform Service

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

Code F8 - VM COP Not Enabled None Cycle key switch to clear.

1. If the problem is
intermittent, check for
shorts to frame. See “Shorts
to Frame” on page 5-2.
2. Re-flash the software. See
“FlashWare” on page 3-8.
3. Replace the VM.

Code FE Inform Service

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

Code FE - VM Not Calibrated None Message clears in 30 seconds.

The VM detected an internal Cycle key switch.
calibration error. BSOC If code continues, replace VM.
information could be inaccurate.

Publication: 1112860, Issued: 15 Feb 2012 6-19

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Code FG - 5 and/or 12V Power Supply Out-of-Range

Code FG Inform Service

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

Code FG - 5 and/or 12V Power Test A14 - +12VDC Cycle key switch.
Supply Out-of-Range Power Supply
The +5 and/or +12V power supply (Page 6-36)
voltage is out-of-range.

Code FH Inform Service

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

Code FH - Battery Voltage Test A15 - Battery Cycle key switch.

Out-of-Range Voltage (Page 6-37) Check Fuse FU10.
Battery voltage is <28V or >45V at
SelfTest. Results in total
shutdown.

Code FN Inform Service

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

Code FN - Relays Did Not Open at Test O32 - Toggle Brake engages.
Power Off Relays K1, K2, K3, and Disconnect, then re-connect
K4 (Page 6-124) battery connector.
Check other relays and circuits
associated with the K4 relay tips.

Code FP Inform Service

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

Code FP - VM Internal Fault None Brake engages.

Cycle key switch.
Replace VM.

Code FR (displays for 5 seconds)

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

Code FR - VM Config Item None Out-of-range parameter is reset

Out-of-Range after 5 seconds to the default
The value of a configurable value.
parameter is out of the reference
range.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Code FT - VM Internal Software Error

Code FT Inform Service

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

Code FT - VM Internal Software None Brake engages.

Error Cycle key switch.
Document the sequence of events
that occurred just before the code
displayed. Have the dealer service
technician supply them to
Raymond Field Service.

Code FV Inform Service

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

Code FV - Display Internal None Cycle key switch.

Software Error Document the sequence of events
that occurred just before the code
displayed. Have the dealer service
technician supply them to
Raymond Field Service.

Code G0 Inform Service

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

Code G0 - Steer Tiller 1 Channel Test I33 - Steer Tiller Cycle key switch.
A/B Fault (AC Lift) Encoder 1 Connect
Steer tiller 1 is missing pulses Detect (AC Lift)
compared to steer tiller 2, or (Page 6-84)
intermittent connection detected at Test I35 - Steer Tiller
JPC10-6 or JPC18-5. Encoder 1 - Channels
A & B (AC Lift)
(Page 6-86)

Code G3 Inform Service

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

Code G3 - Steer Feedback Prox Test I24 - Steer Cycle key switch.
Sensor Fault (AC Lift) Feedback Prox Sensor
A steer motor encoder count (AC Lift) (Page 6-80)
should have put the steer feedback
prox sensor past the steer limit
flag, but the flag was not sensed.
The steer prox sensor is either low
or high all the time.

Publication: 1112860, Issued: 15 Feb 2012 6-21

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Code G4 - Open Detected in Steer Control Circuit (AC Lift)

Code G4 Inform Service

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

Code G4 - Open Detected in Test I39 - Neutral Cycle key switch.

Steer Control Circuit (AC Lift) Pulses (AC Lift)
The VM did not detect either (Page 6-88)
neutral pulses at JPC6-1 or tiller
encoder inputs at JPC22-5,
JPC22-12, JPC22-13, and
JPC22-14.

Code G5 Inform Service

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

Code G5 - Short Detected in Test I25 - Steer Motor Cycle key switch.
Steer Motor Encoder Circuit Encoder (AC Lift)
(AC Lift) (Page 6-81)
A steer command or steer motor
encoder pulses were detected
without steer tiller encoder pulses
detected.

Code G7 Inform Service

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

Code G7 - Steer Tiller 2 Channel Test I34 - Steer Tiller Cycle key switch.
A/B Fault (AC Lift) Encoder 2 Connect
Steer tiller 2 is missing pulses Detect (AC Lift)
compared to steer tiller 1, or (Page 6-85)
intermittent connection detected at Test I36 - Steer Tiller
JPC10-7 or JPC18-6. Encoder 2 - Channels
A & B (AC Lift)
(Page 6-87)

Code GD Inform Service

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

Code GD - Open Detected in Test I25 - Steer Motor Cycle key switch.
Steer Motor Encoder Circuit Encoder (AC Lift) Verify correct steer flag is
(AC Lift) (Page 6-81) installed.
A steer command was issued while Test I90 - Degrees
traveling >1 mph but no steer Turned Past Steer Flag
position feedback encoder pulses (Page 6-99)
were detected.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Code GE - Steer Encoder Failure (AC Lift)

Code GE Inform Service

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

Code GE - Steer Encoder Failure Test I33 - Steer Tiller Cycle key switch.
(AC Lift) Encoder 1 Connect
The VM detected connect-detect Detect (AC Lift)
failures or abnormal inputs on (Page 6-84)
both channels of the steer tiller Test I34 - Steer Tiller
encoder. Encoder 2 Connect
Detect (AC Lift)
(Page 6-85)
Test I35 - Steer Tiller
Encoder 1 - Channels
A & B (AC Lift)
(Page 6-86)
Test I36 - Steer Tiller
Encoder 2 - Channels
A & B (AC Lift)
(Page 6-87)

Code T0 Inform Service

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

Code T0 - SOL5T Current Test A31 - Solenoid 5T Cycle key switch.

Incorrect (AUX1) Current
Current being drawn by SOL5T, as (Page 6-45)
seen by the VM, is not at the
expected level.

Code T1 Inform Service

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

Code T1 - SOL5B Current Test A32 - Solenoid 5B Cycle key switch.

Incorrect (AUX2) Current
Current being drawn by SOL5B, as (Page 6-46)
seen by the VM, is not at the
expected level.

Code T2 Inform Service

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

Code T2 - SOL3 Current Test A33 - Aux Dump Cycle key switch. Dump valve
Incorrect (SOL6 or SOL8)/Main fault causes shut down of Aux
Current being drawn by SOL3, as Relief Dump (SOL3) functions.
seen by the VM, is not at the Current (Page 6-47)
expected level.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Code T3 - SOL2 Current Incorrect

Code T3 Inform Service

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

Code T3 - SOL2 Current Test A34 - Lift/Lower Cycle key switch.

Incorrect Current (SOL2)
Current being drawn by SOL2, as (Page 6-48)
seen by the VM, is not at the
expected level.

Code VC Inform Service

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

Code VC - CAN Stuck In Reset Test I23 - CAN Bus Cycle key switch.
State Test (Page 6-78)

Code X4 Inform Service

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

Code X4 - Switch Mismatch Test I02 - 1st Speed Cycle key switch. Cross First
System detects both S12 (First Limiting Switch (S12) Speed Limit Switch (S12) and/or
Speed Limit Switch) and S27 (Lift (Page 6-66) Lift Cutout Switch (S27).
Cutout Switch) ON at the same Test I22 - Lift Cutout
time. Switch (S27)
(Page 6-77)

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Electrical Tests

Electrical Test Summary List

Section 6. Electrical Tests

Analog Tests
Test A04 - Primary Throttle Pot (VR1) Voltage . . . . . . . . . . . . . . . . . 6-28
Test A05 - Lift/Lower Pot Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Test A08 - Traction Motor Temperature . . . . . . . . . . . . . . . . . . . . . . 6-30
Test A09 - Lift Motor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Test A10 - TPA Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Test A11 - Traction Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Test A13 - Pressure Sensor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Test A14 - +12VDC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Test A15 - Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Test A19 - LPA Temp (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Test A20 - Lift Motor Current (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . 6-39
Test A22 - Traction Throttle (VR1) Request . . . . . . . . . . . . . . . . . . . 6-40
Test A23 - Lift Throttle (VR2) Request . . . . . . . . . . . . . . . . . . . . . . . 6-41
Test A26 - +5VDC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Test A29 - Secondary Traction Throttle Pot (VR3) Voltage (optional) . 6-43
Test A30 - Secondary Traction Throttle (VR3) Request (optional) . . . 6-44
Test A31 - Solenoid 5T (AUX1) Current . . . . . . . . . . . . . . . . . . . . . . 6-45
Test A32 - Solenoid 5B (AUX2) Current . . . . . . . . . . . . . . . . . . . . . . 6-46
Test A33 - Aux Dump (SOL6 or SOL8)/
Main Relief Dump (SOL3) Current . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Test A34 - Lift/Lower Current (SOL2) . . . . . . . . . . . . . . . . . . . . . . . 6-48
Test A35 - Brake Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Test A36 - Ambient Air Temp Sensor . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Test A37 - Steer Power Amp Current . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Test A39 - Analog Reference Voltage (AC Lift) . . . . . . . . . . . . . . . . . . 6-52
Test A40 - Handle Heater Reference Voltage (optional) . . . . . . . . . . . 6-53
Test A41 - Emergency Power Off (EPO) Switch . . . . . . . . . . . . . . . . . 6-54
Test A42 - Primary Travel Pot Learn Value . . . . . . . . . . . . . . . . . . . . 6-55
Test A43 - Lift Pot Learn Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Test A96 - BSM Curr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Test A97 - BSM Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Test A98 - BSM Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Test A99 - H2O Snse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Test A100 - BSM Comm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

Input Tests
Test I00 - Deadman Switch (DS1) . . . . . . . . . . . . . . . . . . . . . . . .. . 6-64
Test I01 - Nested Switch (S14) . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-65
Test I02 - 1st Speed Limiting Switch (S12) . . . . . . . . . . . . . . . . . .. . 6-66
Test I06 - Reach Switch (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-67
Test I07 - Retract Switch (S5) . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-68
Test I08 - Tilt Up Switch (S6) . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-69
Test I09 - Tilt Down Switch (S7) . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-70
Test I10 - Sideshift Right Switch (S9) . . . . . . . . . . . . . . . . . . . . . .. . 6-71
Test I11 - Sideshift Left Switch (S8) . . . . . . . . . . . . . . . . . . . . . . .. . 6-72

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Electrical Test Summary List Models 7500/7520 Reach-Fork ® Trucks

Test I14 - Steering Fuse (FU1) . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-73

Test I15 - Horn Switch (S3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-74
Test I19 - Traction Motor Speed Sensor . . . . . . . . . . . . . . . . . . . .. . 6-75
Test I20 - Lift Motor Speed Sensor (AC Lift) . . . . . . . . . . . . . . . . .. . 6-76
Test I22 - Lift Cutout Switch (S27) . . . . . . . . . . . . . . . . . . . . . . .. . 6-77
Test I23 - CAN Bus Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-78
Test I24 - Steer Feedback Prox Sensor (AC Lift) . . . . . . . . . . . . . .. . 6-80
Test I25 - Steer Motor Encoder (AC Lift) . . . . . . . . . . . . . . . . . . . .. . 6-81
Test I26 - Height Indicator Encoder . . . . . . . . . . . . . . . . . . . . . . .. . 6-82
Test I27 - Secondary Horn Switch (S10) . . . . . . . . . . . . . . . . . . . .. . 6-83
Test I33 - Steer Tiller Encoder 1 Connect Detect (AC Lift) . . . . . .. . 6-84
Test I34 - Steer Tiller Encoder 2 Connect Detect (AC Lift) . . . . . .. . 6-85
Test I35 - Steer Tiller Encoder 1 - Channels A & B (AC Lift) . . . . .. . 6-86
Test I36 - Steer Tiller Encoder 2 - Channels A & B (AC Lift) . . . . .. . 6-87
Test I39 - Neutral Pulses (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . .. . 6-88
Test I60 - Security Start Switch (S23) (optional) . . . . . . . . . . . . . .. . 6-89
Test I63 - High Speed Travel Switch (S25) . . . . . . . . . . . . . . . . . .. . 6-90
Test I80 - OCSS Upper Beam . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-91
Test I81 - OCSS Lower Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-93
Test I82 - OCSS Cnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-95
Test I83 - BatGateL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-96
Test I84 - BatGateR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-97
Test I86 - Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-98
Test I90 - Degrees Turned Past Steer Flag . . . . . . . . . . . . . . . . . .. . 6-99
Test I91 - iPort Communication Test . . . . . . . . . . . . . . . . . . . . . .. 6-100
Test I92 - iPort Error Bitmap . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-102

Output Tests
Test O00 - Toggle TPC or MPC Contactor . . . . . . . . . . . . . . . . . . . . 6-104
Test O01 - Toggle STR Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . 6-105
Test O02 - Toggle LPC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106
Test O03 - Toggle AUX Contactor . . . . . . . . . . . . . . . . . . . . . . . . . 6-107
Test O04 - Toggle Aux1 Directional (SOL5T) Solenoid . . . . . . . . . . 6-108
Test O05 - Toggle Aux2 Directional (SOL5B) Solenoid . . . . . . . . . . 6-109
Test O06 - Toggle Reach Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 6-110
Test O07 - Toggle Tilt Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111
Test O08 - Toggle the Sideshift Solenoid . . . . . . . . . . . . . . . . . . . . 6-112
Test O09 - Aux Dump (SOL6 or SOL8)/Main Relief Dump (SOL3) . 6-113
Test O11 - Toggle the Load Hold (SOL1) Solenoid . . . . . . . . . . . . . . 6-114
Test O12 - Ramp the Proportional Lower (SOL2) Solenoid . . . . . . . 6-115
Test O18 - Toggle Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-116
Test O19 - Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
Test O20 - Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118
Test O23 - Toggle Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
Test O25 - Toggle the 2d Pump (SOL4) Solenoid . . . . . . . . . . . . . . 6-120
Test O28 - Ramp Lift Motor (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . 6-121
Test O29 - Ramp Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Test O30 - Toggle Brake Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
Test O32 - Toggle Relays K1, K2, K3, and K4 . . . . . . . . . . . . . . . . . 6-124

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests

Analog Tests
Section 6. Messages, Codes, and Tests

A Diagnosis and Repair table is provided for

most tests. If a test fails, refer to the Diagnosis
and Repair table.

Through the process of elimination, these tables

provide a step-by-step approach to diagnosing a
problem and the necessary corrective action.
See the example below.

Table 6-2. Example Diagnosis and Repair Table

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

This column identifies

any actions required
before testing the
circuit, such as
disconnecting certain
connectors. If no
instructions are given,
The next
all circuits must be Probe Probe The next
action to
Do the connected. point for point for action to
The reading perform if
testing Note: If something the the perform if
required to consider the
in this was disconnected in positive negative the Expected
the step a success. Expected
order. the prior step, (+) meter (–) meter Results are
Results are
reconnect it before lead. lead. met.
not met.
performing the next
step.

This column also

identifies the required
setting on the meter
for this step.

Publication: 1112860, Issued: 15 Feb 2012 6-27

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A04 - Primary Throttle Pot (VR1) Voltage Analog Tests

Test A04 - Primary 2. The test is a success if the voltage

displayed is within these limits:
Throttle Pot (VR1)
Throttle Position Value Displayed
Voltage Full Tractor-First 0.45 to 0.8

This test displays the voltage the Vehicle Neutral 0.9 to 1.3
Manager reads from the control handle throttle
Full Forks-First 1.4 to 1.8
potentiometer (VR1).
NOTE: Run Learn after you replace, repair, or
adjust the throttle assembly. • The values should change smoothly
and evenly as the handle is moved from
NOTE: For information on how to use Service full tractor-first to full forks-first
Mode, see “Using Service Mode” on direction.
page 3-23.
• If voltages are not within reference
ranges, the test has failed.
Run Test 3. In Active Service Mode, if the voltage
1. The Operator Display shows the voltage fluctuates erratically as you move the
the Vehicle Manager reads from the handle back and forth, replace the control
primary throttle potentiometer (VR1). handle cable.
4. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector.

Diagnosis and Repair

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

JPC12-1 JPH1-1
Disconnect
1 JPC12-12 JPH1-12 0 Ohms Perform step 2 Replace cable
JPC12/Ohms
JPC12-3 JPH1-3

Run Test
Replace control
Disconnect A26 - +5VDC
2 JC12-1 JC12-12 4.75 to 5.25V handle or pot
JPC12/DCV Power Supply
VR1
(Page 6-42)

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A05 - Lift/Lower Pot Voltage

Test A05 - Lift/Lower Pot 2. The test is a success if the voltage

displayed is within these limits:
Voltage
Throttle Position Value Displayed
This test displays the voltage the Vehicle Full Lift 0.45 to 0.8
Manager reads from the lift/lower
potentiometer (VR2). Neutral 0.9 to 1.3

NOTE: Run Learn after you replace, repair, or Full Lower 1.4 to 1.8
adjust the lift/lower potentiometer.
NOTE: For information on how to use Service • The values should change smoothly
Mode, see “Using Service Mode” on and evenly as the handle is moved from
page 3-23. full lower to full lift.
• If voltages are not within reference
Run Test ranges, the test has failed.
3. In Active Service Mode, run the test while
1. The Operator Display shows the voltage
moving the control handle back and forth.
the Vehicle Manager reads from the
If the voltage fluctuates erratically, replace
lift/lower potentiometer (VR2).
the control handle cable.
4. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector.

Diagnosis and Repair

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

JPC12-1 JPH1-1
Disconnect
1 JPC12-12 JPH1-12 0 Ohms Perform step 2 Replace cable
JPC12/Ohms
JPC12-2 JPH1-2

Run Test
Replace control
Disconnect A26 - +5VDC
2 JC12-1 JC12-12 4.75 to 5.25V handle or pot
JPC12/DCV Power Supply
VR2
(Page 6-42)

Publication: 1112860, Issued: 15 Feb 2012 6-29

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A08 - Traction Motor Temperature Analog Tests

Test A08 - Traction Motor below the activation temperature minus

50°F (10°C).
Temperature
Run Test
This test displays Traction Motor temperature.
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
Limits page 3-23.

• Normal operation: ambient to 286°F If the temperature displayed matches the truck
(141°C) operation to the limits listed, allow the truck to
• Speed is linearly reduced starting at 286°F cool and investigate the operation of the brake
(141°C) to 1 mph (1.6 km/h) at 311°F and drive unit. If the brake and drive unit are
(155°C) functioning correctly, look at the truck
• Temperature icon illuminates at 295°F application for over use. If the temperature
(146°C) displayed does not match the limits listed,
proceed to Diagnosis and Repair.
• Fault Code 2A and travel limited to 1 mph
(1.6 km/h) at 311°F (155°C)
NOTE: Cooling fans are turned on when the
traction motor temperature exceeds
176°F (80°C).

Cooling fans are deactivated only when

the temperature for all devices falls

Diagnosis and Repair

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

Temp. Icon is illuminated OR Fault Code 2A is present and Traction Motor is hot to touch

Disconnect
1 JPT1-8 JPT1-7 >1200 ohms Perform step 2 Replace TPA
JPT1/Ohms

Less than See section on

Repeat step 1 after
2 measurement in motor Perform step 3
cooling for one hour.
step 1 overheating

Less than T/S Traction Replace Traction

Disconnect
3 JPT3-2 JPT3-1 measurement in Motor sensor Motor temp
JPT3/Ohms
step 1 wires sensor

Temp. Icon is illuminated OR Fault Code 2A is present and Traction Motor is NOT hot to touch

Disconnect
1 JPT1-8 JPT1-7 Replace TPA Perform step 2
JPT1/Ohms
<800 ohms T/S Traction Replace Traction
Disconnect
2 JPT3-2 JPT3-1 Motor sensor Motor temp
JPT3/Ohms
wires sensor

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A09 - Lift Motor Temperature

Test A09 - Lift Motor Run Test

Temperature NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.
This test displays Lift Motor temperature.
If the temperature displayed matches the truck
Limits operation to the limits listed, allow the truck to
cool. Check the mast for binding and
investigate the operation of the pump. If the
AC Lift mast and pump are functioning correctly, look
• Normal operation: ambient to 294°F at the truck application for over use. If the
(145°C) temperature displayed does not match the
limits listed, proceed to Diagnosis and Repair.
• Temperature icon illuminates at 295°F
(146°C)
• Fault Code 6F and lift shutdown at 300°F
(149°C)
NOTE: Cooling fans are turned on when the lift
motor temperature exceeds 176°F
(80°C).

Cooling fans are deactivated only when

the temperature for all devices falls
below the activation temperature minus
50°F (10°C).

DC Lift
• Normal operation, single pump:
ambient to 271°F (133°C)
• Normal operation, dual pump:
ambient to 221°F (105°C)
• Temperature icon illuminates at 223°F
(106°C), single and dual pump
• Fault Code 6F and lift shutdown at 279°F
(137°C), both single and dual pump
NOTE: Cooling fans are turned on when the lift
motor temperature exceeds 176°F
(80°C).

Cooling fans are deactivated only when

the temperature for all devices falls
below the activation temperature minus
50°F (10°C).

Publication: 1112860, Issued: 15 Feb 2012 6-31

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A09 - Lift Motor Temperature Analog Tests

Diagnosis and Repair

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

AC Lift - Temp. Icon is illuminated OR Fault Code 6F is present and Lift Motor is hot to touch

Disconnect
1 >1200 ohms Perform step 2 Replace LPA
JPL1/Ohms
JPL1-8 JPL1-7 Less than See section on
Repeat step 1 after
2 measurement in motor Perform step 3
cooling for one hour.
step 1 overheating

Less than Replace Lift

Disconnect T/S Lift Motor
3 JPL3-2 JPL3-1 measurement in Motor temp
JPL3/Ohms sensor wires
step 1 sensor

AC Lift - Temp. Icon is illuminated OR Fault Code 6F is present and Lift Motor is NOT hot to touch

Disconnect
1 JPL1-8 JPL1-7 Replace LPA Perform step 2
JPL1/Ohms
<800 ohms Replace Lift
Disconnect T/S Lift Motor
2 JPL3-2 JPL3-1 Motor temp
JPL3/Ohms sensor wires
sensor

DC Lift - Temp. Icon is illuminated OR Fault Code 6F is present and Lift Motor is hot to touch

Disconnect
1 JPC24-22 JPC24-10 >2200 ohms Perform step 2 Replace VM
JPC24/Ohms

Less than T/S cause of

Repeat step 1 after
2 measurement in overheated Perform step 3
cooling for one hour.
step 1 motor

Less than Replace Lift

Disconnect T/S Lift Motor
3 JPZ-1 JPZ-2 measurement in Motor temp
JPZ/Ohms sensor wires
step 1 sensor

DC Lift - Temp. Icon is illuminated OR Fault Code 6F is present and Lift Motor is NOT hot to touch

Disconnect
1 JPC24-22 JPC24-10 Replace VM Perform step 2
JPC24/Ohms
<2200 ohms Replace Lift
Disconnect T/S Lift Motor
2 JPZ-1 JPZ-2 Motor temp
JPZ/Ohms sensor wires
sensor

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A10 - TPA Temperature

Test A10 - TPA Run Test

Temperature NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.
This test measures the temperature of the TPA.
The TPA heatsink temperature is displayed.
Limits
As truck is operated, the readings should
• Normal operation: ambient to 185°F (85°C) increase evenly over time. If not, the test has
• TPA is performance limited at 187°F (86°C) failed.
and temperature icon illuminates
• Fault Code 1H is displayed at 205°F (96°C)
NOTE: Cooling fans activate when the TPA
temperature exceeds 133°F (56°C).

Cooling fans are deactivated only when

the temperature for all devices falls
below the activation temperature minus
50°F (10°C).

Diagnosis and Repair

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

Heatsink should
Run Test
Operate truck for 15 heat up and
O23 - Toggle
1 to 20 minutes of N/A N/A fans turn ON at Replace TPA
Fans
hard operation. approx. 133°F
(Page 6-119)
(56°C)

Publication: 1112860, Issued: 15 Feb 2012 6-33

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A11 - Traction Motor Current Analog Tests

Test A11 - Traction Motor • Phase currents should be approx. equal.

Significant differences indicate a problem.
Current If readings are not within reference limits, the
test has failed.
This test displays the current in the Traction
Motor power circuits. 1. If any one phase differs significantly from
the other two, check power cable
continuity. Replace cables as necessary.
Limits See “Power Cable Terminals” on
page 7-81.
• 0 to 450A while driving or plugging
• If power cable continuity is OK,
• Above 266°F (130°C) current is reduced
troubleshoot the Traction Motor. See
linearly
“AC Motors” on page 5-14.
• Maximum current up to 540A when
• If all phases give high readings, the
deadman pedal is released, unaffected and
drive unit may be binding. Check drive
unreduced by temperature
unit.
2. The TPA may be bad. Run “Test
Run Test O29 - Ramp Traction Motor” on
NOTE: For information on how to use Service page 6-122.
Mode, see “Using Service Mode” on NOTE: For instructions on selecting Modes of
page 3-23. Operation, see “Modes of Operation” on
NOTE: This test shows better results in Active page 3-11.
Service. See “Active Service Mode” on
page 3-24
NOTE: Set speed to 3.0 mph (4.8 km/h) in
Configure Mode. See “Using Configure
Mode” on page 3-13.

System Condition Value Displayed (amps)

Static at Rest <20

375 at 0 mph
Travel 0 to 3.0 mph
80 at 3.0 mph
(4.8 km/h)
(4.8 km/h)

Plugging
(from 3.0 mph 275 Max
(4.8 km/h))

Diagnosis and Repair

NOTE: Check all motor and power amplifier
connections for tightness and corrosion.

Check individual phase currents with a

clamp-on ammeter.
• The current should ramp evenly as the
truck accelerates and decelerates.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A13 - Pressure Sensor Voltage

Test A13 - Pressure

Sensor Voltage
This test measures the voltage from the
pressure sensor used for load weight sensing.

Use extreme caution when working

near the elevated forks.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The voltage shown on the Operator Display

should increase and decrease linearly as the
load weight is increased or decreased. If it does
not, the test has failed. If the weight display is
inaccurate, the test has failed.

Carriage Position Value Displayed (Volts)

Fully Lowered Approx. 1.0

Lifted in Free Lift Approx. 1.5

Lifted in Second Stage Approx. 2.0

Diagnosis and Repair

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

1 JPY1-2 JPY1-3 1.0V fully Perform step 2 Perform step 3

lowered
1.5V lifted in
2 JPC24-18 JPC24-6 free lift Replace VM
DCV 2.0V in second
stage T/S pressure
sensor harness
Replace
3 JPY1-1 JPY1-3 10.5 to 13V pressure
transducer

Publication: 1112860, Issued: 15 Feb 2012 6-35

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A14 - +12VDC Power Supply Analog Tests

Test A14 - +12VDC

Power Supply
This test displays the VM +12V Power Supply
voltage.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.
1. The Operator Display shows the voltage
measured from the +12V power supply.
2. The test is a success if the voltage
displayed is within these limits:

System Condition Value Displayed

Lift truck at rest 10.1 to 13.0V

If the reading fluctuates by more than

0.8V in 10 seconds, the test has failed.

Diagnosis and Repair

Disconnect everything powered by +12V except
JPC14 (includes Operator Display). Monitor the
+12V and reconnect each connector.
Troubleshoot the circuit that causes the +12V
supply to go out-of-range. Otherwise, replace
VM.

6-36 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A15 - Battery Voltage

Test A15 - Battery

Voltage
This test displays the voltage used to calculate
Battery State-of-Charge (BSOC).

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.
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 has failed.

Diagnosis and Repair

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

Check battery voltage/

specific gravity
1 TP1 Perform step 2 Replace battery
T/S or replace battery
cables

DCV TP4 B+ T/S harness TP1 to

2 JPF4-1 Perform step 3
JPF4-1

Replace Fuse/Relay
3 JPF4-7 Perform step 4
Card

T/S harness from

4 JPC24-24 Replace VM
Fuse/Relay Card to VM

Publication: 1112860, Issued: 15 Feb 2012 6-37

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A19 - LPA Temp (AC Lift) Analog Tests

Test A19 - LPA Temp

(AC Lift)
This test displays the temperature of the Lift
Power Amplifier.

Limits
• Normal operation: ambient to 185°F (85°C)
• LPA is performance limited at 187°F (86°C)
and temperature icon illuminates
• Fault Code 1V is displayed at 205°F (96°C)
NOTE: Cooling fans activate when the LPA
temperature exceeds 133°F (56°C).

Cooling fans are deactivated only when

the temperature for all devices falls
below the activation temperature minus
50°F (10°C).

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display shows the heatsink

temperature the LPA reads.

As the lift is operated, the readings should

increase evenly over time. If not, the test has
failed.

Diagnosis and Repair

1. Check for dirt and debris in the LPA
cooling fins.
2. Run truck hard for 15 to 20 minutes.
Check operation of the LPA cooling fans.
Run Test O23 - Toggle Fans (Page 6-119).
3. The LPA may be bad. Replace the LPA.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A20 - Lift Motor Current (AC Lift)

Test A20 - Lift Motor • Phase currents should be approx. equal.

Significant differences indicate a problem.
Current (AC Lift) • If readings are not within reference limits,
the test has failed.
This test measures the Lift Motor current
through the Lift Power Amplifier. If any one phase differs significantly from the
other two, check power cable continuity.
Replace cables as necessary. See “Power Cable
Terminals” on page 7-81.

The carriage will move during this test. • If power cable continuity is OK,
troubleshoot the Lift Motor. See “AC
Motors” on page 5-14.
• If all phases give high readings, the mast
may be binding. Check mast.
The area around the forks should be
clear. The ceiling clearance should allow NOTE: For instructions on selecting Modes of
for the highest lift. Operation, see “Modes of Operation” on
page 3-11.
Limits
• 0 to 550A lifting
• Maximum current 675A

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.
NOTE: This test shows better results in Active
Service. See “Active Service Mode” on
page 3-24

The Operator Display shows the current the

LPA reads from one phase of the Lift Motor.

Lifting an empty carriage in free lift gives

readings of 280 to 320 amps. Readings are
approx. the same if a clamp-on ammeter is
used.

Diagnosis and Repair

NOTE: Check all motor and power amplifier
connections for tightness and corrosion.

Check individual phase currents with a

clamp-on ammeter.
• The current should ramp evenly as the
truck accelerates and decelerates.

Publication: 1112860, Issued: 15 Feb 2012 6-39

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A22 - Traction Throttle (VR1) Request Analog Tests

Test A22 - Traction The Operator Display shows the percentage of

throttle request the VM reads from VR1.
Throttle (VR1) Request Throttle Position Value Displayed

This test displays the percentage of primary Full Tractor-First 0 to +100

control handle traction throttle request from
Neutral 0
VR1 being read by the VM.
Full Forks-First 0 to –100
Run Test
NOTE: Run Learn after you replace, repair, or The values must change smoothly and evenly
adjust the throttle assembly. as the handle moves from full tractor-first to
full forks-first.
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on If percentages are not within reference limits,
page 3-23. the test has failed.

Diagnosis and Repair

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

Disconnect JPC12-1 JPH1-1

1 JPC12 JPC12-12 JPH1-12 0 Ohms Perform step 2 Replace cable
/Ohms JPC12-3 JPH1-3

Run Test
Disconnect A26 - +5VDC
2 JC12-1 JC12-12 4.75 to 5.25V Perform step 3
JPC12/DCV Power Supply
(Page 6-42)

Neutral: 0.9 to 1.3V

Full tractor-first: 0.45 to
3 DCV JPC12-3 JPC12-12 0.8V Replace VM Replace VR1
Full forks-first: 1.4 to
1.8V

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A23 - Lift Throttle (VR2) Request

Test A23 - Lift Throttle

(VR2) Request
This test displays the percentage of lift throttle
request from VR2 being read by the VM.

Run Test
NOTE: Run Learn after you replace, repair, or
adjust the lift/lower potentiometer.
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display shows the percentage of

lift request the VM reads from VR2.

Throttle Position Value Displayed

Full Lower 0 to –100

Neutral 0

Full Lift 0 to +100

The values must change smoothly and evenly

as the handle moves from full lower to full lift.

If percentages are not within reference limits,

the test has failed.

Diagnosis and Repair

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

Disconnect JPC12-1 JPH1-1

1 JPC12 JPC12-12 JPH1-12 0 Ohms Perform step 2 Replace cable
/Ohms JPC12-2 JPH1-2

Run Test
Disconnect
A26 - +5VDC
2 JPC12 JC12-1 JC12-12 4.75 to 5.25V Perform step 3
Power Supply
/DCV
(Page 6-42)

Neutral: 0.9 to 1.3V

3 DCV JPC12-2 JPC12-12 Full lift: 0.45 to 0.8V Replace VM Replace VR2
Full lower: 1.4 to 1.8V

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A26 - +5VDC Power Supply Analog Tests

Test A26 - +5VDC Power

Supply
This test measures the +5V Power Supply
voltage used for the control handle switches
and potentiometers.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

If the Operator Display does not read

+5 ±0.25V, the test has failed.

Diagnosis and Repair

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

Disconnect JPC12
1 Perform step 2 Replace VM
and JPC4/DCV

PC12-1 PC12-12 4.75 to 5.25V Repair/replace Repair/replace

Connect JPC12,
secondary primary control
2 disconnect
control handle handle and
JPC4/DCV
and harness harness

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A29 - Secondary Traction Throttle Pot (VR3) Voltage (optional)

Test A29 - Secondary

Traction Throttle Pot
(VR3) Voltage (optional)
This test displays the voltage the VM reads from
the optional secondary traction throttle
potentiometer (VR3).
NOTE: Run Learn after you replace, repair, or
adjust the throttle assembly.
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

Run Test
The test is a success if the voltage displayed is
within these limits:

VR3 Throttle Position Value Displayed

Full Tractor-First 1.4 to 1.8

Neutral 0.9 to 1.3

Full Forks-First 0.45 to 0.8

• The values should change smoothly and

evenly as the handle is moved from full
tractor-first to full forks-first direction.
• If voltages are not within reference ranges,
the test has failed.

Diagnosis and Repair

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

1 JPC4-1 JPC4-2 Approx. 5V Perform step 2 Replace VM

Neutral: approx. 1V
Test cable from
DCV Full forks-first:
handle to VM. If
2 JPC4-4 JPC4-2 approx. 1.5V Replace VM
OK, replace
Full tractor-first:
handle or pot
approx. 0.5V

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A30 - Secondary Traction Throttle (VR3) Request (optional) Analog Tests

Test A30 - Secondary

Traction Throttle (VR3)
Request (optional)
This test displays the percentage of secondary
control handle traction throttle request from
VR3 being read by the VM.

Run Test
NOTE: Run Learn after you replace, repair, or
adjust the throttle assembly.
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display shows the percentage of

throttle request the VM reads from VR3.

Throttle Position Value Displayed

Full Tractor-First 0 to –100

Neutral 0

Full Forks-First 0 to +100

The values must change smoothly and evenly

as the handle moves from full tractor-first to
full forks-first.

If percentages are not within reference limits,

the test has failed.

Diagnosis and Repair

Run “Test A29 - Secondary Traction Throttle
Pot (VR3) Voltage (optional)” on page 6-43.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A31 - Solenoid 5T (AUX1) Current

Test A31 - Solenoid 5T

(AUX1) Current
This test displays the current the Aux1
directional solenoid coil is drawing.

It does not prove the Aux1 directional solenoid

valve is functioning properly mechanically. It
does not prove the condition of the wiring or the
VM itself.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The test is a success if the current displayed is:

Function Value Displayed (amps)

Retract - Slow Approx. 0.3

Retract - High Approx. 0.5

Tilt Down/Sideshift
Approx. 0.5
Left

Because the directional coil is proportional,

current for tilt/sideshift can be different from
the current for reach/retract. If any one
function passes, run input test for failed
functions (I07, I09, or I11).

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

Disconnect T/S wires and

1 JC20-18 Approx. 40 Ohms Perform step 2
JPC20/Ohms coil
JC20-17
T/S B+K2 from
2 DCV TP4 B+ Replace VM
Fuse/Relay Card

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A32 - Solenoid 5B (AUX2) Current Analog Tests

Test A32 - Solenoid 5B

(AUX2) Current
This test displays the current the Aux2
directional solenoid coil is drawing.

It does not prove the Aux2 directional solenoid

valve is functioning correctly mechanically. It
does not prove the condition of the wiring or the
VM itself.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The test is a success if the current displayed is:

Function Value Displayed (amps)

Reach - Slow Approx. 0.3

Reach - High Approx. 0.5

Tilt Up/Sideshift Right Approx. 0.5

Because the directional coil is proportional,

current for tilt/sideshift can be different from
the current for reach/retract. If any one
function passes, run input test for failed
functions (I06, I08, or I10).

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

Disconnect T/S wires and

1 JC20-20 Approx. 40 Ohms Perform step 2
JPC20/Ohms coil
JC20-19
T/S B+K2 from
2 DCV TP4 B+ Replace VM
Fuse/Relay Card

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A33 - Aux Dump (SOL6 or SOL8)/Main Relief Dump (SOL3) Current

Test A33 - Aux Dump

(SOL6 or SOL8)/Main
Relief Dump (SOL3)
Current
This test displays the current the dump
solenoid coil is drawing.

It does not prove the solenoid valve is

functioning correctly mechanically. It does not
prove the condition of the wiring or the VM
itself.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The test is a success if the current displayed is:

Function Value Displayed (amps)

Any Aux Function

Approx. 0.8
Activated

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

Disconnect Approx. T/S wires and

1 JC20-12 Perform step 2
JPC20/Ohms 39 Ohms coil
JC20-13 T/S B+K2 from
2 DCV TP4 B+ Replace VM Fuse/Relay
Card

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A34 - Lift/Lower Current (SOL2) Analog Tests

Test A34 - Lift/Lower

Current (SOL2)
This test displays the current the proportional
lift/lower solenoid coil is drawing.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The test is a success if the current displayed is:

State Value Displayed (amps)

Neutral Approx. 0

Full Lower Approx. 1.5

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

Disconnect T/S wires and

1 JC20-15 JC20-16 Approx. 13 Ohms Perform step 2
JPC20/Ohms coil

T/S B+K2 from

2 DCV PC20-15 TP4 B+ Replace VM Fuse/Relay
Card

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A35 - Brake Armature

Test A35 - Brake

Armature
The brake coil is activated by a coil driver
located inside the Vehicle Manager. This test
displays the voltage measured across that coil
driver.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The test is a success if the voltage displayed is

within these limits:

Value Displayed
State of Brake
(Volts)

Approx. 0.25
Brake pulling in
for 2 seconds

Deadman Pedal Depressed/

Approx. 9
Travel Requested

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

Disconnect T/S wires and

1 JF2-2 JC20-14 Approx. 9 Ohms Perform step 2
JPC20/Ohms coil

T/S B+K2 from

2 DCV PF2-2 TP4 B+ Replace VM Fuse/Relay
Card

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A36 - Ambient Air Temp Sensor Analog Tests

Test A36 - Ambient Air

Temp Sensor
This test displays the ambient air temperature
of the area around the lift truck.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display should display the

temperature of the room where the truck is
located.

If not, the test has failed.

Diagnosis and Repair

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

Disconnect
1 JPC24-23 JPC24-11 Approx. 5V Perform step 2 Replace VM
JPA/ DCV

JPC24-23 JPA-1 Replace temp T/S wires as

2 Ohms 0 Ohms
JPC24-11 JPA-2 sensor indicated by test

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A37 - Steer Power Amp Current

Test A37 - Steer Power

Amp Current
This test displays the current the steer motor is
drawing.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The test is a success if the current displayed is:

Steer Direction Value Displayed (amps)

At rest <3

Clockwise (CW) –20 to –50

Counterclockwise
20 to 50
(CCW)

Note: CW and CCW is drive unit direction.

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

At rest: approx. 2.5V

Steering CCW: less
Replace Steer
1 DCV JPC6-3 TP4 than voltage at rest Replace VM
Amp
Steering CW: more
than voltage at rest

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A39 - Analog Reference Voltage (AC Lift) Analog Tests

Test A39 - Analog

Reference Voltage
(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 3-23.

You should see 2.4 to 2.6V. If not, the test has

failed.

Diagnosis and Repair

Replace Vehicle Manager.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A40 - Handle Heater Reference Voltage (optional)

Test A40 - Handle Run Test

Heater Reference NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
Voltage (optional) page 3-23.

The test is a success if the voltage displayed is

This test displays the voltage the Vehicle within these limits:
Manager sees going through the internal
primary control handle heater (HTR6). Heater OFF Heater ON
NOTE: Heater operation requires ambient 0V Approx. 8V
temperature sensor to be activated.
Heaters then turn on at 40°F (4.4°C).
If results do not match the preceding table, the
test has failed. Verify option is turned ON.

Diagnosis and Repair

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

Check cable
wiring. If OK,
Disconnect
1 JPC12-7 JPC12-12 9 to 10 Ohms Perform step 2 replace handle
JPC12/Ohms
or internal
heater

Heater ON:
Disconnect JPC12-7 JPC12-12
2 approx. 8V Perform step 1 Replace VM
JPC12/DCV on VM on VM
Heater OFF: 0V

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A41 - Emergency Power Off (EPO) Switch Analog Tests

Test A41 - Emergency

Power Off (EPO) Switch
This test shows the voltage the Vehicle Manager
is reading from the EPO switch.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The test is a success if the voltage displayed is

within these limits:

Displayed Value
State of Switch
(Volts)

Up (closed) B+

Down (open) 0

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

Clean pin connection then

1 JPF4-12 Perform step 2
replace Fuse/Relay Card

Repair/replace wiring or
2 JPF4-5 Perform step 3
switch
DCV TP4 (B–) B+
Clean pin connection then
3 JPF4-6 Perform step 4
replace Fuse/Relay Card

Repair/replace wiring or
4 JPC22-21 Replace VM
switch

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A42 - Primary Travel Pot Learn Value

Test A42 - Primary

Travel Pot Learn Value
This test displays the voltage value that was
stored in the Vehicle Manager the last time
LEARN was performed on the travel pot.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A43 - Lift Pot Learn Value Analog Tests

Test A43 - Lift Pot Learn

Value
This test displays the voltage value that was
stored in the Vehicle Manager the last time
LEARN was performed on the lift pot.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A96 - BSM Curr

Test A96 - BSM Curr

Real time current as seen by the Battery Sensor
Module (BSM). Displays in whole amps (for
example: 150 A).

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A97 - BSM Volt Analog Tests

Test A97 - BSM Volt

Real time voltage as seen by the Battery Sensor
Module (BSM). Displays in tenths of a volt (for
example: 37.8V).

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A98 - BSM Temp

Test A98 - BSM Temp

Battery temperature as seen by the Battery
Sensor Module (BSM). Displays in whole
degrees centigrade (for example: 23°C).

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A99 - H2O Snse Analog Tests

Test A99 - H2O Snse

Battery water sensed by the Battery Sensor
Module (BSM). Displays as True or False. False
indicates water level is low.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Analog Tests Test A100 - BSM Comm

Test A100 - BSM Comm

Communication level indicator between the
iBattery ™ Auxiliary Processing Module (APM
and Battery Sensor Module (BSM). This is
represented with 0 to 4 bars: 4 bars indicates
excellent communication, 0 bars indicates no
communication.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test A100 - BSM Comm Analog Tests

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests

Input Tests
Section 6. Messages, Codes, and Tests

A Diagnosis and Repair table is provided for

most tests. If a test fails, refer to the Diagnosis
and Repair table.

Through the process of elimination, these tables

provide a step-by-step approach to diagnosing a
problem and the necessary corrective action.
See the example below.

Table 6-3. Example Diagnosis and Repair Table

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

This column identifies

any actions required
before testing the
circuit, such as
disconnecting certain
connectors. If no
instructions are given,
The next The next
all circuits should be Probe Probe
action to action to
Do the connected. point for point for
The reading required perform if perform if
testing Note: If something the the
to consider the step a the the
in this was disconnected in positive negative
success. Expected Expected
order. the prior step, (+) meter (–) meter
Results are Results are
reconnect it before lead. lead.
met. not met.
performing the next
step.

This column also

identifies the required
scale on the meter for
this step.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I00 - Deadman Switch (DS1) Input Tests

Test I00 - Deadman

Switch (DS1)
This test shows what the Vehicle Manager is
reading from the deadman switch (DS1).

Do not perform this test on a ramp.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display shows the state of the

switch.

Operator Action Message Displayed

Off deadman Up

On deadman Down

If the display does not change when you step on

the pedal, the test has failed.

Make sure the gap between the proximity

sensor (DS1) and the indicator flag is within
tolerance. Refer to “Deadman Pedal” on
page 7-63.

Diagnosis and Repair

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

1 Disconnect JPC18, JPC22-8 4.5 to 5V Perform step 2

JPC20, and JPC22 JPC18-7 Replace VM
2 /DCV JPC20-2 10.5 to 13V Perform step 3

3 Disconnect JPDS JPDS-2 4.5 to 5V Perform step 4

JPDS-3 T/S wires to VM
4 /DCV JPDS-1 10.5 to 13V Replace DS1

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I01 - Nested Switch (S14)

Test I01 - Nested Switch Run Test

(S14) NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.
NOTE: This test applies only to lift trucks with
the nested switch option.
The Operator Display shows the state of the
switch:
This test shows what the Vehicle Manager is
reading from the nested switch (S14). Mast Position Message Displayed

Nested In

Use extreme caution when working Unnested Out

around an elevated mast.
If these results are not observed, the test has
failed.

Lift only in an area with a ceiling height

greater than the truck’s maximum
elevated height.

Diagnosis and Repair

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

Disconnect S14 open: open circuit T/S wires and

1 JPF2-8 JPC22-18 Perform step 2
JPF2/Ohms S14 closed: 0 Ohms switch

Verify option is
Disconnect
2 JPC22-18 TP4 S14 closed: B+ ON, then replace T/S K2 circuit
JPC22/DCV
VM

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I02 - 1st Speed Limiting Switch (S12) Input Tests

Test I02 - 1st Speed

Limiting Switch (S12)
This test shows what the Vehicle Manager is
reading from the 1st speed limiting mast switch
(S12).

Use extreme caution when working

around an elevated mast.

Run Test
Run this test in Active Service Mode.
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display should show the

following:

Mast Position Message Displayed

Lowered Below

Raised Above

If these results are not observed, the test has

failed.

Diagnosis and Repair

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

Disconnect
1 JS4-3 10.5 to 13V Perform step 4 Perform step 2
JPS4/DCV
JS4-1
Disconnect JPS4 Repair or
2 JC20-1 Perform step 3
& JPC20/Ohms replace wire
0 Ohms Inspect pin
Disconnect JPS4 Repair or
3 JS4-3 JF3-8 connection to
& JPF3/Ohms replace wire
FRC

4 JPS4-2 JPS4-3 Perform step 5 Replace S12

Mast lowered: 0V
DCV Repair or
5 JPC22-1 JPS4-3 Mast elevated: 5V Replace VM
replace wire

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Input Tests Test I06 - Reach Switch (S4)

Test I06 - Reach Switch The Operator Display shows the state of the
switch:
(S4) State of Switch Message Displayed

Use this test to monitor the state of reach Depressed In

switch (S4). This test shows what the Vehicle
Released Out
Manager is reading from the switch.

Run Test 1. If results do not match the preceding

table, the test has failed. Perform
NOTE: For information on how to use Service diagnosis.
Mode, see “Using Service Mode” on 2. In Active Service Mode, run the test while
page 3-23.
moving the control handle back and forth.
If the voltage fluctuates erratically, replace
the control handle cable.
3. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector.

Diagnosis and Repair

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

Disconnect
1 JPC12-4 JPC12-12 Perform step 2 Replace VM
JPC12/DCV
>4V
Disconnect Repair or replace
2 JPH1-4 JPH1-12 Perform step 3
JPH1/DCV cable to VM

S4 open: >4V Replace control

3 DCV JPH1-4 JPH1-12 Replace VM
S4 closed: <1V handle

Note: Voltage to switch being tested may drop when any other control handle switch is depressed.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I07 - Retract Switch (S5) Input Tests

Test I07 - Retract Switch The Operator Display shows the state of the
switch:
(S5) State of Switch Message Displayed

Use this test to monitor the state of retract Depressed In

switch (S5). This test shows what the Vehicle
Released Out
Manager is reading from the switch.

Run Test 1. If results do not match the preceding

table, the test has failed. Perform
NOTE: For information on how to use Service diagnosis.
Mode, see “Using Service Mode” on 2. In Active Service Mode, run the test while
page 3-23.
moving the control handle back and forth.
If the voltage fluctuates erratically, replace
the control handle cable.
3. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector.

Diagnosis and Repair

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

Disconnect
1 JPC12-11 JPC12-12 Perform step 2 Replace VM
JPC12/DCV
>4V
Disconnect Repair or replace
2 Perform step 3
JPH1/DCV cable to VM
JPH1-11 JPH1-12
S5 open: >4V Replace control
3 DCV Replace VM
S5 closed: <1V handle

Note: Voltage to switch being tested may drop when any other control handle switch is depressed.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I08 - Tilt Up Switch (S6)

Test I08 - Tilt Up Switch The Operator Display shows the state of the
switch:
(S6) State of Switch Message Displayed

Use this test to monitor the state of tilt up Depressed In

switch (S6). This test shows what the Vehicle
Released Out
Manager is reading from the switch.

Run Test 1. If results do not match the preceding

table, the test has failed. Perform
NOTE: For information on how to use Service diagnosis.
Mode, see “Using Service Mode” on 2. In Active Service Mode, run the test while
page 3-23.
moving the control handle back and forth.
If the voltage fluctuates erratically, replace
the control handle cable.
3. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector.

Diagnosis and Repair

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

Disconnect
1 JPC12-5 JPC12-12 Perform step 2 Replace VM
JPC12/DCV
>4V
Disconnect JPH1 Repair or replace
2 Perform step 3
/DCV cable to VM
JPH1-5 JPH1-12
S6 open: >4V Replace control
3 DCV Replace VM
S6 closed: <1V handle

Note: Voltage to switch being tested may drop when any other control handle switch is depressed.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I09 - Tilt Down Switch (S7) Input Tests

Test I09 - Tilt Down The Operator Display shows the state of the
switch:
Switch (S7) State of Switch Message Displayed

Use this test to monitor the state of tilt down Depressed In

switch (S7). This test shows what the Vehicle
Released Out
Manager is reading from the switch.

Run Test 1. If results do not match the preceding

table, the test has failed. Perform
NOTE: For information on how to use Service diagnosis.
Mode, see “Using Service Mode” on 2. In Active Service Mode, run the test while
page 3-23.
moving the control handle back and forth.
If the voltage fluctuates erratically, replace
the control handle cable.
3. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector.

Diagnosis and Repair

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

Disconnect
1 JPC12-6 JPC12-12 Perform step 2 Replace VM
JPC12/DCV
>4V
Disconnect JPH1 Repair or replace
2 Perform step 3
/DCV cable to VM
JPH1-6 JPH1-12
S7 open: >4V Replace control
3 DCV Replace VM
S7 closed: <1V handle

Note: Voltage to switch being tested may drop when any other control handle switch is depressed.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I10 - Sideshift Right Switch (S9)

Test I10 - Sideshift Right 2. In Active Service Mode, run the test while
moving the control handle back and forth.
Switch (S9) If the voltage fluctuates erratically as you
move the handle back and forth, replace
the control handle cable.
Use this test to monitor the state of sideshift
right switch (S9). This test shows what the 3. If there is a problem after reconnecting the
Vehicle Manager is reading from the switch. control handle cable, inspect the pins in
the DB15 connector.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display shows the state of the

switch:

State of Switch Message Displayed

Depressed In

Released Out

1. If results do not match the preceding

table, the test has failed. Perform
diagnosis.

Diagnosis and Repair

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

Disconnect
1 JPC12-9 JPC12-12 Perform step 2 Replace VM
JPC12/DCV
>4V
Disconnect JPH1 Repair or replace
2 Perform step 3
/DCV cable to VM
JPH1-9 JPH1-12
S9 open: >4V Replace control
3 DCV Replace VM
S9 closed: <1V handle

Note: Voltage to switch being tested may drop when any other control handle switch is depressed.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I11 - Sideshift Left Switch (S8) Input Tests

Test I11 - Sideshift Left The Operator Display shows the state of the
switch:
Switch (S8) State of Switch Message Displayed

Use this test to monitor the state of sideshift left Depressed In

switch (S8). This test shows what the Vehicle
Released Out
Manager is reading from the switch.

Run Test 1. If results do not match the preceding

table, the test has failed. Perform
NOTE: For information on how to use Service diagnosis.
Mode, see “Using Service Mode” on 2. In Active Service Mode, run the test while
page 3-23.
moving the control handle back and forth.
If the voltage fluctuates erratically, replace
the control handle cable.
3. If there is a problem after reconnecting the
control handle cable, inspect the pins in
the DB15 connector.

Diagnosis and Repair

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

Disconnect
1 JPC12-8 JPC12-12 Perform step 2 Replace VM
JPC12/DCV
>4V
Disconnect JPH1 Repair or replace
2 Perform step 3
/DCV cable to VM
JPH1-8 JPH1-12
S8 open: >4V Replace control
3 DCV Replace VM
S8 closed: <1V handle

Note: Voltage to switch being tested may drop when any other control handle switch is depressed.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I14 - Steering Fuse (FU1)

Test I14 - Steering Fuse Use the following table as a guideline.

(FU1) Deadman Pedal

Position
Message Displayed

This test reports the absence or presence of B+ Down Clsd (closed)

voltage at the load side of the steer motor (STR) Up Open
contactor.

NOTE: The contactor opens, but capacitors in

the steer amplifier take some time to
When this test is activated and the
bleed off.
deadman pedal is depressed, the steer
motor/pump activates.
If the STR contactor tips do not close, run Test
O01 - Toggle STR Contactor (Page 6-105).
Run Test
If the display message does not change when
NOTE: For information on how to use Service the test is activated, the test has failed.
Mode, see “Using Service Mode” on
page 3-23.

Diagnosis and Repair

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

Remove FU1
1 Fuse Fuse 0 Ohms Perform step 2 Replace fuse FU1
/Ohms

STR Tips open: 0V Replace STR

2 STR-1 Perform step 3
STR Tips closed: B+ contactor tips
DCV TP4
STR Tips open: 0V T/S wiring from
3 JPC22-19 Replace VM
STR Tips closed: B+ VM to contactor

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I15 - Horn Switch (S3) Input Tests

Test I15 - Horn Switch The Operator Display shows the state of the
switch:
(S3) State of Switch Message Displayed

Use this test to monitor the state of the horn Depressed In

switch (S3). This test shows what the Vehicle
Released Out
Manager is reading from the switch.

Run Test If results do not match the preceding table, the

test has failed. Perform diagnosis.
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

Diagnosis and Repair

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

Disconnect
1 JPC12-10 JPC12-12 Perform step 2 Replace VM
JPC12/DCV
>4V
Disconnect JPH1 Repair or replace
2 Perform step 3
/DCV cable to VM
JPH1-10 JPH1-12
S3 open: >4V Replace control
3 DCV Replace VM
S3 closed: <1V handle

Note: Voltage to switch being tested may drop when any other control handle switch is depressed.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I19 - Traction Motor Speed Sensor

Test I19 - Traction Motor

Speed Sensor
This test displays the Traction Motor speed
sensor output as seen by the TPA.

Do this test in an area free of

obstructions with ample room for
maneuvering.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

“0000 to ±3200 rpm” should be displayed.

NOTE: The Operator Display shows rpm as
measured by the TPA.

Diagnosis and Repair

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

1 JPT1-26 JPT1-7 Perform step 2 Replace TPA

10.5 to 13V T/S wiring from TPA to
2 JPT2-1 Perform step 3
Traction Motor
JPT2-4
3 DCV JPT2-2 Perform step 4 Replace Traction Motor
At rest: 0V or speed sensor
4 JPT2-3 10.5 to 13V Perform step 5

5 JPT1-31 Traveling: Perform step 6

approx. 5V T/S wiring from TPA to
JPT1-7
6 JPT1-32 Replace TPA Traction Motor

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I20 - Lift Motor Speed Sensor (AC Lift) Input Tests

Test I20 - Lift Motor NOTE: The Operator Display shows rpm as
measured by the LPA.
Speed Sensor (AC Lift)
This test displays the input from the speed
sensor on the Lift Motor as seen by the lift
power amplifier.

Do this test in an area free of

obstructions with ample room for lifting.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.
NOTE: This test shows better results in Active
Service. See “Active Service Mode” on
page 3-24

“0000 to ±2450 rpm” should be displayed.

Diagnosis and Repair

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

1 JPL1-26 JPL1-7 Perform step 2 Replace LPA

10.5 to 13V T/S wiring from LPA to
2 JPL2-1 Perform step 3
Lift Motor
JPL2-4
3 DCV JPL2-2 Perform step 4 Replace Lift Motor
At rest: 0V or speed sensor
4 JPL2-3 10.5 to 13V Perform step 5

5 JPL1-31 Lifting: Perform step 6

Approx 5V T/S wiring from LPA to
JPL1-7
6 JPL1-32 Replace LPA Lift Motor

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I22 - Lift Cutout Switch (S27)

Test I22 - Lift Cutout

Switch (S27)
This test displays what the VM is reading from
the Lift Cutout switch (S27).

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display shows the state of the

switch:

Message
Mast Position
Displayed

Over Flag ON

Not Over Flag OFF

Diagnosis and Repair

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

1 JPC20-6 JPF3-12 Perform step 2 Replace VM

DCV 10.5 to 13V
2 JPS5-1 JPS5-3-6 Perform step 3 R/R wiring to switch

3 Disconnect JPS5 JPC22-6 Perform step 4 Replace VM

JPF3-12 5V
4 /DCV JPS5-2 Replace S27 R/R wiring to switch

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I23 - CAN Bus Test Input Tests

Test I23 - CAN Bus Test The Operator Display shows:

• T if the TPA is communicating with the VM
This test verifies the VM is communicating with • L if the LPA is communicating with the VM
the TPA, LPA, and Operator Display. • V if the Operator Display is
communicating with the VM
Run Test
If T, L, or V is not present, the test has failed.
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

Diagnosis and Repair

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

Unable to enter the test and see letters (DC Lift)

Remove JPD1-2 and

1 JPD1-3 from N/A N/A V visible in test Perform step 2 Perform step 3
connector

Test wires for

continuity.
Approx. Make sure they
2 JPD1-2 JPD1-3 Replace TPA
19K Ohms are not shorted
together. If OK,
Disconnect replace TPA.
JPD1/Ohms Test wires for
continuity.
Approx. Make sure they
3 JPD1-6 JPD1-7 Replace display
120 Ohms are not shorted
together. If OK,
replace VM.

Unable to enter the test and see letters (AC Lift)

Remove JPD1-2 and

1 JPD1-3 from V visible in test Perform step 2 Perform step 5
connector N/A N/A
L and V visible
2 Disconnect JPT1 Replace TPA Perform step 3
in test

T and V visible
3 Disconnect JPL1 N/A N/A Replace LPA Perform step 4
in test

Test wires for

continuity.
Disconnect Approx.
4 JPD1-2 JPD1-3 Perform step 1 Make sure they
JPD1/Ohms 38 Ohms
are not shorted
together.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I23 - CAN Bus Test

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

Test wires for

continuity.
Disconnect Approx. 120 Make sure they
5 JPD1-6 JPD1-7 Replace display
JPD1/Ohms Ohms are not shorted
together. If OK,
replace VM.

T Missing (DC Lift)

Verify LED's on
TPA are
illuminated. If Troubleshoot B+
not, test TM from K3 Relay
1 DCV JPT1-1 TPA B– B+
temp sensor and and B– from
speed encoder TP4.
circuits. If OK,
perform step 2.

2 Disconnect JPT1 JPT1-23 JPD1-2 Perform step 3

0 Ohms Repair wiring
3 and JPD1/Ohms JPT1-35 JPD1-3 Replace TPA

T Missing (AC Lift)

Verify LED's on
TPA are
illuminated. If Troubleshoot B+
not, test TM from K3 Relay
1 DCV JPT1-1 JPT1-7 B+
temp sensor and and B– from
speed encoder TP4.
circuits. If OK,
perform step 2.

2 Disconnect JPT1 JPT1-23 JPL1-23 Perform step 3

0 Ohms Repair wiring
3 and JPL1/Ohms JPT1-35 JPL1-35 Replace TPA

L Missing

Verify LED's on
LPA are
illuminated. If Troubleshoot B+
not, test LM from K3 Relay
1 DCV JPL1-1 LPA B– B+
temp sensor and and B– from
speed encoder TP4.
circuits. If OK,
perform step 2.

2 Disconnect JPD1 JPL1-23 JPD1-2 Perform step 3

0 Ohms Repair wiring
3 and JPL1/Ohms JPL1-35 JPD1-3 Replace TPA

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I24 - Steer Feedback Prox Sensor (AC Lift) Input Tests

Test I24 - Steer Feedback

Prox Sensor (AC Lift)
This test reads the input to the Vehicle Manager
from the Steer Feedback Proximity Sensor.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display shows the state of the

sensor:

Sensor Position Message Displayed

Over Metal On

Not Over Metal Off

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

Disconnect
1 PC20-9 PC22-11 Perform step 2 Replace VM
JPC20/DCV 12V
2 JPST-1 JPST-3 Perform step 3 Repair or replace wiring
Disconnect
3 JPC22-22 JPC22-11 Perform step 4 Replace VM
JPST/DCV 5V
4 JPST-2 JPST-3 Replace sensor Repair or replace wiring

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I25 - Steer Motor Encoder (AC Lift)

Test I25 - Steer Motor

Encoder (AC Lift)
This test displays the encoder counts from the
steer motor encoder.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

You should see “0 to 255” while steering. If not,

the test has failed.

Diagnosis and Repair

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

Disconnect
1 JPC20-7 JPC10-9 Perform step 2 Replace VM
JPE4/DCV
12V
T/S wiring to
2 JPE4-1 Perform step 3
VM
JPE4-4
3 JPE4-3 Perform step 4 Replace Steer
DCV Motor encoder
4 JPE4-2 Steering: approx. 1.8V Perform step 5

5 JPC22-10 Not steering: 0 or 4.5V Perform step 6 T/S wiring to

JPC10-9
6 JPC22-9 Replace VM encoder

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I26 - Height Indicator Encoder Input Tests

Test I26 - Height

Indicator Encoder
This test reads the input from the height
encoder to the Operator’s Display.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

Above free lift: counts increase “0 to 255” lifting

counts decrease “255 to 0” lowering

If not, the test has failed.

Diagnosis and Repair

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

Replace
Disconnect
1 JPD2-1 JPD2-2 Perform step 2 Operator
JPD2/DCV
10.5 to 13V Display

Repair or
2 JPE3-1 Perform step 3
replace wiring
JPE3-4
JPE3-3
3 Perform step 4
(Channel A) Replace height
JPE3-2 encoder
4 JPE3-4 Not lifting: Approx. 5 Perform step 5
DCV (Channel B) or 0V
JPD2-3
5 Lifting above free lift: Perform step 6
(Channel A)
Approx. 2.3V Repair or
JPD2-2 Replace
JPD2-4 replace wiring
6 Operator
(Channel B)
Display

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I27 - Secondary Horn Switch (S10)

Test I27 - Secondary

Horn Switch (S10)
NOTE: Only with optional secondary control
handle

This test shows what the Vehicle Manager is

reading from S10.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display shows the state of the

switch:

Message
State of Switch
Displayed

Depressed In

Released Out

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

Disconnect
1 JPC4-1 JPC4-2 Perform step 2 Replace VM
JPC4/DCV

2 JPH3-1 JPH3-2 >4V Perform step 3 R/R wiring to VM

3 DCV JPC4-3 JPC4-2 Perform step 4 R/R wiring to switch

4 JPH3-3 JPH3-2 Replace switch R/R wiring to VM

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I33 - Steer Tiller Encoder 1 Connect Detect (AC Lift) Input Tests

Test I33 - Steer Tiller

Encoder 1 Connect Detect
(AC Lift)
This test verifies the Vehicle Manager sees the
12V circuit connected to the Steer Tiller
Encoder Channel 1.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display should show the

following:

Connection Status Message Displayed

Connected Yes

Not Connected No

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

1 JPC10-6 JPC18-5 Perform step 2 Replace VM

DCV 10.5 to 13V Replace Steer
2 JPE1-1 JPE1-4 R/R wiring from VM
Tiller Encoder

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I34 - Steer Tiller Encoder 2 Connect Detect (AC Lift)

Test I34 - Steer Tiller

Encoder 2 Connect Detect
(AC Lift)
This test verifies the Vehicle Manager sees the
12V circuit connected to the Steer Tiller
Encoder Channel 2.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display should show the

following:

Connection Status Message Displayed

Connected Yes

Not Connected No

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

1 JPC10-7 JPC18-6 Perform step 2 Replace VM

DCV 10.5 to 13V Replace Steer
2 JPE2-1 JPE2-4 Repair wiring from VM
Tiller Encoder

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I35 - Steer Tiller Encoder 1 - Channels A & B (AC Lift) Input Tests

Test I35 - Steer Tiller

Encoder 1 - Channels
A & B (AC Lift)
This test monitors input to Vehicle Manager
from Channel 1.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

Count should increase CW; decrease CCW. If

not, the test has failed.

Diagnosis and Repair

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

1 JPC10-6 JPC18-5 Perform step 2 Replace VM

10.5 to 13V
2 JPE1-1 Perform step 3 Repair wiring from VM

3 JPE1-3 JPE1-4 Perform step 4 Replace Steer Tiller

DCV
4 JPE1-2 Perform step 5 Encoder
Turning tiller:
5 JPC22-5 approx. 2.5V Perform step 6 Repair or replace
JPC18-5
6 JPC22-12 Replace VM wiring

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I36 - Steer Tiller Encoder 2 - Channels A & B (AC Lift)

Test I36 - Steer Tiller

Encoder 2 - Channels
A & B (AC Lift)
This test monitors input to Vehicle Manager
from Channel 2.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

Count should increase CW; decrease CCW. If

not, the test has failed.

Diagnosis and Repair

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

1 JPC10-7 JPC18-6 Perform step 2 Replace VM

10.5 to 13V
2 JPE2-1 Perform step 3 Repair wiring from VM

3 JPE2-3 JPE2-4 Perform step 4 Replace Steer Tiller

DCV
4 JPE2-2 Perform step 5 Encoder
Turning tiller:
5 JPC22-13 approx. 2.5V Perform step 6 Repair or replace
JPC18-6
6 JPC22-14 Replace VM wiring

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I39 - Neutral Pulses (AC Lift) Input Tests

Test I39 - Neutral Pulses

(AC Lift)
This test displays the neutral pulses seen by
the Vehicle Manager from the Steer Power
Amplifier.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display should show the

following:

Deadman Pedal Message Displayed

Toggles between On
Depressed
and Off

Released >15 sec = On or Off

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

1 JPC6-6 10.5 to 13V Perform step 2 Replace VM

Deadman Pedal
DCV JPC6-4 Up: >4V Repair wiring or replace
2 JPC6-1 Replace VM
Down: 1.7 to Steer Power Amp
3.4V

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I60 - Security Start Switch (S23) (optional)

Test I60 - Security Start

Switch (S23) (optional)
This test shows what the Vehicle Manager is
reading from S23.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

The Operator Display shows the state of the

switch:

State of Switch Message Displayed

Depressed In

Released Out

If results do not match the preceding table, the

test has failed.

Diagnosis and Repair

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

Disconnect
1 >4.0V Perform step 2 Verify option is ON
JPC10/DCV
JPC10-2 JPC10-4
S23 open: >4.0V T/S switch and
2 DCV Replace VM
S23 closed: 0V wires

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I63 - High Speed Travel Switch (S25) Input Tests

Test I63 - High Speed The Operator Display should show the
following:
Travel Switch (S25) Mast Position Message Displayed

This test shows what the Vehicle Manager is Lowered Below

reading from the high speed travel switch (S25).
Raised Above

If these results are not observed, the test has

Use extreme caution when working
failed.
around an elevated mast.

Run Test
Run this test in Active Service Mode.
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

Diagnosis and Repair

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

Disconnect
1 JPC20-3 10.5 to 13V Perform step 2
JPC20/DCV
TP4 Replace VM
Disconnect
2 JPC22-4 Approx. 5V Perform step 3
JPC22/DCV

T/S wire to
3 TP1 JPS6-3 B+ Perform step 4 Fuse/Relay
Disconnect Card
JPS6/DCV
4 JPS6-2 Approx. 5V Perform step 5
T/S wire to VM
5 10.5 to 13V Perform step 6
TP4 Switch not over
JPS6-2 metal: approx. 5V
6 DCV Replace VM Replace switch
Switch over metal:
0V

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Input Tests Test I80 - OCSS Upper Beam

Test I80 - OCSS Upper Run Test

Beam Make sure the beam is not blocked by objects,
debris, or dirt. The Operator Display shows the
state of the beam:
This test verifies the upper beam is working
correctly.
Deadman Pedal Message Displayed
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on Down On
page 3-23.
Up Off

If results do not match the preceding table, the

test has failed. Perform Diagnosis and Repair.

Diagnosis and Repair

Deadman
Component Pedal LED Status
Position

Remove sensor housing covers. Turn key switch ON and verify LEDs are illuminated as follows:

Up or Down Green ON +12V present at RCVR_1

Receiver (3 wires)
Down Yellow ON Receiver is receiving light beam (correctly aligned)

Emitter (2 wires) Down Green ON +12V present at EMTR_1

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 JX1-1 JX1-4 Replace Expander Module Perform step 2

Disconnect
JPX1/DCV; PT1-8 10.7 to Replace harness between
Deadman (AC Lift) 13V
2 PD1-1 Expander Module and OD/PA, T/S VM
pedal down PT1-7
JX1 to JD1-1/JT1
(DC Lift)

Fault: EMITTER - Green LED not illuminated

Disconnect
JPCS1/DCV;
1 JCS1-1 JCS1-2 Replace Emitter harness PCS1 Perform step 2
Deadman
pedal down 10.7 to
Disconnect 13V
Replace harness between Replace
JPX2/DCV;
2 PX2-4 PX2-9 Expander Module and Emitter Expander
Deadman
harness JX2 to JCS1 Module
pedal down

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I80 - OCSS Upper Beam Input Tests

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

Fault: RECEIVER - Green LED not illuminated

Disconnect
JPCS2/DCV;
1 JCS2-1 JCS2-4 Replace Receiver harness PCS2 Perform step 2
Deadman
pedal up 10.7 to
Disconnect 13V
Replace harness between Replace
JPX2/DCV;
2 PX2-1 PX2-6 Expander Module and Receiver Expander
Deadman
harness JX2 to JCS2 Module
pedal up

Fault: RECEIVER - Yellow LED not illuminated

Replace harness
between
Disconnect Expander
1 JPCS2 and JCS2-2 PX2-2 0 Ohms Perform step 2 Module and
JPX2/Ohms Receiver
harness JX2 to
JPCS2

Clean Emitter
Make sure Emitter is not obscured (dirty) and is
2 Perform step 3 eye and/or align
aligned correctly
correctly

Replace
Disconnect
3 PX2-2 PX2-6 Approx. 5V Replace Receiver harness PCS2 Expander
JPX2/DCV
Module

Fault Code 58 - Previous Tests Pass

JT1-15
(AC Lift)
1 JX1-5 Perform step 2
JT1-14
Disconnect (DC Lift) Repair/Replace
JPX1 and 0 Ohms harness
JPT1/Ohms JT1-23 JX1-JT1
(AC Lift)
2 JX1-2 Replace Expander Module
JT1-22
(DC Lift)

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Input Tests Test I81 - OCSS Lower Beam

Test I81 - OCSS Lower Run Test

Beam Make sure the beam is not blocked by objects,
debris, or dirt. The Operator Display shows the
state of the beam:
This test verifies the lower beam is working
correctly.
Deadman Pedal Message Displayed
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on Down On
page 3-23.
Up Off

If results do not match the preceding table, the

test has failed. Perform Diagnosis and Repair.

Diagnosis and Repair

Deadman Pedal
Component LED Status
Position

Remove sensor housing covers. Turn key switch ON and verify LEDs are illuminated as follows:

Up or Down Green ON +12V present at RCVR_2

Receiver (3 wires)
Down Yellow ON Receiver is receiving light beam (correctly aligned)

Emitter (2 wires) Down Green ON +12V present at EMTR_2

If the LEDs do not illuminate as described above, troubleshoot as follows:

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

Fault: All LEDS not illuminated

1 JX1-1 JX1-4 Replace Expander Module Perform step 2

Disconnect
JPX1/DCV; PT1-8 10.7 to Replace harness between
Deadman (AC Lift) 13V
2 PD1-1 Expander Module and OD/TPA T/S VM
pedal down PT1-7
JX1 to JD1-1/JT1
(DC Lift)

Fault: EMITTER - Green LED not illuminated

Disconnect
JPCS3/DCV;
1 JCS3-1 JCS3-2 Replace Emitter harness PCS3 Perform step 2
Deadman
pedal down 10.7 to
Disconnect 13V
Replace harness between Replace
JPX2/DCV;
2 PX2-5 PX2-10 Expander Module and Emitter Expander
Deadman
harness PX2 to JCS1 Module
pedal down

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I81 - OCSS Lower Beam Input Tests

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

Fault: RECEIVER - Green LED not illuminated

Disconnect
JPCS4/DCV;
1 JCS4-1 JCS4-4 Replace Receiver harness PCS4 Perform step 2
Deadman
pedal up 10.7 to
Disconnect 13V
Replace harness between Replace
JPX2/DCV;
2 PX2-3 PX2-8 Expander Module and Receiver Expander
Deadman
harness JX2 to JPCS4 Module
pedal up

Fault: RECEIVER - Yellow LED not illuminated

Replace harness
between
Disconnect
Expander
1 JPCS4 and JCS4-3 PX2-7 0 Ohms Perform step 2
Module and
JPX2/Ohms
Receiver harness
JX2 to JCS4

Clean Emitter
Make sure Emitter is not obscured (dirty) and is
2 Perform step 3 eye and/or align
aligned correctly
correctly

Replace
Disconnect
3 PX2-7 PX2-8 approx. 5V Replace Receiver harness PCS4 Expander
JPX2/DCV
Module

Fault Code 58 - Previous Tests Pass

Disconnect JT1-15
harness at (AC Lift)
1 JX1-5 0 Ohms Perform step 2
JPX1 and JT1-14
JPT1/Ohms (DC Lift) Repair/replace
harness
Disconnect JT1-23 JX1-JT1
harness at (AC Lift)
2 JX1-2 0 Ohms Replace Expander Module
JPX1 and JT1-22
JPT1/Ohms (DC Lift)

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Input Tests Test I82 - OCSS Cnt

Test I82 - OCSS Cnt

This test displays the number of times the
beams have been broken on the OCSS system.
The number can be reset to 0 by activating the
Clear OCSS function at the end of the Service
menu.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I83 - BatGateL Input Tests

Test I83 - BatGateL

The state of the optional Left Battery Gate
Switch (S57), as seen by the VM, is displayed.

Run Test
The input is good if these values are displayed:

Battery Gate Value Displayed

Removed Out

Installed In

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

1 JPC24-1 10.5 to 13VDC Perform step 2

JPC24-8 Replace VM
2 JPC22-11 S57 Open: 5VDC Perform step 3

Repair wires to
3 JPS17-1 10.5 to 13VDC Perform step 4
DCV JPS17-3 VM

4 JPS17-2 Perform step 5 Replace S57

S57 Open: 5VDC
Closed: 0VDC Repair wires to
5 JPC22-11 JPC24-8 Replace VM
S57

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Input Tests Test I84 - BatGateR

Test I84 - BatGateR

The state of the optional Right Battery Gate
Switch (S58), as seen by the VM, is displayed.

Run Test
The input is good if these values are displayed:

Battery Gate Value Displayed

Removed Out

Installed In

If these values are not displayed, refer to

Diagnosis and Repair.

Diagnosis and Repair

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

1 JPC20-10 10.5 to 13VDC Perform step 2

JPC24-3 Replace VM
2 JPC22-3 S58 Open: 5VDC Perform step 3

Repair wires to
3 JPS16-1 10.5 to 13VDC Perform step 4
DCV JPS16-3 VM

4 JPS16-2 Perform step 5 Replace S58

S58 Open: 5VDC
Closed: 0VDC Repair wires to
5 JPC22-3 JPC24-3 Replace VM
S58

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I86 - Lift Height Input Tests

Test I86 - Lift Height

This test displays fork height above free lift.

Run Test
NOTE: This test cannot be run in Active Service
Mode.
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

You should see: below free lift = 0; height

increase going up; height decrease going down.

If not, the test has failed.

Diagnosis and Repair

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

Disconnect
1 JPD2-1 JPD2-2 Perform step 2 Replace display
JPD-2/DCV 10.5 to 13V
2 JPE3-1 Perform step 3 T/S wiring
JPE3-4
3 JPE3-3 Perform step 4
Replace encoder
4 DCV JPE3-2 JPE3-4 Lifting: approx. Perform step 5

5 JPD2-3 2.4V Perform step 6

JPD2-2 T/S wiring
6 JPD2-4 Replace display

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Input Tests Test I90 - Degrees Turned Past Steer Flag

Test I90 - Degrees

Turned Past Steer Flag
This test shows the number of degrees the drive
unit has turned after the steer flag is no longer
under the steer proximity switch.

Use this test to adjust the switch so the drive

unit does not contact the hard stop on either
side during normal operation.

Run Test
Turn the steering wheel all the way in one
direction until the drive unit is against the
mechanical stop. Record the steering degrees
displayed. Turn the steering wheel all the way
in the opposite direction against the mechanical
stop. Compare this reading to the reading from
the opposite side.

Both sides should be approx. 10°.

Diagnosis and Repair

Adjust the Steer Limit Switch (S11) mounting
bracket so the reading on both ends is as close
to 10° as possible.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I91 - iPort Communication Test Input Tests

Test I91 - iPort

Communication Test
This test shows the status of communication
between the VM and Supplier Wireless Module
(SWM).
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

Run Test
When running the test, the numbers may
alternate:
• between 2 and 3, indicating correct
operation of SWM and VM
• between 1 and 2, indicating a
communication error; perform Diagnosis
and Repair

Diagnosis and Repair

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

Connect FlashWare
to another truck to
make sure the
Connect cable and program
FlashWare to FlashWare can are functioning
Perform
1 VM and N/A N/A communicate with correctly. If OK,
step 2
attempt to the VM reconnect to the
communicate original truck. If
still unable to
communicate,
replace VM.

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Input Tests Test I91 - iPort Communication Test

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

Check connection
Perform at TP1, in-line fuse,
2 JRDP1-6 B–
step 3 and wire
continuity.
B+
Perform
3 JRDP1-5 Check connection
step 4
B+ at TP4 and wire
Perform continuity.
4 JRDP1-3
step 5

Check connection
Perform
5 JRDP1-2 B– at VM and wire
DCV Step 6
continuity.

Make
sure VM
and
–5 to –10V SWM are Check connection
loaded at SWM and wire
6 JRDP1-1 B– with continuity. Refer to
latest SWM
software documentation.
and
option is
enabled

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test I92 - iPort Error Bitmap Input Tests

Test I92 - iPort Error

Bitmap
This test is for factory use only.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Output Tests

Output Tests
Section 6. Messages, Codes, and Tests

A Diagnosis and Repair table is provided for

most tests. If a test fails, refer to the Diagnosis
and Repair table.

Through the process of elimination, these tables

provide a step-by-step approach to diagnosing a
problem and the necessary corrective action.
See the example below.

Table 6-4. Example Diagnosis and Repair Table

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

This column identifies

any actions required
before testing the
circuit, such as
disconnecting certain
connectors. If no
instructions are given,
The next
all circuits should be Probe Probe The next
action to
Do the connected. point for point for action to
The reading perform if
testing Note: If something the the perform if
required to consider the
in this was disconnected in positive negative the Expected
the step a success. Expected
order. the prior step, (+) meter (–) meter Results are
Results are
reconnect it before lead. lead. met.
not met.
performing the next
step.

This column also

identifies the required
scale on the meter for
this step.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test O00 - Toggle TPC or MPC Contactor Output Tests

Test O00 - Toggle TPC or

MPC Contactor
This test turns the TPC (DC lift) or MPC (AC lift)
contactor ON and OFF.

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
support the lift truck. See “Jacking
Safety” on page 2-8.

Jack the drive wheel off the floor for this test.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

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, the test has failed.

Diagnosis and Repair

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

Disconnect JPS1
T/S wires and
1 from contactor JPS1-8 Approx. 38 ohms Perform step 2
coil
panel/Ohms JPS1-10
T/S K2 relay and
2 TP4 B+ Perform step 3
Fuse/Relay Card
DCV
Test ON: 18V Test contactor Test wire to VM.
3 B+ JPS1-8
Test OFF: 0V for binding If OK, replace VM

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Output Tests Test O01 - Toggle STR Contactor

Test O01 - Toggle STR

Contactor
This test turns the STR contactor ON and OFF.

DO NOT attempt to drive the truck while

performing this test.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

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, the test has failed.

Diagnosis and Repair

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

Disconnect
1 JPS1-11 Approx. 40 Ohms Perform step 2 T/S wires and coil
JPS1/Ohms JPS1-10
2 Perform step 4 Perform step 3
TP4 B+ T/S wire to Replace
3 JPF2-1
JPS1-10 Fuse/Relay Card
DCV Test contactor
4 JPS1-11 Perform step 5
OFF: 0V for binding
B+
ON: approx. 24V T/S wire to
5 JPC18-11 Replace VM
JPS1-11

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test O02 - Toggle LPC Contactor Output Tests

Test O02 - Toggle 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.

If the STR contactor is shorted on a truck

with DC lift, the carriage lifts when the
LPC contactor is toggled ON.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

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, the test has failed.

Diagnosis and Repair

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

Disconnect
1 JPS1-9 Approx. 38 Ohms Perform step 2 T/S wires and coil
JPS1/Ohms
JPS1-10
T/S K2 relay and
2 TP4 B+ Perform step 3
Fuse/Relay Card

DCV Test ON: Test wire to LPA or

18V (AC Lift) Test contactor VM. If OK, replace
3 B+ JPS1-9
24V (DC Lift) for binding LPA
Test OFF: 0V or VM

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Output Tests Test O03 - Toggle AUX Contactor

Test O03 - Toggle AUX

Contactor
This test turns the AUX contactor ON and OFF.

DO NOT attempt to drive the lift truck

while performing this test.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

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, the test has failed.

Diagnosis and Repair

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

Disconnect
1 JPS1-9 Approx. 40 Ohms Perform step 2 T/S wires and coil
JPS1/Ohms JPS1-10
2 Perform step 4 Perform step 3
TP4 B+ T/S wire to Replace
3 JPF2-1
JPS1-10 Fuse/Relay Card
DCV Test contactor
4 JPS1-9 Test OFF: 0V Perform step 5
for binding
B+ Test ON:
Approx. 24V T/S wire to
5 JPC18-9 Replace VM
JPS1-9

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test O04 - Toggle Aux1 Directional (SOL5T) Solenoid Output Tests

Test O04 - Toggle Aux1

Directional (SOL5T)
Solenoid
Refer to Test A31 - Solenoid 5T (AUX1) Current
(Page 6-45).

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Output Tests Test O05 - Toggle Aux2 Directional (SOL5B) Solenoid

Test O05 - Toggle Aux2

Directional (SOL5B)
Solenoid
Refer to Test A32 - Solenoid 5B (AUX2) Current
(Page 6-46).

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test O06 - Toggle Reach Solenoid Output Tests

Test O06 - Toggle Reach 2. Disconnect wire REACH-1 from the reach
solenoid.
Solenoid 3. Connect a digital ammeter in series with
the reach solenoid coil, positive lead (+) to
This test turns the reach solenoid ON and OFF, the wire removed, and the negative lead (–)
verifying its correct operation electrically. to terminal REACH-1 on the solenoid.
4. Reconnect the battery connector and turn
A successful test proves the reach solenoid coil, the key switch ON.
wiring, and related circuitry in the Vehicle 5. Run Test O06 and toggle the solenoid coil
Manager are functioning correctly. ON. Use the ENTER button to toggle the
test ON and OFF. The Operator Display
It does not prove the reach solenoid valve is shows ON or OFF. The ammeter must read
functioning mechanically. approx. 560 mA.
a. If the ammeter reading is correct, the
Run Test solenoid coil is functioning electrically.
NOTE: For information on how to use Service b. If the solenoid is not working correctly,
Mode, see “Using Service Mode” on check for a mechanical problem in the
page 3-23. valve, such as binding or
contamination.
1. Turn the key switch OFF and disconnect
the battery connector.

Diagnosis and Repair

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

Disconnect JPC18 Approx. T/S coil and

1 JPC18-12 Perform step 2
and JPF2/Ohms JPF2-8 41 Ohms wires

2 DCV TP4 B+ Replace VM T/S K2 circuit

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Output Tests Test O07 - Toggle Tilt Solenoid

Test O07 - Toggle 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 the tilt solenoid coil, terminal TILT-1 on the solenoid.
wiring, and related circuitry in the Vehicle 4. Reconnect the battery connector and turn
Manager are functioning correctly. the key switch ON.

It does not prove the tilt solenoid valve is 5. Run Test O07 and toggle the solenoid coil
functioning mechanically. ON. Use the ENTER button to toggle the
test ON and OFF. The Operator Display
shows ON or OFF. The ammeter must read
Run Test approx. 560 mA.
NOTE: For information on how to use Service a. If the ammeter reading is correct, the
Mode, see “Using Service Mode” on solenoid coil is functioning electrically.
page 3-23. b. If the solenoid is not working correctly,
NOTE: This test is available only if the tilt check for a mechanical problem in the
option is configured for the lift truck. valve, such as binding or
contamination.

Diagnosis and Repair

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

Disconnect JPC18 T/S coil and

1 JPC18-15 Approx. 41 Ohms Perform step 2
and JPF2/Ohms JPF2-8 wires

2 DCV TP4 B+ Replace VM T/S K2 circuit

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test O08 - Toggle the Sideshift Solenoid Output Tests

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 the sideshift solenoid (–) to terminal SIDESHIFT-1 on the
coil, wiring, and related circuitry in the Vehicle solenoid.
Manager are functioning correctly. 4. Reconnect the battery connector and turn
the key switch ON.
It does not prove the sideshift solenoid valve is
functioning mechanically. 5. Run Test O08 and toggle the solenoid coil
ON. Use the ENTER button to toggle the
test ON and OFF. The Operator Display
Run Test shows ON or OFF. The ammeter must read
approx. 560 mA.
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on a. If the ammeter reading is correct, the
page 3-23. solenoid coil is functioning electrically.
NOTE: This test is available only if the sideshift b. If the solenoid is not working correctly,
option is configured for the lift truck. check for a mechanical problem in the
valve, such as binding or
contamination.

Diagnosis and Repair

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

Disconnect JPC18 T/S coil and

1 JPC18-14 Approx. 41 Ohms Perform step 2
and JPF2/Ohms JPF2-8 wires

2 DCV TP4 B+ Replace VM T/S K2 circuit

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Output Tests Test O09 - Aux Dump (SOL6 or SOL8)/Main Relief Dump (SOL3)

Test O09 - Aux Dump

(SOL6 or SOL8)/Main
Relief Dump (SOL3)
Refer to Test A33 - Aux Dump (SOL6 or
SOL8)/Main Relief Dump (SOL3) Current
(Page 6-47).

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test O11 - Toggle the Load Hold (SOL1) Solenoid Output Tests

Test O11 - Toggle the 2. Disconnect wire SOL1-1 from the load
hold solenoid.
Load Hold (SOL1) 3. Connect a digital ammeter in series with
the load hold solenoid coil, positive lead (+)
Solenoid to the wire removed, and the negative
lead (–) to terminal SOL1-1 on the
This test turns the load hold solenoid ON and solenoid.
OFF, verifying its correct operation electrically. 4. Reconnect the battery connector and turn
the key switch ON.
A successful test proves the load hold solenoid
5. Run Test O11 and toggle the solenoid coil
coil, wiring, and related circuitry in the Vehicle
ON. Use the ENTER button to toggle the
Manager are functioning correctly.
test ON and OFF. The Operator Display
shows ON or OFF. The ammeter must read
It does not prove the load hold solenoid valve is
approx. 800 mA.
functioning mechanically.
a. If the ammeter reading is correct, the
solenoid coil is functioning electrically.
Run Test
b. If the solenoid is not working correctly,
NOTE: For information on how to use Service check for a mechanical problem in the
Mode, see “Using Service Mode” on valve, such as binding or
page 3-23. contamination.
1. Turn the key switch OFF and disconnect
the battery connector.

Diagnosis and Repair

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

Disconnect JPC18 T/S coil and

1 JPF2-5 JPC18-10 Approx. 30 Ohms Perform step 2
and JPF2/Ohms wires

2 DCV JPC18-10 TP4 B+ Replace VM T/S K2 circuit

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Output Tests Test O12 - Ramp the Proportional Lower (SOL2) Solenoid

Test O12 - Ramp the

Proportional Lower
(SOL2) Solenoid
Refer to Test A34 - Lift/Lower Current (SOL2)
(Page 6-48).

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test O18 - Toggle Horn Output Tests

Test O18 - Toggle Horn

This test turns the truck’s horn ON and OFF.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.
1. Run this test in Active Service Mode while
taking readings,
2. Use the ENTER button to toggle the 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, the test
has failed.

Diagnosis and Repair

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

T/S wires and Fuse/Relay

1 H2 TP4 B+ Perform step 2
Card

2 DCV H1 Replace horn Perform step 3

Test ON: B+
TP1
3 JPC18-16 Test OFF: 0V T/S wires to Replace VM
horn

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Output Tests Test O19 - Audible Alarm

Test O19 - Audible

Alarm
This test turns on the Operator Display alarm
by gradually increasing the PWM voltage.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

If the alarm does not sound when you depress

the ENTER button, the test has failed.

Diagnosis and Repair

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

Button Up: 0V Replace Operator

1 JPD3-1 JPD3-2 Perform step 2
Hold Up Button ON Display card
DCV
Sounder Sounder for 6 seconds:
2 Approx. 4.0V Replace sounder T/S wiring to sounder
B1 B2

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test O20 - Travel Alarm Output Tests

Test O20 - Travel Alarm

NOTE: This test only applies to trucks with
Travel Alarm option.

This test toggles the travel alarm ON and OFF.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

Use the ENTER button to toggle the test ON and

OFF. The Operator Display shows ON or OFF.

Diagnosis and Repair

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

1 H2– Replace travel alarm Perform step 2

H2+ Test ON: B+
2 DCV TP4 Perform step 3 T/S FU9 and wiring
Test OFF: 0V
3 TP1 JPC18-18 T/S wiring to horn Replace VM

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Output Tests Test O23 - Toggle Fans

Test O23 - Toggle Fans

This test toggles the power amplifier fans and
motor compartment cooling fans ON and OFF.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

Use the TILT UP/DOWN buttons to toggle the

test ON and OFF. The Operator Display shows
ON or OFF.
NOTE: Upon exiting this test, the power
amplifier fans remain in the state last
chosen (ON or OFF), until the technician
exits Program Mode. This permits
running Test O23 in conjunction with
other tests.

Diagnosis and Repair

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

OFF: 0V
1 TP1 JPC18-17 Perform step 2 Replace VM
DCV ON: B+

2 JPF2-3 TP4 B+ T/S wires and fans T/S K2 circuitry

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test O25 - Toggle the 2d Pump (SOL4) Solenoid Output Tests

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: This test only applies to DC lift trucks 3. Connect a digital ammeter in series with
with a dual pump. 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
A successful test proves the 2d Pump solenoid
the key switch ON.
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 the 2d Pump solenoid valve is test ON and OFF. The Operator Display
functioning mechanically. shows ON or OFF. The ammeter must read
650 to 900 mA.
Run Test a. If the ammeter reading is correct, the
solenoid coil is functioning electrically.
NOTE: For information on how to use Service
b. If the solenoid is not working correctly,
Mode, see “Using Service Mode” on
check for a mechanical problem in the
page 3-23.
valve, such as binding or
contamination.

Diagnosis and Repair

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

Disconnect JPF2 T/S solenoid coil

1 JPF2-5 JPC18-1 40 Ohms Perform step 2
and JPC18/Ohms and wiring

T/S K2 relay
2 DCV JPC18-1 B– B+ Replace VM
circuit

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Output Tests Test O28 - Ramp Lift Motor (AC Lift)

Test O28 - Ramp Lift The Operator Display first shows the current
RPM request.
Motor (AC Lift) Use the tilt down button to increase the RPM
request by 600 RPM increments, from a
This test ramps the Lift Motor by gradually minimum of 600 RPM to a maximum of
increasing the command to the Lift Power 3000 RPM.
Amplifier via the CAN Bus. This test verifies the
Lift Power Amplifier can drive the Lift Motor. 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,
The Lift Motor may rotate during this and exit the test. If instead, you press tilt up,
test. Make sure truck is in an area with tilt down, sideshift left, or sideshift right, the
sufficient overhead clearance for lifting test is still active with the request set to 0.
the mast.

Running this test for an extended period

of time can cause damage to the Lift
Motor, Lift Power Amplifier, or wiring.

Run Test
NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.

Diagnosis and Repair

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

If current does not ramp

on one or two phases,
test cables to Lift Motor.
Current must be
If OK, replace Lift Motor.
Current probe even on all
If phases are low or
(amp clamp) on phases and
1 N/A N/A Replace LPA unequal, replace the
phases U, V, and ramp up as the
LPA. If phases are equal
W percentage
and high but motor runs
increases
slowly, check for
binding. If not binding,
replace Lift Motor.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test O29 - Ramp Traction Motor Output Tests

Test O29 - Ramp Run Test

Traction Motor NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-23.
This test ramps the Traction Motor by gradually
increasing the command to the Traction Power NOTE: The deadman pedal must be depressed
Amplifier via the CAN Bus. This test verifies the for the brake to release.
Traction Power Amplifier can drive the Traction
Motor. 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
The Traction Motor will rotate during this minimum of 25 RPM to a maximum of 725
test. Jack the drive wheels off the floor. RPM.
Use extreme caution whenever the lift
truck is jacked up. Never block the lift Once the maximum RPM request is reached,
truck between the telescopic and the pressing tilt down again resets the request to 0.
floor. Use a suitable hoist to stabilize the Tilt up also resets the request to 0.
mast. Keep hands and feet clear from
vehicle while jacking the lift truck. After Use the horn button to stop the motor, reset the
the lift truck is jacked, place solid blocks RPM request to 0, and exit the test. If instead,
or jack stands beneath it to support it. you press tilt up, tilt down, sideshift left, or
DO NOT rely on the jack alone to sideshift right, the test is still active with the
support the lift truck. See “Jacking request set to 0.
Safety” on page 2-8.

Running this test for an extended period

of time can cause damage to the
Traction Motor, Traction Power Amplifier,
or wiring.

Diagnosis and Repair

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

If current does not ramp

on one or two phases,
test cables to Traction
Current must be Motor. If OK, replace
Current probe even on all Traction Motor. If
(amp clamp) on phases and phases are low or
1 N/A N/A Replace TPA
phases U, V, and ramp up as the unequal, replace the
W percentage TPA. If phases are equal
increases and high but motor runs
slowly, check for
binding. If not binding,
replace Traction Motor.

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Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests

Output Tests Test O30 - Toggle Brake Coil

Test O30 - Toggle Brake

Coil
See “Test A35 - Brake Armature” on page 6-49.

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Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks

Test O32 - Toggle Relays K1, K2, K3, and K4 Output Tests

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 Service
Mode, see “Using Service Mode” on
page 3-23.
NOTE: OFF is displayed when entering the test
even if the relays are closed.

Press the ENTER button to toggle the test.

The Operator Display shows:

Test Status Relay Status

ON Tips closed

OFF Tips open

If results do not match the preceding table, the

test has failed.
NOTE: Codes are written to the Error Log when
this test is run. Clear the Error Log
when done.

Diagnosis and Repair

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

Check K1, K2, and

K3 relay coils. If OK,
1 JPF4-5 Approx. 1.6M ohm Perform step 2
replace Fuse/Relay
Disconnect Card.
JPF4/Ohms
JPF4-13 Check K4 relay coil.
2 JPF4-10 Approx. 1.7K ohm Perform step 3 If OK, replace
Fuse/Relay Card.

Replace Fuse/Relay
3 Perform step 4
Card.
DCV TP4 B+
T/S wiring from
4 JPC14-6 Replace VM
Fuse/Relay Card.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Section 7. Component Procedures

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

List of Component Procedures

List of Component Procedures

Component Locator Photos . . . . . . . . . . 7-5 Removal . . . . . . . . . . . . . . . . . . . . . . 7-64
Mast and Reach Carriage . . . . . . . . . . 7-5 Installation and Adjustment . . . . . . . 7-65
Tractor, AC Lift, Fore/Aft Stance . . . . . 7-6
Tractor, AC Lift, Dockstance . . . . . . . . 7-8 Electrical Components . . . . . . . . . . . . 7-67
Tractor, DC Lift . . . . . . . . . . . . . . . . . 7-10 Battery Procedures . . . . . . . . . . . . . . . . 7-68
Reach Carriage . . . . . . . . . . . . . . . . . 7-12 Battery Connector/Cables . . . . . . . . 7-68
Underside Components . . . . . . . . . . . 7-13 Battery Exterior Cleaning . . . . . . . . . 7-69
Testing, Charging, and Maintenance. 7-69
Special Tools, Decals, and Chassis ... 7-15 Battery State-of-Charge . . . . . . . . . . 7-70
Special Tools . . . . . . . . . . . . . . . . .... 7-16 Wiring and Harness Connectors . . . . . . 7-71
Decals and Plates . . . . . . . . . . . . .... 7-17 General Repair Procedures . . . . . . . . 7-71
Baselegs . . . . . . . . . . . . . . . . . . . .... 7-22 Molex Connectors. . . . . . . . . . . . . . . 7-72
Removal . . . . . . . . . . . . . . . . . . .... 7-22 AMP Water-Resistant Connectors . . . 7-73
Installation . . . . . . . . . . . . . . . . .... 7-22 AMP Harness/Power Amp Connector 7-76
Power Cables . . . . . . . . . . . . . . . . . . . . 7-79
Steering and Controls . . . . . . . ...... 7-25 Power Cable Repair . . . . . . . . . . . . . 7-79
Steer Tiller Encoder (AC Lift) . ....... 7-26 Motors . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Removal . . . . . . . . . . . . . . . ....... 7-26 Power Cable Terminals . . . . . . . . . . . 7-81
Installation . . . . . . . . . . . . . ....... 7-26 DC Motor Troubleshooting . . . . . . . . 7-81
Steer Limit Switch (S11) . . . . ....... 7-27 AC Motor Troubleshooting . . . . . . . . 7-81
Vertical Gap Adjustment . . . ....... 7-27 DC Motor Service . . . . . . . . . . . . . . . 7-81
Lateral Adjustment . . . . . . . ....... 7-27 AC Motor Service . . . . . . . . . . . . . . . 7-83
Steerable Caster . . . . . . . . . . ....... 7-28 Steer Amplifier (AC Lift) . . . . . . . . . . . . 7-84
Initial Adjustment . . . . . . . . ....... 7-28 Removal . . . . . . . . . . . . . . . . . . . . . . 7-84
Caster Height Adjustment . . ....... 7-29 Installation. . . . . . . . . . . . . . . . . . . . 7-84
Steering Linkage . . . . . . . . . . ....... 7-31 Cold Storage Conditioning . . . . . . . . . . 7-85
Control Handle . . . . . . . . . . . ....... 7-32 Components . . . . . . . . . . . . . . . . . . . 7-85
Primary Control Handle - Lubricants . . . . . . . . . . . . . . . . . . . . 7-85
Fore/Aft Stance . . . . . . . . . . . . . . 7-32 Sealing Treatment . . . . . . . . . . . . . . 7-85
Dockstance Control Handle . . . . . . . . 7-37 Corrosion Inhibitor Coating . . . . . . . 7-85
Secondary Control Handle - Condensation Drip Guard . . . . . . . . 7-85
Fore/Aft Stance . . . . . . . . . . . . . . 7-41
Hydraulic Components . . . . . . . . . . . . 7-87
Drive and Brake . . . . . . . . . . . ...... 7-43 Hydraulic System Bleeding . . . . . . . . . . 7-88
Drive Unit . . . . . . . . . . . . . . . ....... 7-44 Procedure. . . . . . . . . . . . . . . . . . . . . 7-88
Required Tools . . . . . . . . . . ....... 7-45 Hydraulic Filter . . . . . . . . . . . . . . . . . . 7-89
Troubleshooting . . . . . . . . . ....... 7-47 AC Lift . . . . . . . . . . . . . . . . . . . . . . . 7-89
Radial Ring Inspection . . . . ....... 7-48 DC Lift . . . . . . . . . . . . . . . . . . . . . . . 7-89
Drive Unit Removal . . . . . . . ....... 7-48 Lift Pressure Adjustment . . . . . . . . . . . 7-91
Drive Unit Disassembly . . . . ....... 7-49 AC Lift with Regen Lower . . . . . . . . . 7-91
Drive Unit Assembly . . . . . . ....... 7-53 DC Lift . . . . . . . . . . . . . . . . . . . . . . . 7-91
Brake . . . . . . . . . . . . . . . . . . ....... 7-61 Manual Lowering of Fork Carriage . . . . 7-93
Inspection . . . . . . . . . . . . . . ....... 7-61 AC Lift - Standard . . . . . . . . . . . . . . 7-93
Brake Removal . . . . . . . . . . ....... 7-61 AC Lift - Regen Lower . . . . . . . . . . . . 7-93
Pad Replacement. . . . . . . . . ....... 7-61 DC Lift . . . . . . . . . . . . . . . . . . . . . . . 7-93
Coil Replacement . . . . . . . . ....... 7-62 Proportional Valve Adjustment . . . . . . . 7-94
Brake Installation . . . . . . . . ....... 7-62 Auxiliary Pressure Adjustment . . . . . . . 7-95
Deadman Pedal . . . . . . . . . . . ....... 7-63 AC Lift . . . . . . . . . . . . . . . . . . . . . . . 7-95
Inertial Dampener . . . . . . . . . ....... 7-64 DC Lift . . . . . . . . . . . . . . . . . . . . . . . 7-95

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

List of Component Procedures

Main Manifold - Standard AC Lift . . . . . 7-96 Mast, Chain, Hose, Cable . . . . . . . . . . 7-127
Lift/Lower Manifold - AC Lift with Reach Carriage Bearings . . . . . . . . . . . 7-128
Regen Lower . . . . . . . . . . . . . . . . . . . 7-97 Removal . . . . . . . . . . . . . . . . . . . . . 7-128
Aux Manifold - AC Lift with Installation . . . . . . . . . . . . . . . . . . . 7-128
Regen Lower . . . . . . . . . . . . . . . . . . . 7-98 Adjustment. . . . . . . . . . . . . . . . . . . 7-128
Main Manifold - DC Lift . . . . . . . . . . . . 7-99 Mast Shimming . . . . . . . . . . . . . . . . . . 7-129
Aux Manifold (Standard Reach) . . . . . 7-100 Shimming Procedure . . . . . . . . . . . 7-129
Removal . . . . . . . . . . . . . . . . . . . . . 7-101 Bow Pads - Model 7500 . . . . . . . . . . . . 7-131
Installation . . . . . . . . . . . . . . . . . . . 7-101 Inspection and Adjustment . . . . . . . 7-131
Deep-Reach ® Manifold . . . . . . . . . . . . 7-102 Carriage . . . . . . . . . . . . . . . . . . . . . . . 7-133
Removal . . . . . . . . . . . . . . . . . . . . . 7-102 Removal . . . . . . . . . . . . . . . . . . . . . 7-133
Installation . . . . . . . . . . . . . . . . . . . 7-102 Installation . . . . . . . . . . . . . . . . . . . 7-133
Tilt/Sideshift Manifold (Deep-Reach ®) 7-103 Chain Anchors . . . . . . . . . . . . . . . . . . 7-134
Removal . . . . . . . . . . . . . . . . . . . . . 7-103 Main Lift Chain Anchors . . . . . . . . . 7-134
Installation . . . . . . . . . . . . . . . . . . . 7-103 Free Lift Chain Anchors . . . . . . . . . 7-135
Manifold Port Torque Specifications . . 7-104 Lift Chains . . . . . . . . . . . . . . . . . . . . . 7-137
Chains, Main Lift . . . . . . . . . . . . . . 7-137
Hydraulic Components, Cylinder . . . . 7-107 Chains, Free Lift . . . . . . . . . . . . . . . 7-137
Lift Cylinder, Free Lift, Remove/Install 7-108 Hose, Main Lift . . . . . . . . . . . . . . . . . . 7-139
Left Side Free Lift Cylinder . . . . . . . 7-108 Removal . . . . . . . . . . . . . . . . . . . . . 7-139
Right Side Free Lift Cylinder . . . . . . 7-109 Installation . . . . . . . . . . . . . . . . . . . 7-139
Lift Cylinder, Free Lift, Seal Repacking 7-110 Hose and Cable, Over-the-Mast . . . . . . 7-140
AC Lift. . . . . . . . . . . . . . . . . . . . . . . 7-110 Removal . . . . . . . . . . . . . . . . . . . . . 7-141
DC Lift . . . . . . . . . . . . . . . . . . . . . . 7-111 Installation . . . . . . . . . . . . . . . . . . . 7-142
Lift Cylinder, Main, Remove/Install . . 7-113 Cable, Over-the-Mast . . . . . . . . . . . . . 7-146
Left Side Main Lift Cylinder . . . . . . . 7-113 Over-the-Mast Cable Replacement . 7-146
Right Side Main Lift Cylinder . . . . . . 7-114 Hose/Tubing, Free Lift Feed . . . . . . . . 7-149
Lift Cylinder, Main, Seal Repacking . . 7-116 Removal . . . . . . . . . . . . . . . . . . . . . 7-149
Disassembly . . . . . . . . . . . . . . . . . . 7-116 Installation . . . . . . . . . . . . . . . . . . . 7-149
Reassembly . . . . . . . . . . . . . . . . . . . 7-116 Mast, Model 7500
Lift Cylinder Lowering Cushion . . . . . 7-117 (Complete Disassembly) . . . . . . . . . . 7-150
Main Lift Cylinders . . . . . . . . . . . . . 7-117 Separation of Tractor and Mast. . . . 7-150
Free Lift Cylinders - AC Lift . . . . . . . 7-117 Hose/Cable, Free Lift Cylinder,
Free Lift Cylinders - DC Lift . . . . . . . 7-118 and Carriage Removal . . . . . . . . 7-150
Reach Cylinder . . . . . . . . . . . . . . . . . 7-119 Main Lift Chain Removal. . . . . . . . . 7-151
Removal . . . . . . . . . . . . . . . . . . . . . 7-119 Separation of Telescopics . . . . . . . . 7-151
Disassembly . . . . . . . . . . . . . . . . . . 7-119 Mast, Model 7500
Reassembly . . . . . . . . . . . . . . . . . . . 7-119 (Complete Assembly) . . . . . . . . . . . . 7-154
Installation . . . . . . . . . . . . . . . . . . . 7-120 Assembling and Shimming Outer
Adjustment . . . . . . . . . . . . . . . . . . . 7-120 Telescopic to Main Frame . . . . . . 7-154
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . 7-122 Assembling and Shimming Inner
Removal . . . . . . . . . . . . . . . . . . . . . 7-122 Telescopic to Outer Telescopic . . 7-155
Disassembly . . . . . . . . . . . . . . . . . . 7-122 Main Lift Chain Installation . . . . . . 7-155
Reassembly . . . . . . . . . . . . . . . . . . . 7-123 Shimming Carriage to Inner
Installation . . . . . . . . . . . . . . . . . . . 7-123 Telescopic . . . . . . . . . . . . . . . . . 7-156
Flow Limiter, Main Lift . . . . . . . . . . . . 7-124 Carriage, Free Lift Cylinder, and
Removal . . . . . . . . . . . . . . . . . . . . . 7-124 Hose/Cable Installation . . . . . . . 7-157
Installation . . . . . . . . . . . . . . . . . . . 7-124 Mating Mast to Tractor . . . . . . . . . . 7-159
Flow Limiter, Free Lift . . . . . . . . . . . . 7-125 Mast, Model 7520
Removal . . . . . . . . . . . . . . . . . . . . . 7-125 (Complete Disassembly) . . . . . . . . . . 7-162
Installation . . . . . . . . . . . . . . . . . . . 7-125 Separation of Tractor and Mast. . . . 7-162

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

List of Component Procedures

Hose/Cable, Free Lift Cylinder,

and Carriage Removal. . . . . . . . . 7-162
Main Lift Chain Removal . . . . . . . . . 7-164
Separation of Telescopics . . . . . . . . 7-165
Mast, Model 7520
(Complete Assembly) . . . . . . . . . . . .7-167
Assembling and Shimming Outer
Telescopic to Main Frame . . . . . . 7-167
Assembling and Shimming Inner
Telescopic to Outer Telescopic . . 7-168
Main Lift Chain Installation. . . . . . . 7-168
Shimming Carriage to Inner
Telescopic. . . . . . . . . . . . . . . . . . 7-169
Carriage, Free Lift Cylinder,
and Hose/Cable Installation . . . . 7-169
Mating Mast to Tractor . . . . . . . . . . 7-172

7-4 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Component Locator Photos

Component Locator Photos

Section 7. Component Procedures

Mast and Reach Carriage

Figure 7-1. Mast and Carriage (R45TT Shown)
76353_117g.jpg

Main Lift Chain

Free Lift Cylinder & Chain Overhead Guard

Tractor

Load Backrest

Fork Carriage

Sideshift Cylinder

Traction Tire

Reach Mechanism Load Wheels Baseleg Battery Gate

Publication: 1112860, Issued: 15 Feb 2012 7-5

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Component Locator Photos

Tractor, AC Lift, Fore/Aft Stance

Figure 7-2. Tractor, AC Lift, Fore/Aft Stance
7DSC_901a.jpg

Mast Guard

Operator Display

Primary Control
Handle
Steer Tiller Secondary
Control Handle
(optional)
Hydraulic Filter

Fuse/Relay Card
Hydraulic
Reservoir
Vehicle Manager
Horn
Aux Manifold
(Regen Lower only)
Contactor Panel
Brake
Electric Steer Specification Plate
Motor
Traction Motor Traction Power
Amp
Reservoir Drain
Hose Cooling Fan
Drive Unit
(not visible)
Inertial Dampener

ESD Ground Jack

Deadman Pedal

Steer Idler
(not visible)

Traction Tire

7-6 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Component Locator Photos

Figure 7-3. Tractor Deck, Standard AC Lift, Fore/Aft Stance
Emergency Power Off
Lift Power Amp

Operator Display
Key Switch
Lift Pump

Main Manifold

Sounder

Fuse/Relay Card Primary Control Handle

Figure 7-4. Tractor Deck, AC Lift, Fore/Aft Stance, Regen Lower

Emergency Power Off Key Switch

Lift Power Amp Operator Display

Lift/Lower Manifold Lift Pump

Steer Amplifier

Aux Motor

Sounder

Primary Control Handle

Fuse/Relay Card

Publication: 1112860, Issued: 15 Feb 2012 7-7

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Component Locator Photos

Tractor, AC Lift, Dockstance

Figure 7-5. Tractor, AC Lift, Dockstance
7DSC_901a.jpg

Steer Tiller

Steer Amplifier
Hydraulic Filter Fuse/Relay Card

Hydraulic
Reservoir
Vehicle Manager
Horn

Contactor Panel
Brake
Specification Plate

Electric Steer
Traction Power
Motor
Amp

Cooling Fan
Traction Motor

Inertial Dampener
Drive Unit
ESD Ground Jack
(not visible)
Deadman Pedal

Steer Idler
(not visible)

Traction Tire

Aux Manifold
(Regen Lower only)

7-8 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Component Locator Photos

Figure 7-6. Tractor Deck, AC Lift, Dockstance (Standard Lift shown)

Lift Power Amp Operator Display Lift Pump Emergency Power Off

Main Manifold

Lift Motor

Control Handle

Publication: 1112860, Issued: 15 Feb 2012 7-9

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Component Locator Photos

Tractor, DC Lift
Figure 7-7. Tractor, DC Lift (Fore/Aft Stance shown)
7DSC_854a.jpg

Fuse/Relay Card Operator Display

Steering
Wheel

Hydraulic Fluid
Level Indicator

Hydraulic
Reservoir

Steering
Orbitrol Vehicle
Manager
Aux Motor/
Pump

Horn Contactor
Panel

Traction
Brake Power Amp

Cooling Fan
Traction
Motor Inertial
Dampener

ESD Ground
Jack
Drive Unit
Deadman
Pedal

Steer Idler
(not visible)

Traction Tire Hydraulic Steer Motor

7-10 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Component Locator Photos

Figure 7-8. Tractor Deck, DC Lift (Fore/Aft Stance shown)
7DSC_0866a.jpg

Emergency Power Off

Hydraulic Reservoir Lift Motor Operator Display Key Switch

Primary Control
Handle

Sounder

Fuse/Relay Card

Main Manifold

Hydraulic Fluid Steering Aux Motor Secondary Control Handle

Level Indicator Orbitrol (optional)

Publication: 1112860, Issued: 15 Feb 2012 7-11

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Component Locator Photos

Reach Carriage
Figure 7-9. Standard Reach Carriage, Operator View (Mast Guard removed for clarity)
7DSC_0873a.jpg

Hose
Retainer/ Free Lift
Guide Cylinder
Chain
Anchor

Bleed Screw

Aux
Manifold

Hose
Tensioning Reach
Spring Cylinder

Tilt Cylinder

7-12 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Component Locator Photos

Underside Components
Figure 7-10. Underside Components
7P5180009.tif

Static Strap

Steering
Linkage

A-frame
Drive Wheel
Steer Idler

Publication: 1112860, Issued: 15 Feb 2012 7-13

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Component Locator Photos

7-14 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Special Tools, Decals, and Chassis

Special Tools, Decals, and Chassis

Section 7. Component Procedures

Publication: 1112860, Issued: 15 Feb 2012 7-15

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Special Tools Special Tools, Decals, and Chassis

Special Tools
The following tools are available from your local
authorized Raymond Sales and Service Center.

Table 7-1. Special Tools

Tool Part Number Purpose

Anti-static Field Kit 1-187-059

Anti-static Wrist Straps 1-187-058/001

ESD Protection
Anti-static Wrist Strap 1-187-060/100
Tester

Chain Gauge 950-350/CG Lift chain inspection

Connector Unlatching 950-042 Separate AMP connectors

Crimp Tool 1069861 Crimp power cable lugs

End Cap A9587 Main Lift Cylinder end cap removal/installation

End Cap 1090761/005 Free Lift Cylinder w/staging end cap removal/installation

End Cap 1090761/007 Main Lift and Free Lift Cylinder w/o staging end cap
removal/installation

Fork Wear Caliper 922-369 Fork inspection

Pin Extraction 950-009 AMP connector pin extraction

Pin Extraction 950-026 MOLEX connector pin extraction

Seal Driver 401-000-051 Free Lift Cylinder seal installation

Surge Protector 154-010-801 ESD/voltage surge protection for serial type FlashWare
connections

USB/CAN Interface 230489-001 FlashWare connection to truck

7-16 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Special Tools, Decals, and Chassis Decals and Plates

Decals and Plates

Table 7-2. Decal and Plate Location Chart

Decal and Specification Plate Locations

Identifier Description Location

1 Raymond Tractor frame, aft of battery compartment

(both sides)

2 ACR or ACR Regen Tractor frame, with respect to battery

compartment opening, aligned with front edge
and bottom of decal 5.8 in. (147 mm) above
opening (both sides)

3 EE Compliance (optional) Tractor frame, centered 5 in. (127 mm) above

battery opening (both sides), above battery
warning decal

4 Battery Warning Decal Tractor frame, centered 0.25 in. (6.35 mm)
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 in.
(38 mm) above bottom of guard, left edge of
decal 11.5 in. (292 mm) 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 Patent Decal Inside of Traction Motor compartment door,

above and centered with ventilation slots

15 Lubrication Decal Inside of Traction Motor compartment door,

centered with ventilation slots, above patent
decal

16 Traction Motor Warning Decal Inside of Traction Motor compartment door,

centered with ventilation slots, above
lubrication decal

17 Hydraulic Filter Locator On reservoir, forward of filler cap

Publication: 1112860, Issued: 15 Feb 2012 7-17

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Decals and Plates Special Tools, Decals, and Chassis

Decal and Specification Plate Locations

Identifier Description Location

18 Mast Specification Plate Right side of mast, 2 in. (50.8 mm) above top
of baseleg

19 ISO 9001 Decal Centered on mast main frame (both sides),

61.7 in. (156.7 cm) above floor

20 Operating Instructions Centered on left mast upright under ISO9001

decal

21 Manual Replacement Centered at top of operator manual pocket

22 No Riding Centered on load backrest

23 Overhead Guard ANSI/ITSDF Inside left side of overhead guard

conformance

NOTE: Items in italics are safety decals.

7-18 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Special Tools, Decals, and Chassis Decals and Plates

Figure 7-11. Decal and Specification Plate Locations, Tractor
7R1017410_A1.CGM R1010652_A1.CGM R1017410_A2.CGM R1010652_A2.CGM

Fore/Aft Stance Dockstance

7 8
7 6

9
2
2

3
3

4
4

1
1

10 10

16
16

15 11
15 11

14
14
12
12

13
13

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Decals and Plates Special Tools, Decals, and Chassis

Figure 7-12. Decal and Specification Plate Locations, Mast
7R1017504_A1.cgm

23 (inside surface)

22
19

21
5
20

18

7-20 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Special Tools, Decals, and Chassis Decals and Plates

Figure 7-13. Warning/Safety Decals
71024303_02Mar04.eps,R1017269.eps,R1017233.eps,R1017232.eps,R1017362.eps,R411_587.eps

10

17

23

Publication: 1112860, Issued: 15 Feb 2012 7-21

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Baselegs Special Tools, Decals, and Chassis

Baselegs 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
assist in removing baseleg.
2. Turn the key switch OFF and disconnect
the battery connector.
8. Slide the baseleg off the locating pins. See
3. Remove the right or left front cover. Figure 7-15. 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.

Figure 7-15. Baseleg Removal, Model 7500 shown

R1015167_Ax.cgm

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
support the lift truck. See “Jacking Locating
Safety” on page 2-8. Pins

5. Jack and block the lift truck under the

side of the tractor.
6. Remove the bolts holding the load wheel Installation
plates to the baseleg. Slide the load wheel
assembly forward off the baseleg. See 1. Apply anti-seize compound (P/N 990-452)
Figure 7-14. to the baseleg alignment pins and mating
surfaces of main frame, baseleg, and
Figure 7-14. Load Wheel Assembly and Baseleg baseleg shim, if used. Insert locating pins
(closed toe version shown) into the mast.
1040765_B.cgm

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 to 165 ft. lb. (223 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),

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Special Tools, Decals, and Chassis Baselegs

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 follows:

Bolt Torque

Wheel Plate, Mounting 50 ft. lb. (68 Nm)

Wheel Plate, Top 21 ft. lb. (28 Nm)

Nose, 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.
10. Install battery gate.

Publication: 1112860, Issued: 15 Feb 2012 7-23

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Baselegs Special Tools, Decals, and Chassis

7-24 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Steering and Controls

Steering and Controls

Section 7. Component Procedures

Publication: 1112860, Issued: 15 Feb 2012 7-25

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Steer Tiller Encoder (AC Lift) Steering and Controls

Steer Tiller Encoder 3. Assemble the snubber and tighten the jam
nut on the eyebolt so that the force
(AC Lift) required to turn the steering wheel is 5 to
7 in. lb. (0.5 to 0.7 Nm).
4. Apply thread-locking compound
Removal (P/N 990-536) to the steering wheel cap
screws.
1. Turn the key switch OFF and disconnect
the battery connector. 5. Position the steering wheel over the steer
tiller encoder. Install cap screws.
6. Install the steering wheel cover.
Use correct electrostatic discharge 7. Attach the steering wheel cover to the
precautions. See “Static Precautions” on steering wheel with two bolts.
page 2-7. 8. Apply anti-seize compound (P/N 990-452)
to the shoulder bolt. Install the steering
2. Remove the top cover and steering cover. knob.
(You must remove the knob, steering wheel
9. Install the top cover.
cover, and steering wheel before removing
the steering cover.)
3. Remove the snubber adjustment nut and
swing the halves of the snubber out of the
way. See Figure 7-16.

Figure 7-16. Steer Tiller Encoder and Snubber

Snubber
Adjustment Nut

4. Disconnect encoder harness connectors

JPE1 and JPE2. Cut cable ties as needed.
5. Remove three bolts holding the steer tiller
encoder to the bracket.

Installation
1. Route wiring harness of new encoder
through the hole in the bracket. Install
encoder to bracket with three bolts.
2. Route encoder harness and install cable
ties where previously removed. Connect
harness connectors JPE1 and JPE2.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Steering and Controls Steer Limit Switch (S11)

Steer Limit Switch (S11)

Figure 7-17. Steer Limit Switch

Steer Limit Steer Motor

Switch

Sensing Rail (Steer Flag)

View is toward
Mounting motor compartment
Bracket door, Traction Motor
removed for clarity

Vertical Gap Adjustment

1. Turn the key switch OFF and disconnect
the battery connector.
2. Open the Traction 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 0.12 to 0.25 in. (3.0
to 6.4 mm). Tighten the nuts.

Lateral Adjustment
1. Run Test I90 - Degrees Turned Past Steer
Flag (Page 6-99).
2. Adjust the mounting bracket so the
reading on both ends is as close to 10° as
possible.

Publication: 1112860, Issued: 15 Feb 2012 7-27

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Steerable Caster Steering and Controls

Steerable Caster truck to provide access to adjustment

bolts underneath.
b. Loosen the center steering link locking
Correct caster adjustment is critical for correct
bolts. See Figure 7-19.
performance. A misadjusted caster can cause
excessive braking distances, poor stability, or
Figure 7-19. Steering Adjustments
damage to inertial dampener components.
Drive
C Caster
Wheel Wheel
Initial Adjustment B
1. The drive and caster wheels should be
parallel.
2. Place a straightedge along the tractor B
frame. Measure the distance from the C
straightedge to the front edge of the drive
tire and to the back edge. Adjust steering
until the measurements are equal. The
drive wheel is now parallel to the tractor
A
frame. See Figure 7-18.

Figure 7-18. Setting Drive Wheel Parallel Steering Steering

Link Link
Straightedge Drive Tire Locking Adjusting
Bolts (4) Bolts (2)

E E

C c. Loosen jam nuts on center steering link

adjusting bolts and adjust the bolts to
get both wheels parallel to the tractor
frame.
d. Apply thread-locking compound
(P/N 990-536) to steering link adjusting
bolts and locking bolts.

C e. Tighten the jam nuts on the adjusting

bolts.
f. Tighten locking bolts and torque to
70 ft. lb. (95 Nm).
g. Re-install the battery rollers. Using a
A
3. Place a straightedge along the opposite suitable battery removing device,
side tractor frame. Measure the distance re-install the lift truck battery.
from the straightedge to the front edge of Re-install battery gates.
the caster wheel and to the back edge. If
the dimensions are not equal, adjust as Caster height adjustment varies, depending
follows. upon the type of mast. See “Caster Height
Adjustment” on page 7-29.
a. Turn the key switch OFF and
disconnect the battery connector.
Remove battery gates. Using a suitable
battery removing device, remove the
battery and battery rollers from the lift

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Steering and Controls Steerable Caster

Caster Height Adjustment Figure 7-21. A-frame Down-Travel Adjustment Bolt

NOTE: Make sure a correctly rated battery is A-frame Spring Nuts

installed in the lift truck prior to making
this adjustment.
1. Remove the inertial dampener cover plate.
See Figure 7-20.

Figure 7-20. Inertial Dampener Cover Plate

A-frame
Down-Travel
Adjustment Bolt

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
Cover Plate 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
support the lift truck. See “Jacking
Safety” on page 2-8.
2. Check the A-frame down-travel
adjustment bolt in Figure 7-21. Make sure Figure 7-22. A-frame Spring Adjustments
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.
Initially
1 in. Initially
(25 mm) 6 in.
(152 mm)

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 in.
(25 mm) between the arm and frame.
Adjust the A-frame spring nuts to obtain
an initial spring length of 6 in. (152 mm).
See Figure 7-21 and Figure 7-22.

Publication: 1112860, Issued: 15 Feb 2012 7-29

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Steerable Caster Steering and Controls

5. Lower the lift truck back onto the floor. the top of the A-frame as follows (See
Make sure the lift truck is sitting on a flat Figure 7-23):
floor surface.
6. Adjust the A-frame spring nuts to obtain
Elevated Height Gap
the spring length in the table that follows.
The dimension is measured from the top of Below 330 in. (8328 mm) 0.38 in. (9.65 mm)
the spring to the top of the caster, not the
frame. Above 331 in. (8407 mm) 0.25 in. (6.35 mm)

10. Apply thread-locking compound

Elevated Height Spring Length
(P/N 990-536) to the A-frame up-travel
Below 330 in. (8328 mm) 5.75 in. (146 mm) stop bolt. Tighten the jam nut.
Above 331 in. (8407 mm) 5.50 in. (140 mm) 11. Test the lift truck for correct braking
action.
12. Reinstall the inertial dampener cover
7. Apply thread-locking compound plate.
(P/N 990-536) and turn the A-frame
down-travel adjustment bolt to set the
correct gap between the bottom of the bolt
head and the top of the flat washer. See
Figure 7-22 and the table below.

Elevated Height Gap

All 0.12 in. (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 7-23.

Figure 7-23. A-frame Up-Travel Stop Adjustment

A-frame
Up-Travel
Stop Bolt

9. Turn the A-frame up-travel stop bolt to

adjust the gap between the bolt head and

7-30 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Steering and Controls Steering Linkage

Steering Linkage
Use Figure 7-24 as a reference when
removing/replacing steering linkage
components. After replacing any components,
make sure the steering is adjusted correctly.

Figure 7-24. Steering Linkage

Section BB
and
Section CC

D
C
B

B
C D

A A

Detail of
Section AA

E E

Section EE
Section AA

Publication: 1112860, Issued: 15 Feb 2012 7-31

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Control Handle Steering and Controls

Control Handle Travel Pot Repair/Replacement

1. Carefully peel the flex heater from the
travel pot. It is attached to the pot with
Primary Control Handle - double-sided tape. See Figure 7-26.
Fore/Aft Stance
Figure 7-26. Control Handle, Fore/Aft Stance
If a ThermaKit component fails, replace both Travel Pot Heater
handle shells; however, it may be more cost
effective to replace the entire handle.
Lift Pot
Disassembly
1. Remove the lift knob.
NOTE: The outer spring paddle may fall off
when the lift knob is removed.
Lift Pot
Connector Connector

ThermaKit Connector
Use correct electrostatic discharge
precautions. See “Static Precautions” on 2. Press the latch on the travel pot connector
page 2-7. and disconnect the travel pot from the flex
circuit. See Figure 7-26.
2. Remove the socket head cap screws from 3. Slide the travel pot out of the pivot shaft
the handle shell. assembly. See Figure 7-27.
3. Slide out the cable clamp. NOTE: Do not lose the D-shaped clip inside the
4. Remove the screws securing the harness pivot shaft.
connector.
Figure 7-27. Pivot Shaft Assembly
5. Carefully pull the flex circuit down the
cable clamp slot. See Figure 7-25. D-Clip

Figure 7-25. Flex Circuit in Cable Clamp Slot

Spring Snap Ring
Flex Circuit
Pin

Paddle

4. Remove the external snap ring.

NOTE: Observe orientation of the spring and
paddles on the pivot shaft.
5. Remove the spring and paddles from the
pivot shaft. See Figure 7-27.
6. Apply a thin coat of lubricant
6. Lift off the upper handle shell. If (P/N 990-635) to the inside surface of the
ThermaKit equipped, the upper shell can spring. Assemble spring between the
be removed but wiring will connect the two spring paddles. See Figure 7-28.
halves.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Steering and Controls Control Handle

Figure 7-28. Travel Pot Spring Assembly 3. Press the latch on the lift pot connector
and disconnect the lift pot from the flex
circuit. See Figure 7-29.
4. Carefully peel the flex heater from the lift
pot. It is attached to the pot with
double-sided tape.
5. Pull the lift pot/bracket assembly out of
the handle shell.
6. Slide the lift pot out of the lift pot bracket.
7. Slide the spring and paddles part way
7. Slide a new lift pot into the lift pot bracket.
down the pivot shaft to engage the lower
The lift pot tang must slide into the slot on
spring tang.
the lift pot bracket. See Figure 7-30.
8. Using the upper paddle, press the upper
spring tang over the pin on the pivot shaft. Figure 7-30. Lift Pot and Bracket
7HNDL_FA6.jpg
With one paddle and one spring tang on
each side of the pin, slide all parts down to
expose the snap ring groove. See Tang Slot in
Figure 7-27. Bracket

9. Install the external snap ring. See

Figure 7-27.
10. Slide the travel pot shaft into the pivot
shaft assembly (make sure D-clip is in
pivot shaft).
8. Slide the inner spring paddle onto the lift
11. Re-tape the flex heater to the travel pot
pot bracket.
body. Replace the double-sided tape if
necessary. See Figure 7-26. 9. Apply a thin coat of lubricant
(P/N 990-635) to the inside surface of the
12. Re-seat the travel pot flex connector in the
spring. Install the spring with one tang
handle shell. Re-connect the travel pot to
resting on the inner spring paddle (not the
the flex circuit. See Figure 7-26.
dowel pin).
10. Slide the outer spring paddle part way
Lift Pot Repair/Replacement onto the lift pot shaft to engage the outer
1. Slide the outer paddle and lift pot spring spring tang.
off the lift pot shaft. See Figure 7-29. 11. Using the outer paddle, press the outer
NOTE: Observe orientation of the lift pot spring, spring tang over the dowel. Slide parts
paddles, and dowel pin. together until the outer paddle is flush
with the lift pot bracket. See Figure 7-29.
Figure 7-29. Lift Pot and Spring Assembly 12. Make sure the tilt/sideshift card is
7HNDL_FA5.jpg
correctly positioned. Slide the lift
Lift Pot Paddle (flush pot/bracket assembly into the lower
with bracket handle shell. See Figure 7-31.
stem)

Lift Pot Shaft

Connector Dowel Pin

Paddle Spring
2. Slide the inner spring paddle off the lift pot
shaft.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Control Handle Steering and Controls

Figure 7-31. Lift Pot Bracket Position Figure 7-33. ThermaKit Heaters and Connector
7HNDL_FA11.jpg 7HNDL_FA7.jpg

ThermaKit Horn Reach/Retract

Slot in Shell Buttons
Connector Button

Tab on Pot
Bracket

ThermaKit
13. Re-tape the flex heater to the lift pot body. Heaters Tilt/Sideshift Card
Replace the double-sided tape if
necessary. Use a screwdriver blade to
press the heater against the pot body.
14. Re-connect the ThermaKit (if so equipped)
to the flex circuit. 2. Hold the tilt/sideshift button and card
between thumb and forefinger. Tip the
15. Align the tang on the travel pot with the
card back and remove it from the handle
2nd rib on the flex circuit side of the lower
shell (the gasket on the tilt/sideshift
handle shell. See Figure 7-32.
button may fall off as the tilt/sideshift
Figure 7-32. Travel Pot Alignment in Shell card is removed from the handle shell).
7HNDL_FA12.jpg
3. Carefully remove the lift pot connector
from the slot in the handle shell.
Tang
4. Remove the reach/retract and horn
buttons from the handle shell.
5. Carefully remove the ThermaKit and travel
pot connectors from the slots in the handle
shell. See Figure 7-26.
6. Lift the flex circuit out of the handle shell.
Rib 7. Remove the tilt/sideshift button and
spring from the flex circuit by removing
one screw from the back of the
Flex Circuit Repair/Replacement tilt/sideshift card.
1. Press the latch on the ThermaKit 8. To install the tilt/sideshift button and
connector and disconnect the ThermaKit spring on the tilt/sideshift card, place the
(if so equipped) from the flex circuit. See spring over the post on the back of the
Figure 7-33. tilt/sideshift button. Align the “A” on the
back of the button with the “A” on the
card. See Figure 7-34. 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 an additional 1/8 turn. Do
not overtighten.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Steering and Controls Control Handle

Figure 7-34. Tilt/Sideshift Card and Button 2. Position the upper handle shell over the
7HNDL_FA8.jpg
lower shell and ease it into position. See
Orientation Letter ”A” Figure 7-36. 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
Tilt/Sideshift passing between the paddles of the
Button Circuit Card pivot shaft assembly
9. Slide the horn button over the positioning • D - reach/retract buttons are entering
pin. the holes in the handle shell
10. Press the ThermaKit and travel pot • E - backing ribs that hold the horn
connectors into the slots in the lower button in place are not pinching the
handle shell. See Figure 7-26. flex circuit
11. Place the gasket over the tilt/sideshift • F - harness connector end of the flex
button. Gently position the tilt/sideshift circuit is entering the cable clamp slot
card in the handle shell. The bottom of the without pinching.
card sits forward of a ridge in the handle;
the card edge nearest the lift knob sits Figure 7-36. Primary Control Handle Assembly - Fore/Aft
behind a ridge in the handle. Confirm that Stance
the gasket is in place on the tilt/sideshift 7HNDL_FA13.jpg

button. See Figure 7-35.

D
Figure 7-35. Tilt/Sideshift Card Position
7HNDL_FA10.jpg
F A
D A
Card Sits
Forward B
of Ridge

Card Sits
C E
Behind
Ridge B
3. Squeeze the handle halves together.
4. Place the tip of a screwdriver into the pivot
shaft set screw hole. Gently rotate the
shaft in both directions to confirm that the
12. Correctly position the reach/retract
pin in the upper handle shell is between
buttons and route the harness connector
the paddles. Do not over-rotate the shaft,
end of the flex circuit through the locating
as this can cause damage. You should feel
slots.
spring tension immediately and there
should be no free play in the pivot shaft. If
Assembly you do not feel spring tension, lift off the
1. Confirm the flex circuit is routed correctly upper handle shell, and repeat step 2.
through the locating slots. 5. Fasten the harness connector to the upper
handle shell. Tighten each screw until it
bottoms, plus an additional 1/16 turn. Do
not overtighten.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Control Handle Steering and Controls

6. Install the socket head cap screws.

Tighten each screw until it bottoms, plus
an additional 1/4 turn. Do not
overtighten.
7. Slide the cable clamp into the cable clamp
slot and secure.
8. Confirm the two spring paddles and spring
are in place. The outer paddle must be
flush with the end of the lift pot bracket.
See Figure 7-29.
9. Set the flat on the lift pot shaft 90° to the
top spring paddle. See Figure 7-37.

Figure 7-37. Lift Pot Shaft Alignment

7HNDL_FA14.jpg

Dowel Pin Paddles

10. Install the lift knob with the dowel pin in

between the paddles.
11. Tighten the steel set screw until it
bottoms, plus an additional 1/4 turn.
12. Install the nylon set screw. Run the nylon
set screw down flush or below the surface
of the knob.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Steering and Controls Control Handle

Dockstance Control Handle 4. Lift the travel pot shaft out of the lower
handle shell.
If a ThermaKit component fails, replace both 5. Slide the travel pot out of the pivot shaft
handle shells; however, it may be more cost assembly. See Figure 7-38.
effective to replace the entire handle.
NOTE: Do not lose the D-shaped clip inside the
pivot shaft.
Disassembly
6. Remove the external snap ring.
1. Remove the lift knob.
Figure 7-39. Pivot Shaft Assembly
NOTE: The outer spring paddle may fall off 7HNDL_FA3.jpg

when the lift knob is removed.

D-Clip

Spring Snap Ring

Use correct electrostatic discharge
precautions. See “Static Precautions” on Pin
page 2-7.
Paddle
2. Remove the socket head cap screws from
the handle shell.
NOTE: Observe orientation of the spring and
3. Lift off the upper handle shell. If paddles on the pivot shaft.
ThermaKit equipped, the upper shell can
be removed but wiring will connect the two 7. Remove the spring and paddles from the
halves. pivot shaft. See Figure 7-39.
8. Apply a thin coat of lubricant
Travel Pot Repair/Replacement (P/N 990-635) to the inside surface of the
spring. Assemble spring between the
1. Carefully peel the flex heater from the spring paddles. See Figure 7-40.
travel pot. It is attached to the pot with
double-sided tape. Figure 7-40. Travel Pot Spring Assembly
7HNDL_FA4.jpg
2. Remove harness connector and travel pot
heater from lower shell. See Figure 7-38.

Figure 7-38. Pivot Shaft Components

7HNDL_SS1.jpg

Travel Pot Spring

Travel Pot Connector

Travel Pot

9. Slide the spring and paddles part way

down the pivot shaft to engage the lower
spring tang.
10. Using the upper paddle, press the upper
spring tang over the pin on the pivot shaft.
With one paddle and one spring tang on
Travel Pot Heater Pivot Shaft
each side of the pin, slide all parts down to
Harness Connector expose the snap ring groove. See
3. Press the latch on the travel pot connector Figure 7-40.
and disconnect the travel pot from the flex
11. Install the external snap ring. See
circuit. See Figure 7-38.
Figure 7-39.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Control Handle Steering and Controls

12. Slide the travel pot shaft into the pivot Figure 7-42. Handle Shell - Dockstance
7HNDL_SS5.jpg
shaft assembly (make sure D-clip is in
pivot shaft). Reach/Retract Buttons
Flex Circuit Lift Pot
13. Insert the pivot shaft assembly into the
lower handle shell. Make sure the tang on Horn Button
the travel pot enters the center slot in the
shell. See Figure 7-41. Lift Pot Connector

Figure 7-41. Travel Pot Tang Alignment

7HNDL_SS4.jpg

Tang

ThermaKit Connector

Lift Pot Heater Tilt/Sideshift Button

2. Slide the inner spring paddle off the lift pot
shaft.
3. Press the latch on the lift pot connector
and disconnect the lift pot from the flex
circuit. See Figure 7-42.
4. Carefully peel the flex heater from the lift
pot. It is attached to the pot with
Slot double-sided tape.
5. Pull the lift pot/bracket assembly out of
14. Re-tape the flex heater to the travel pot
the handle shell.
body. Replace the double-sided tape if
necessary. See Figure 7-38. 6. Slide the lift pot out of the lift pot bracket.
15. Re-seat the travel pot flex connector in the 7. Slide a new lift pot into the lift pot bracket.
handle shell. Re-connect the travel pot to The lift pot tang must slide into the slot on
the flex circuit. See Figure 7-38. the lift pot bracket. See Figure 7-43.

Figure 7-43. Lift Pot Tang and Bracket Slot

Lift Pot Repair/Replacement 7HNDL_SS8.jpg

1. Slide the outer paddle and lift pot spring Tang and Slot
off the lift pot shaft. See Figure 7-29.
NOTE: Observe orientation of the lift pot spring,
paddles, and dowel pin.

8. Slide the inner spring paddle onto the lift

pot bracket.
9. Apply a thin coat of lubricant
(P/N 990-635) to the inside surface of the
spring. Install the spring with one tang
resting on the inner spring paddle (not the
dowel pin).
10. Slide the outer spring paddle part way
onto the lift pot shaft to engage the outer
spring tang.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Steering and Controls Control Handle

11. Using the outer paddle, press the outer 5. Carefully remove the ThermaKit and travel
spring tang over the dowel. Slide parts pot connectors from the slots in the handle
together until the outer paddle is flush shell. See Figure 7-42.
with the lift pot bracket. See Figure 7-43. 6. Lift the flex circuit out of the handle shell.
12. Make sure the tilt/sideshift card is 7. Remove the tilt/sideshift button and
correctly positioned. Slide the lift spring from the flex circuit by removing
pot/bracket assembly into the handle one screw from the back of the
shell. See Figure 7-44. tilt/sideshift card.
Figure 7-44. Lift Pot/Bracket Assembly Insertion 8. To install the tilt/sideshift button and
7
H
spring on the tilt/sideshift card, place the
N
spring over the post on the back of the
Bracket Sits on Card Notch Fits in Slot
D
L
_ tilt/sideshift button. Align the “A” on the
S
S
0
back of the button with the “A” on the
6
. card. See Figure 7-45. Press the button
J
P
G
against the card so the post protrudes
H
through the back of the card. Thread the
N
D screw into the post until it just bottoms,
L
_
S
then tighten an additional 1/8 turn. Do
S
7 not overtighten.
.
J
P
G
H
Figure 7-45. Tilt/Sideshift Card and Button
N 7HNDL_FA8.jpg
D
L_SS06.JPG HNDL_SS7.JPG

13. Re-tape the flex heater to the lift pot body. Orientation Letter ”A”
Replace the double-sided tape if
necessary. Use a screwdriver blade to
press the heater against the pot body.
14. Route lift pot wires under the
reach/retract buttons. Re-connect the lift
pot to the flex circuit at the connector.
15. Re-connect the ThermaKit (if so equipped) Tilt/Sideshift
to the flex circuit. Button Circuit Card
9. Press the ThermaKit and travel pot
Flex Circuit Repair/Replacement connectors into the slots in the handle
shell. See Figure 7-42.
1. Press the latch on the ThermaKit
10. Place the gasket over the tilt/sideshift
connector and disconnect the ThermaKit
button. Gently position the tilt/sideshift
(if so equipped) from the flex circuit. See
card in the handle shell. The bottom of the
Figure 7-42.
card sits forward of a ridge in the handle;
2. Hold the tilt/sideshift button and card the card edge nearest the lift knob sits
between thumb and forefinger. Tip the behind a ridge in the handle. Confirm that
card back and remove it from the handle the gasket is in place on the tilt/sideshift
shell (the gasket on the tilt/sideshift button. See Figure 7-46.
button may fall off as the tilt/sideshift
card is removed from the lower handle
shell).
3. Lift the horn button off the positioning
pin.
4. Carefully remove the lift pot connector
from the slot in the handle shell.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Control Handle Steering and Controls

Figure 7-46. Tilt/Sideshift Card Insertion as this can cause damage. You should feel
7HNDL_SS10.jpg
spring tension immediately and there
Horn Button Hole Card Sits should be no free play in the pivot shaft. If
Forward of you do not feel spring tension, lift off the
Ridge upper handle shell, and repeat step 2.
5. Fasten the harness connector to the upper
handle shell. Tighten each screw until it
bottoms, plus an additional 1/16 turn. Do
not overtighten.
6. Install the socket head cap screws.
Card Sits
Tighten each screw until it bottoms, plus
Behind
Ridge
an additional 1/4 turn. Do not
overtighten.
11. Correctly position the reach/retract
7. Confirm the two spring paddles and spring
buttons and re-connect the ThermaKit (if
are in place. The outer paddle must be
so equipped) to the flex circuit.
flush with the end of the lift pot bracket.

Assembly 8. Set the flat on the lift pot shaft parallel to

the top spring paddle. See Figure 7-48.
1. Confirm the flex circuit is routed correctly
through the locating slots. Figure 7-48. Lift Pot Shaft Alignment
7HNDL_SS12.jpg

2. Position the upper handle shell over the

lower shell and ease it into position. See
Figure 7-47. Make sure:
• A - travel pot tang is entering the slot in
the shell
• B - travel shaft rib on upper shell is
passing between the paddles of the
pivot shaft assembly

Figure 7-47. Sidestance Handle Assembly

7HNDL_SS11.jpg

9. Install the lift knob with the dowel pin in

between the paddles.
10. Tighten the steel set screw until it
bottoms, plus an additional 1/4 turn.
11. Install the nylon set screw. Run the nylon
set screw down flush or below the surface
B
of the knob.

3. Squeeze the handle halves together.

4. Place the tip of a screwdriver into the pivot
shaft set screw 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,

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Steering and Controls Control Handle

Secondary Control Handle - Figure 7-50. Secondary Control Handle End Cap
7HNDL_SEC2.jpg

Fore/Aft Stance M4x8 mm

End Plug

Travel Pot Repair/Replacement

1. Remove the travel pot from the handle
shell.
NOTE: Do not lose the D-shaped clip inside the
pivot shaft.

4. Remove the travel pot from the handle

shell.
Use correct electrostatic discharge
precautions. See “Static Precautions” on NOTE: Do not lose the D-shaped clip inside the
page 2-7. pivot shaft.
5. Remove the snap ring in the handle shell.
2. Attach the foam pad to the back of the new
See Figure 7-49.
travel pot body.
6. Remove the pivot shaft assembly from
3. Turn the travel pot shaft so the flat on the
handle shell.
shaft aligns with the tang on the pot body.
See Figure 7-49. 7. Observe the orientation of parts on the
pivot shaft and remove. See Figure 7-51.
Figure 7-49. Secondary Control Handle Travel Pot
7HNDL_SEC1.jpg Figure 7-51. Secondary Handle Pivot Shaft Components
7HNDL_SEC3.jpg
D-Clip Slot

Tang
Snap Ring

4. Insert travel pot into the handle shell,

aligning the flat on the shaft with the 8. Apply a thin coat of lubricant
D-clip, and the tang on the pot body with (P/N 990-635) to the inside surface of the
the slot in the shell. See Figure 7-49. spring. Assemble parts in the correct order
on the shaft.
Disassembly/Assembly 9. Slide the spring and paddles part way
down the pivot shaft to engage the lower
1. Remove the end plug from the end of the spring tang.
handle. See Figure 7-50.
10. Using the upper paddle, press the upper
2. Remove the two button-head socket spring tang over the tab on the pivot shaft.
screws from the end of the handle. See With one paddle and one spring tang on
Figure 7-50. each side of the pin, slide all parts down to
3. Remove the handle grip from the handle expose the snap ring groove. See
shell. Figure 7-52.

Publication: 1112860, Issued: 15 Feb 2012 7-41

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Control Handle Steering and Controls

Figure 7-52. Secondary Control Handle Pivot Shaft Figure 7-53. Secondary Handle, PH3 Connector
Alignment 7HNDL_SEC5.jpg

7HNDL_SEC4.jpg

Paddle/Tang
Spring
Tab on Shaft

Paddle/Tang Insulation

2. Remove the 2 in. (50.8 mm) length of

Tab on Shell shrink tubing from the wires. See
Shell
Figure 7-53.
3. Remove the snap ring from the back of the
11. Install the external snap ring and two horn button. See Figure 7-54.
nylon washers.
12. Confirm that the D-clip is inside the pivot Figure 7-54. Secondary Control Handle Horn Button
shaft. 7HNDL_SEC6.jpg

13. Insert the pivot shaft assembly into the

handle shell. Make sure the tab on the
shell slides between the paddles on the
shaft assembly. See Figure 7-52.
14. Insert travel pot into the handle shell,
aligning the flat on the shaft with the
D-clip, and the tang on the pot body with
the slot in the shell. See Figure 7-49.
15. Slide the handle grip over the handle shaft
Snap Ring
and shell assembly. Orient the notch in
the handle flange with the harness
4. Pull wiring out through the channel in the
channel in the grip.
handle grip.
16. Install the two button-head socket screws
5. Thread new wires down the channel in the
at the end of the handle and end plug.
handle grip.
6. Install the horn button in the grip and
Horn Button secure it with the snap ring.
1. With the handle disassembled, remove the 7. Install a 2 in. (50.8 mm) length of shrink
three wires from the PH3 connector, noting tubing over the wire ends.
their colors and locations for later
8. Re-connect connector PH3 to the horn
re-connection. See Figure 7-53.
button wires: red to pin 1, black to pin 2,
white to pin 3. Make sure there is a
connector seal on the connector.
9. Shrink the tubing.
10. Reassemble handle.

7-42 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Drive and Brake

Drive and Brake

Section 7. Component Procedures

Publication: 1112860, Issued: 15 Feb 2012 7-43

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Drive Unit Drive and Brake

Drive Unit
Figure 7-55. Drive Unit Exploded View
7R1008858_C.cgm

22 23 21 20 19 25 26

24
4

27
3

2
18
6

12 16

13
29

5 9

28 8 10 11 7 14 15 32

7-44 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Drive and Brake Drive Unit

Table 7-3. Drive Unit Set-Up Legend Required Tools

Item Description Before performing any maintenance on the
drive unit, note the tools required. Also, make
1 Housing, Drive Unit
sure that any maintenance performed does not
2 Gear, Pinion, Drive Unit void warranty.

3 Gear, Helical, Drive Unit

Standard Tools
4 Nut, Clamp
The tools listed in Table 7-4 are required for
5 Bearing Set, Drive Unit
performing maintenance tasks on the drive
6 Bearing Set, Drive Unit unit.

7 Gear and Pinion Set, Drive Unit Table 7-4. Standard Hand Tools for Servicing Drive Unit
8 Bearing Set, Drive Unit
Bearing puller
9 Shaft, Flanged Output, Drive
Bearing press
10 Shim, Drive Unit Output Bearing
Micrometer
11 Ring, Retaining
Hammer or mallet
12 Plug, Pipe
Brass punch
13 Screw
Pinion gauge
14 Bearing Set, Drive Unit
Bearing heater
15 Seal, Lip
Screwdriver
16 Cover
Magnetic dial indicator
18 Ring, Pivot
Pry bars
19 Pin, Spiral
Tube 12 in. diam. x 6 in. long
20 Plug, Bearing Filler
Tube 8 in. diam. x 6 in. long
21 Fitting, Grease
Torque wrench, 150 ft. lb. (210 Nm) capacity
22 Screw

23 Washer, Flat

24 Kit, Ring Set

25 Bearing, Ball

26 Gear, Spur, Drive Unit

27 Fitting, Grease

28 Shim

29 Shim

32 Cover, Shim

Publication: 1112860, Issued: 15 Feb 2012 7-45

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Drive Unit Drive and Brake

Special Tools

The tool shown in Figure 7-56 is recommended

for removal/installation of the drive unit.

Figure 7-56. Drive Unit Removal/Installation Tool

73323_002.eps

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

7-46 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Drive and Brake Drive Unit

Troubleshooting
Table 7-5. Troubleshooting Drive Unit Symptoms

Symptom Probable Cause Required Action

Oil leaks Damaged lip seal Replace lip seal, main cover and bearing shims,
and output shaft bearings

Worn or damaged output shaft Replace lip seal, main cover and bearing shims,
output shaft bearings, and output shaft

Housing/main cover joint Reseal

Worn or damaged housing Replace drive unit

Drive wheel Worn or damaged output shaft bearings Replace lip seal, main cover and bearing shims,
wobbles and output shaft bearings

Worn or damaged output shaft Replace lip seal, main cover and bearing shims,
output shaft bearings, and output shaft

Loose wheel mounting hardware Inspect housing and main cover for damage,
re-torque mounting hardware

Noise Worn or damaged output shaft bearings Replace lip seal, main cover and bearing shims,
and output shaft bearings

Worn or damaged pinion bearings Replace pinion bearings and clamp nut

Worn or damaged gear set - Output shaft Replace lip seal, main cover and bearing shims,
is in good condition output shaft bearings, pinion bearings, gear set,
and clamp nut

Worn or damaged gear set - Output shaft Replace lip seal, main cover and bearing shims,
is worn or damaged output shaft bearings, pinion bearings, gear set,
clamp nut, and output shaft

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

Steering Inadequate bearing lubrication Grease pivot bearing and spherical bearing
binds
Worn or damaged pivot bearing Replace radial ring set, steel balls, bearing filler
plug, and spherical bearing

Steering Worn or damaged spur gear Replace spur gear and spherical bearing
binds
Worn or damaged spherical bearing Replace spherical bearing and grease fittings

Worn or damaged pivot ring Replace pivot ring, radial ring set, steel balls,
bearing filler plug, and spherical bearing

Publication: 1112860, Issued: 15 Feb 2012 7-47

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Drive Unit Drive and Brake

Radial Ring Inspection Figure 7-57. Dial Indicator Placement

77400_radialRing1.jpg

If worn radial rings are suspected as the cause

of play in the drive unit, perform the following
steps to determine if the rings should be
replaced.

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
support the lift truck. See “Jacking
Safety” on page 2-8.

1. Jack the rear of the truck up until the

drive tire is clear of the floor.
2. Place a magnetic base dial indicator on the
tractor bumper. Place the indicator pin on
top of the ring gear. See Figure 7-57.
NOTE: When positioning the indicator, try to
align it with a feature on the truck (such
as a grease fitting). This helps maintain
consistent results between trucks. Drive Unit Removal
3. Zero the indicator and lower the truck to
1. Turn the key switch OFF and disconnect
the floor. Observe the new indicator
the battery connector.
reading.
2. Drain the oil from the drive unit.
4. If the reading exceeds 0.090 in. (2.3 mm),
replace the radial rings. 3. Loosen the drive tire lug nuts.

NOTE: Any looseness that results in the pivot 4. Remove the horn assembly.
ring casting contacting the drive unit 5. Disconnect the power cables from the
housing as the unit turns during Traction Motor, labeling the cables if
steering requires that the radial rings be necessary for later installation. Use two
changed immediately. wrenches to avoid twisting the motor
studs.
6. Disconnect remainder of wires and brake
hose.
7. Remove mounting bolts for cable bracket.
8. Remove Traction Motor mounting bolts.
Lift brake assembly and motor off drive
unit.
9. Remove the steering shaft.

7-48 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Drive and Brake Drive Unit

10. To facilitate the removal of the drive unit, Drive Unit Disassembly
construct the tool shown in Figure 7-56.
Attach the tool to the top of the drive unit Numbers within brackets [ ] correspond to item
using the screws that held the Traction shown in the exploded view, Figure 7-55 on
Motor. page 7-44.
11. Remove the dust shield between the ring
gear and the tractor frame. Clean the outside of the drive unit thoroughly
and drain any remaining oil from the drive unit
by removing the drain plug (12].

Visually inspect the outside of the housing [1]

Use extreme caution whenever the lift for damage, wear, or cracks.
truck is jacked up. Never block the lift
truck between the telescopic and the
floor. Use a suitable hoist to stabilize the Pivot Ring Disassembly
mast. Keep hands and feet clear from 1. On the pivot ring [18], remove the grease
vehicle while jacking the lift truck. See fitting [21] and the bearing filler plug [20].
“Jacking Safety” on page 2-8. Inspect the bearing filler plug hole for
uneven wear.
12. Secure the lift truck with a suitable
capacity hoist attached to the overhead Figure 7-58. Remove Grease Fitting and Filler Plug
guard. Jack the rear of tractor so that the 71018_003.tif

bottom edge of the bumper is approx. Filler Plug

6.5 in. (16.5 cm) off the floor.
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

2. Turn the pivot ring [18] to remove the steel

Drive unit weighs approximately 175 lb. balls [25] through the bearing filler plug
(80 kg.) hole.
NOTE: If the pivot ring does not spin or turn, it
16. Loosen, then remove the four mounting is an indication of damaged radial rings
screws holding the drive unit to the tractor and/or excessive wear to the channel in
frame. The steering stop also becomes housing. If this is the case, replace the
unattached at this stage. entire drive unit. No further disassembly
17. Lower the drive unit to the floor. Tip the is necessary.
drive unit over on its side and remove the
hoist.
18. If you have trouble separating the tool
from the drive unit, thread mounting
screws in the threaded holes in the tool to
push the tool off the drive unit.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Drive Unit Drive and Brake

Figure 7-59. Remove Steel Ball Bearings Figure 7-61. Remove Radial Rings
71018_002.tif 71018_001.tif

Radial Rings

3. After removing all the steel balls, remove

the pivot ring [18] by working it off toward Main Cover and Output Shaft
drive end of the housing.
Disassembly
Figure 7-60. Remove Pivot Ring 1. Visually inspect the housing around the
71018_004.tif
main cover [16] for wear outside the cover
bolts [13]. Refer to Figure 7-62.
NOTE: Excessive housing wear outside the
cover bolts can make them difficult to
Pivot Ring remove. If this occurs, replace the entire
drive unit. No further disassembly is
necessary.
2. Remove the main cover bolts [13].
3. Using a mallet, knock the flanged output
shaft [9] to break the seal on the main
cover [16].
4. Remove the radial rings [24] from the 4. Remove the main cover and output shaft
channel in the housing and inside the assembly. Refer to Figure 7-62.
pivot ring.
5. You need a press and 8 x 6 in. tube to
remove the bearing cup [14] on the end of
the output shaft.
Due to normal wear, the edges of the
radial rings could be very sharp.

5. Clean the grease from the radial ring

channel in the housing. Inspect the
channel for uneven wear. Also clean and
inspect the inside of the pivot ring.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Drive and Brake Drive Unit

flanged output shaft [9] and the output

bearing spacer [10] out.
Always watch for pinch points when 9. Remove the exterior retaining ring [11].
using a press or pressing tools.
Figure 7-64. Press Out Output Shaft
71018_011.tif
Figure 7-62. Remove Cover and Output Shaft
71018_005.tif

Main Cover

10. To remove the bevel gear [7], support the

main cover assembly on 8 x 6 in. tube
under press. Press the output shaft [9]
down through the bevel gear. The bearing
Safety glasses are required after this cone [14] is removed at the same time.
point in disassembly.
Figure 7-65. Remove Bevel Gear
6. Place the main cover assembly, gear side 71018_012.tif

down, on the tube under press. Press the

output shaft [9] down slightly to create a
space between the bevel gear [7] and the
output bearing spacer [10].

Figure 7-63. Press Down Output Shaft

71018_010.tif

Output Shaft
Output Shaft

11. Remove the bearing cup [8] from the main

cover with a race driver and pry bars.
12. Remove the lip seal [15] from the main
cover.
Bevel Gear

7. Tighten a bearing puller clamp under the

lip of the output bearing spacer, being
careful not to catch the exterior retaining
ring [11]. Refer to Figure 7-64.
8. Place the main cover assembly, gear side
up, on 12 x 6 in. tube so the bearing puller
clamp is resting on the tube. Press the

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Drive Unit Drive and Brake

Figure 7-66. Remove Bearing Cup and Lip Seal Figure 7-68. Remove Clamp Nut
71018_013.tif 71018_006.tif

Lip Seal

Clamp Nut

13. Remove the output shaft bearing cone [8] 2. Using a brass punch and hammer, drive
in the base of the housing using two pry the spiral pinion [7] out of the housing.
bars. Insert the pry bars under the bottom
NOTE: You may need to remove the spiral
edge of the cone on opposite sides. Apply
pinion with a press or pressing device
even pressure on both tools to lift the cone
equivalent.
out.
Figure 7-69. Remove Spiral Pinion
Figure 7-67. Remove Output Shaft Bearing Cone 71018_007.tif
71018_009.tif

Helical Gear
Output Shaft
Bearing Cone

3. Remove the helical gear [3] and the

14. Remove the shims [28] from the housing
bearing cone [5] from the housing.
bore. Save shims for reference only, as
they are usually damaged when removing 4. Drive out the bearing cup [6]. Inspect the
the bearing cone. Install new shims during bearing cup and housing bores for wear.
reassembly. NOTE: The bearing cups and cones are usually
15. Remove the cover shims [32]. Save the damaged during removal. Replace them
shims for reference only. Install new shims as sets.
during reassembly.

Spiral Pinion Disassembly

NOTE: The spiral pinion and bevel gear are a
matched set. Their alignment is critical.
Do not replace them separately.
1. Loosen the set screw on the clamp nut [4]
on the spiral pinion [7]. Remove the clamp
nut.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Drive and Brake Drive Unit

Figure 7-70. Remove Bearing Cup Figure 7-71. Drive In Bearing Cup
71018_008.tif 71018_014.tif

Bearing Cup Bearing Cup

Thoroughly wash the housing and visually

inspect entire housing again for excessive
damage, wear, or cracks. Always watch for pinch points when
using a press or pressing tools.

Drive Unit Assembly 3. Press the bearing cone [5] onto the spiral
pinion [7] until it is seated.

Figure 7-72. Press Bearing onto Spiral Pinion

Safety glasses are required. 71018_015.tif

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 Bearing Cone
damage.

Spiral Pinion Assembly Spiral Pinion

1. Using a press or mallet, install the bearing
cup into the housing bore.
2. Install the second bearing cup [6] into the
housing bore on the opposite side.
Main Cover and Output Shaft
Assembly
1. Prior to installing the output shaft lip seal
[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 [15] into the housing
until it is just below flush with the housing
surface.

Publication: 1112860, Issued: 15 Feb 2012 7-53

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Drive Unit Drive and Brake

Figure 7-73. Press Lip Seal Figure 7-75. Bearing Cone to Flange Measurement
71018_016.tif 71826_127.tif

Lip Seal

3. Press the output bearing cup [14] into the 6. The reading on the two dial indicators
main cover until it is seated. Place the should be the same. If they are different,
bearing cone into the bearing cup. repeat steps 4 and 5 until the readings are
4. Push down on the bearing and turn to seat identical. Record final reading as
the bearing into the bearing cup. Measurement D on flange surface. This is
required during final assembly.
Figure 7-74. Press Output Bearing Cup 7. Remove the bearing cone [14] in
71018_017.tif
preparation for installing the flanged
Output
output bearing shaft [9].
Bearing Cup 8. Use a light oil on the surface of the lip seal
[15] and inside the bearing cup [14].
9. Place the main cover down over the output
shaft, flange side up. Place the bearing
cone [14] down over the output shaft [9].

Figure 7-76. Install Main Cover and Bearing Cone

71018_021.tif

Bearing Cone

5. Take a measurement from the edge of the

bearing cone [14] to the flange surface of
the main cover [16]. Make sure that the
dial indicator tips come into contact with
the flange surface.

Output Shaft

10. Press the bearing cone onto the output

shaft.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Drive and Brake Drive Unit

Figure 7-77. Press on Bearing Cone Figure 7-79. Press Down Bearing Cone
71018_020.tif 71018_023.tif

Bearing Cone

Output
Bearing
Spacer

11. Place the bevel gear [7] down over the 15. Place the main cover assembly, flange side
output shaft, teeth side up. Pressing the up. Press the bearing cone [8] into place.
bevel gear down seats the bearing cone At the same time, pull the gear sideways to
[14] into the bearing cup. eliminate any backlash in the spline area.

Figure 7-78. Press on Bevel Gear Figure 7-80. Eliminate Backlash

71018_022.tif 71018_024.tif

Bevel Gear
Bearing Cup

Bearing Cone

12. Install the external retaining ring [11] on 16. Place the bearing cup [8] onto the bearing.
the output shaft [9]. Pull up on the bevel Rotate the cup while applying downward
gear [7] to make sure the external pressure to seat the bearing.
retaining ring is installed securely. 17. Position the dial indicator onto the main
13. Place the output bearing spacer [10], with cover so that the tips rest on the bearing
the recessed area down, over the output cup. The readings on the two dial
shaft. Place the bearing cone [8] on top of indicators should be the same. If they are
the output shaft. different, repeat steps 15 and 16 until the
14. Press the bearing cone [8] down until it is readings are identical.
fully seated against the spacer and snap
ring.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Drive Unit Drive and Brake

Figure 7-81. Bearing Cup to Flange Measurement Figure 7-82. Install Helical Gear and Pinion
71826_130.tif 71018_027.tif

Clamp Nut

Helical Gear

18. Record final readings as Measurement E. 5. Remove clamp nut [4]. Apply
This is required during final assembly. thread-locking compound (P/N 990-669)
to the threads of the spiral pinion.
Helical Gear Assembly Re-assemble the clamp nut on the spiral
pinion and hand tighten.
NOTE: The pinion shaft and bevel gear are a 6. While the bearing cone [6] is cooling,
matched set. Their alignment is critical. calculate the formula for determining the
Do not replace them separately. required shim [28] thickness.

Calculate Shim Formulas

Bearing can become extremely hot. Use • A = Dimension A stamped on housing

gloves to protect hands from burns. (2.102/2.108)
• B = Dimension B stamped on housing
1. Preheat the bearing cone with a bearing (3.409/3.412)
heater. Install the heated bearing cone in • C = Number etched on back of gear
the bearing cup [6] in the housing. (nominal 1.812)
NOTE: Complete steps 2 thru 4 before the • D = Distance from bearing cone to flange
bearing cools. surface (see Figure 7-83)
2. Place the helical gear [3] into the housing. • E = Distance from bearing cup to flange
3. Install the spiral pinion [7] up through the surface (see Figure 7-84)
helical gear [3]. • F = Mounting distance etched on spiral
4. Put the clamp nut [4] on the end of the pinion
spiral pinion [7] and hand tighten until the • G = Distance from top of teeth on spiral
bearing cools. pinion to top of lower bearing cup on spiral
pinon
• J = Distance from centerline of output
shaft to top of lower bearing cup on spiral
pinion

S1 = (B - A - E + D + C)

S1 = Shim amount behind bearing cup in main

housing to position gear for correct backlash
(S1).

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Drive and Brake Drive Unit

S2 = E + S1 - B - 0.006 preload Figure 7-85. Remove End Play

71018_028.tif

S2 = Shim amount between cover plate face to

set preload of bearings for output shaft (S2).

S3 = J – F – G

S3 = Shim amount between drive unit housing

and lower bearing on spiral pinion.

Figure 7-83. Bearing Cone to Flange Measurement

71826_127.tif

2. Preload the helical gear [3] for 0.000 to

0.002.
3. Remove any oil from the clamp nut [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 [3] to make sure the
bearings are not too tight. The helical gear
must spin freely for at least one full
Figure 7-84. Bearing Cup to Flange Measurement rotation.
71826_130.tif
5. Only perform the following procedure if
the helical gear assembly is too tight.
a. Unscrew the clamp nut [4] the width of
one spanner slot (0.188 in./4.77 mm).
b. Tap the spiral bevel gear [7] to unseat
the bearing cone.
c. Place the predetermined shims [29] in
the housing bore for the bearing cup
[5].
d. Install the spiral pinion gear and helical
gear. See “Helical Gear Assembly” on
page 7-56.
Installing and Testing Shims e. Repeat steps 1 thru 4 until the helical
1. Remove any end play in the bearings gear spins at least one full rotation.
between the helical gear [3] and the spiral 6. One tooth on the spiral gear [7] is etched
gear [7] using lock nut wrench. Wedge the or marked with an X. With a marker, mark
helical gear, and tighten the clamp nut [4] that tooth surface for the purpose of lining
until there is no end play between the up the spiral and bevel gears [7] to check
gears. backlash. One tooth on the matching bevel
gear is also marked. Mark that tooth
surface also.

Publication: 1112860, Issued: 15 Feb 2012 7-57

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Drive Unit Drive and Brake

Figure 7-86. Mark Spiral and Bevel Gears Figure 7-88. Line Up Spiral and Bevel Gears
71018_029.tif 71018_031.tif

Spiral Gear
Spiral gear

Bevel Gear

7. Place the predetermined shims [28] into

the housing bore for the bearing cup [8]. Measuring Backlash
Install the bearing cup into the housing
bore over the shims. NOTE: Backlash tolerance is critical to the
8. Install the cover shims [32]. performance of the drive unit. Incorrectly
adjusted units will experience premature
Figure 7-87. Install Cover Shims failure.
71018_030.tif
1. Wedge the helical gear [3], then slightly
turn the output shaft to determine
backlash. Backlash reading on the dial
indicator should be between 0.004 and
0.006.

Figure 7-89. Backlash Measurement

71826_131.tif

Cover Shim

9. Place the main cover assembly over the

shims, making sure to line up the marked
teeth on both the spiral and bevel gears
[7].
10. Put in four housing cover bolts [13], evenly
spaced, and tighten to 40 ft. lb. (54 Nm).

2. Calculate any necessary adjustments to

the shims. Remove the main cover
assembly and the bearing cup, and adjust
the shims. Repeat Steps 6 thru 9
“Installing and Testing Shims” until
backlash is between 0.004 and 0.006.
3. When backlash is within acceptable range,
remove the main cover assembly and the
cover shims.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Drive and Brake Drive Unit

Main Cover Installation Figure 7-91. Install Radial Rings

71018_036.tif

1. Clean the cover mating surface on the Radial Rings

housing, then apply thread-locking
compound (P/N 990-411) sparingly.
2. Install the cover shims [32] and the main
cover assembly. Install the main cover
bolts [13], and torque to 40 ft. lb. (54 Nm).

Pivot Ring Assembly

Roll Pins

Safety glasses are required. 5. Install the outer radial rings [24] on the
housing. Refer to Figure 7-92.
1. On the inside of the pivot ring [18], make
sure the roll pins [19] are installed and in Figure 7-92. Install Outer Radial Rings
71018_037.tif
good condition on either side of the
bearing filler plug hole. If they are missing Outer
or damaged, install new roll pins. Radial Ring

Figure 7-90. Install Roll Pins

71018_035.tif

Pivot Ring

6. Lift the drive end of the housing and slide

the pivot ring over the housing. Be careful
not to jar the radial rings out of place.
Roll Pin Slide the pivot ring into place just behind
the spur gear [26].
2. Install the grease fitting [27] on the outside 7. Make sure the pivot ring bearing filler plug
of the pivot ring. hole is on top, in preparation for installing
3. Screw the grease fitting [21] in the bearing the steel balls [25].
filler plug. 8. Put one ball at a time into the pivot ring
4. Install radial rings [24]. Install the flat filler hole. Use a screwdriver to direct the
radial ring on the inside flat surface of the steel balls first to one side then the other.
pivot ring. Place the ends of the chamfered Continue until all 70 balls are installed.
radial rings against the roll pins [19] to 9. Install the bearing filler plug [20] with the
install them in the pivot ring. grease fitting [21] pointing toward the spur
gear [26].

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Drive Unit Drive and Brake

Figure 7-93. Install Ball Bearings 3. Apply thread-locking compound
71018_038.tif
(P/N 990-536) to the steer linkage bolt
Steel Ball 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 Traction Motor and brake. Use
a fiber gasket between the Traction Motor
and drive unit.
7. Install mounting bolts for Traction Motor
and drive unit and torque to 13 ft. lb.
(17.6 Nm).
Excessive thread-locking compound will
damage the ball bearings and pivot 8. Connect cables, wires, and brake line.
ring. Use thread-locking compound Torque motor cables to 18 ft. lb. (24.4 Nm).
sparingly. 9. Install the drive unit dust shield.
10. Install the drive wheel. Torque the drive
10. Apply thread-locking compound tire lug bolts to 170 ft. lb. (230 Nm).
(P/N 990-536) sparingly to the filler plug
bolts [22]. Install the bolts and washers 11. Install the horn assembly.
[23] on either side of the bearing filler plug 12. Check the drive unit fluid level.
[20] and tighten to 20 ft. lb. (27 Nm). 13. Test the brake for correct operation.
11. Grease and then test the pivot ring,
checking to see that it spins freely.

Figure 7-94. Install Bearing Filler Plug

71018_040.tif

Filler Plug and

Grease Fitting Filler Plug Bolt

Washer

Drive Unit 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).

7-60 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Drive and Brake Brake

Brake Insert spacer between the armature plate

and the coil body. Tighten the locking bolt
just enough to prevent rotation of the
Inspection motor shaft.
7. Remove the retaining nut and washer from
1. Turn the key switch OFF and disconnect
the motor shaft. See Figure 7-95.
the battery connector.
8. Remove the three brake mounting bolts.
2. Open the motor compartment door.
9. Use a brake puller to remove the brake
3. Check air gap between the armature and assembly from the motor.
armature plate near all three spacers. See
Figure 7-95. If air gap exceeds 0.040 in. (1
mm), replace the brake pads. See “Pad Pad Replacement
Replacement”.
1. Install the brake release bolts.
Figure 7-95. Checking Brake Air Gap NOTE: Do not overtighten the brake release
7brake3.JPG
bolts.
2. Turn the brake assembly over and remove
Motor the three bolts securing the adapter plate.
Shaft See Figure 7-96.

Brake Figure 7-96. Adapter Plate Removal

Mounting 7brake1.JPG

Bolt (qty. 3)

Armature

Armature
Plate

Adapter Spacer
Plate

Brake Removal
1. Turn the key switch OFF and disconnect
the battery connector.
Adapter
2. Block the drive tire to prevent movement.
Plate Bolts
3. Open the motor compartment door.
4. Note the location of cable ties securing the 3. Remove the adapter plate. Inspect spacers
motor cable bundle to the cable bracket. and replace if damaged.
Cut cable ties to free the cables from the
bracket. Remove the cable bracket. 4. Remove old pads from carrier and install
new pads. See Figure 7-97.
5. Disconnect the brake armature lead
connection.
6. Loosen one of the locking bolts and obtain
a spacer approx. 0.005 to 0.015 in.
(0.12 to 0.38 mm) thicker than the
measured total air gap (non-energized).

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Brake Drive and Brake

Figure 7-97. Pad Replacement
7brake1.JPG
Brake Installation
Small Flange 1. Correctly position the brake assembly on
Carrier motor. Make sure the keyways on the
(large flange
opposite side) motor shaft and carrier are correctly
aligned.
2. Gently tap the carrier flange onto motor
shaft until seated.
3. Apply thread-locking compound
(P/N 990-536) and install the three brake
mounting bolts. Torque to 16 ft. lb.
(21.7 Nm).
4. Remove brake release bolts and install in
Pad (qty. 6) their storage locations.
5. Loosen one of the retainer bolts and insert
5. Install adapter plate. Torque adapter plate a 0.030 to 0.040 in. (0.76 to 1 mm) spacer
bolts to 6 ft. lb. (8.6 Nm). between the armature plate and coil body.
NOTE: Leave the brake release bolts installed Tighten the retainer bolt just enough to
for reassembly to motor. prevent rotation of the motor shaft as the
retaining nut is torqued.
Coil Replacement 6. Install retaining nut and a new washer to
motor shaft. Torque retaining nut to 150
1. If installed, carefully remove the brake ft. lb. (203 Nm).
release bolts. Separate the coil from the
7. Loosen the retainer bolt and remove the
armature plate.
spacer.
NOTE: The brake release bolts are under 8. Attach the motor cable bracket. Apply
tension from the springs inside the coil thread-locking compound (P/N 990-536)
body. to the bolts and torque to 6 ft. lb. (8.6 Nm).
2. With the coil inverted, make sure all eight 9. Attach the cable bundle to the cable
springs are inserted into the cavities. bracket with cable ties and connect the
NOTE: On coils with ten spring cavities, the two brake armature lead connector.
empty cavities must be 180° apart. 10. Unblock the drive tire. Reconnect the
battery connector and turn the key switch
3. Place the thin washer shaped spacer over
ON.
the springs.
11. Make sure brake operates correctly and
4. Note the orientation and place the inverted
traction motor rotates without interference
armature plate on the coil directly over the
to motor cables.
spacer.
5. Assemble the armature and coil: NOTE: When the truck is stationary, depressing
and releasing the deadman pedal should
a. Using a clamp, mate the armature plate cause the brake to release and engage.
to the coil. Make sure the thin washer When the truck is traveling, the brake
is correctly aligned. should remain released (coil energized)
b. Install the brake release bolts through until the truck speed reaches 0.5 mph
the coil and armature plate and tighten. (0.8 km/h).
6. Install carrier, pads, and adapter plate.
Torque adapter plate bolts to 6 ft. lb.
(8.6 Nm).

7-62 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Drive and Brake Deadman Pedal

Deadman Pedal
If the proximity sensor does not activate when
pedal is fully depressed, perform the following
procedure.
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove pad over the deadman pedal.
3. Remove bolt securing deadman switch
cable clamp to floor. Leave deadman
switch plugged in and remove deadman
pedal.
4. Measure gap between the proximity sensor
and the indicator flag.
a. Fully depress the pedal. The gap
between the proximity sensor and the
indicator flag should be between 0.05
and 0.07 in. (1.2 to 1.7 mm). Adjust as
necessary. See Figure 7-98.

Figure 7-98. Deadman Pedal Adjustment

78D14068S.TIF

Indicator Flag

0.05 to 0.07 in. Proximity Sensor

(1.2 to 1.7 mm) gap

b. If gap is OK or sensor does not activate

after adjustment, replace proximity
sensor.
5. Run Test I00 - Deadman Switch (DS1)
(Page 6-64).
6. Reinstall deadman pedal in floor.
7. Reinstall pad over deadman pedal.
NOTE: If pad was previously glued, apply glue
(P/N 990-569/102) in locations
originally glued.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Inertial Dampener Drive and Brake

Inertial Dampener
Figure 7-99. Inertial Dampener Assembly
7R1014725_B.cgm

Mounting
Bracket

Slide Plate
Friction
Plate
Friction
Plate

Dampener
Spring

Spring
Retainer

Lock Nut

NOTE: The A-frame up-travel stop bolt Figure 7-100. Inertial Dampener (unrelated parts removed
adjustment is critical. Incorrect for clarity)
713y7s001.tif
adjustment results in damage to the
inertial dampener. See “Steerable Dampener
Dampener Spring
Spring
Caster” on page 7-28. If extra A-frame (1 (1
9/16
9/16
in.in.
oror
4040
mm)
travel is required such that the stop bolt
adjustment cannot be maintained, Spring
remove the inertial dampener. Retainer Friction
Plate
Removal
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the right side cover. Lock Nut
3. Remove the inertial dampener cover plate.
4. Loosen and remove the inertial dampener 5. If necessary, turn the A-frame down-travel
lock nuts, spring retainer, two springs, adjustment bolt clockwise until there is
and friction plate. See Figure 7-100. clearance between the dampener bolts and
the bottom of the slot in the slide plate.
See Figure 7-101 on page 7-65 and
Figure 7-105 on page 7-66.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Drive and Brake Inertial Dampener

6. Remove the cap screws holding the slide Figure 7-102. Inertial Dampener (A-frame springs, slide
plate mounting bracket to the frame. plate removed)
713y7s004.tif
Remove the bracket. See Figure 7-101.

Figure 7-101. Inertial Dampener (nuts, retainer, springs, Friction Plate

friction plate removed)
713y7s002.tif

Cap Screws

A-frame
Spring Slide
Plate Bolt

Figure 7-103. Inertial Dampener (jacked up for shoulder

A-frame Down-Travel bolt removal)
Adjustment Bolt 713y7s005.tif

7. Loosen the A-frame down-travel A-frame Friction Plate

adjustment bolt and remove the bolt and Down-Travel
Adjustment
washers.
Bolt Hole

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
Bolt
mast. Keep hands and feet clear from Thread-Locking
vehicle while jacking the lift truck. After Compound
the lift truck is jacked, place solid blocks
or jack stands beneath it to support it.
DO NOT rely on the jack alone to Installation and Adjustment
support the lift truck. See “Jacking 1. Attach the friction plate to the A-frame
Safety” on page 2-8. yoke with the bolt and nylon lock nut.
8. Jack the tractor up approx. 2 in. (50 mm) 2. Install the A-frame springs. Lower the lift
at the tractor frame and block. See truck slightly on the jack to seat the
Figure 7-103. springs in their retainer holes.
9. Remove the A-frame springs. See 3. Install the A-frame down-travel
Figure 7-101 and Figure 7-102. adjustment bolt with the plastic washer
between the metal washer and the frame.
10. Remove the bolt holding the friction plate Tighten until the distance between the top
to the A-frame yoke. See Figure 7-102 and of the A-frame and the bottom of the
Figure 7-103. A-frame spring upper weldment is 7 in.
(17.7 cm).

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Inertial Dampener Drive and Brake

Figure 7-104. Inertial Dampener parts 8. Install the inertial dampener cover plate.
76906_001.JPG

9. Reattach the right side cover.

Dampener Slide Plate
Spring

Spring
Retainer

Lock Nuts

Friction Plates
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. The
pivot joint on the mounting bracket should
be free to flex. Torque the slide plate
mounting cap screws to 18 ft. lb.
(24.4 Nm).

Figure 7-105. Inertial Dampener adjustment

76906_002.JPG

Pivot Joint Slide Plate

Clearance Here Friction Plate

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 7-104 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.
(40 mm) at both bolts. See Figure 7-100 on
page 7-64.
7. Adjust the idler. See “Steerable Caster” on
page 7-28.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Electrical Components

Electrical Components
Section 7. Component Procedures

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Battery Procedures Electrical Components

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 2-5.
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 Figure 7-107. Battery Cable and Connector
Battcon2.tif

The battery connector is located at the

front-right of the tractor, above the battery.

Figure 7-106. Battery Connector location

6353_118g.jpg

Battery
Connector

When replacing battery cable ends,

remove only one end at a time from the
Inspection connector to avoid the cable ends
touching and causing a short circuit. Do
1. Turn the key switch OFF and disconnect not allow the metal cable end to touch
the battery connector. 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 1. To remove a cable from the connector,
out of the connector. push the retainer down while pulling the
4. Check the cables at the battery terminals. battery cable towards the rear and out of
Connections should be tight, with no the connector. See Figure 7-108 and
corrosion. Figure 7-107.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Electrical Components Battery Procedures

Figure 7-108. Battery Cable Removal from Connector Figure 7-109. Battery Cable and Filler Plug
Battcon1.tif 09g6s047.tif

Battery Cable

Filler Plug
Vent Hole

2. Do not attempt to repair battery cables by 5. Keep the top of the battery clean and dry.
crimping new terminals. Replace the Corrosion, dust, and moisture provide a
cable. conducting path to short-circuit cells or
create shorts to ground.
Battery Exterior Cleaning
1. Read, understand, and follow procedures,
recommendations and specifications in the Do not clean the top of the battery with
battery and battery charger the soda solution while it is installed in
manufacturer’s manuals. the lift truck. Water can seep into the
25l6s014.eps
electrical components and cause serious
damage.

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,
2. Wear personal protective equipment. See indicating that the battery exterior is
“Battery Safety” on page 2-5. neutralized.
3. Turn the key switch OFF and disconnect 8. Rinse the battery with clean water.
the battery connector. Remove the battery 9. Dry the battery completely before
from the lift truck. reinstalling it.
4. Inspect the battery cables to make sure 10. Reinstall the battery in the lift truck, using
they are not frayed or loose. Inspect the a suitable battery moving device.
battery connector to make sure there is no Reconnect the battery connector.
foreign material inside the connector.
Make sure the filler plugs are tight and the
vent holes in the filler plugs are open. Testing, Charging, and
Maintenance
For information on testing, charging, and
maintaining your lift truck battery, consult the

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Battery Procedures Electrical Components

battery manufacturer’s specifications and

instruction manual.

Never plug the battery charger into the

lift truck. This will severely damage the
lift truck’s electrical system. Plug the
charger only into the connector from the
battery.
6173_012.eps

Battery State-of-Charge
Battery State-of-Charge (BSOC) is a feature that
monitors and remembers the charge level of the
battery connected to the lift truck and prevents
excessive discharging of that battery. Operating
a lift truck using a discharged battery can
damage both the battery and the electrical
components of the lift truck. Refer to page 5-5
for a detailed description of how BSOC works
and the procedure for setting BSOC Cutout.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Electrical Components Wiring and Harness Connectors

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.
See “Electrical Troubleshooting” on page 5-2. • Do not cut away a terminal lug and reuse
the wire strands that were crimped into
Whenever working on the lift truck, use care the original lug.
around wiring harnesses. • When stripping wire, use new wire strands
• Carefully connect and disconnect all for new terminations. Make sure to use a
connections. new wire with extra length to allow for
cutting and stripping of the ends to install
• Do not pry connectors apart with
new terminations.
unspecified tools.
• Use a new wire that is the same gauge
There should be a wire marker at each (typically gauge 18 AWG), size, type, and
termination. If the marker is missing or color as the wire it is replacing.
unreadable, remark the wire to allow easier • Use a hand stripper capable of stripping
identification. by wire gauge number. Use care not to
NOTE: It is normal to find unused connectors nick or cut any of the wire strands.
for uninstalled options that have had Discard and replace a wire with damaged
heat shrink applied over them and have strands. Insert the wire strands the
been strapped to the harness. correct length into termination before
crimping.
Repair
Soldering Procedures

To prevent damage from excessive heat when

Use correct electrostatic discharge soldering small components in assemblies,
precautions. See “Static Precautions” on follow these guidelines:
page 2-7. • Make sure the soldering tip is clean. A
dirty tip does not transfer heat well and
When pulling a wire out through a bundle, cut encourages long dwell time and greater
off the pin or socket so it does not snag. When pressure. Apply light pressure on the
replacing wires, in some cases you can tape or terminal.
solder one end of a new wire to one end of the • Flux: rosin base
failed wire. Then you can pull the old wire out of
the bundle and pull the new wire into the • Solder: 60/40 rosin core or equivalent
bundle, all at the same time. Make sure to • Solder Iron: 15-25 watt “pencil-type”
disconnect the old wire from the new wire. maximum
• Tip Size: 3 mm (0.118 in.) diameter x
In other cases, it is easier to secure a new wire 30 mm (1.182 in.) long screwdriver tip.
to the outside of the existing wire bundle with Make sure the tip is clean.
straps of an appropriate size. You can leave the
failed wire in the bundle, or pull it by one end to • After soldering, clean the terminals with a
remove it from the bundle. brush dampened with an alcohol-based
cleaner (P/N 990-600/FOF). Do not allow
any cleaner to seep into the switches or
potentiometers, or contact contamination
may occur.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Wiring and Harness Connectors Electrical Components

Molex Connectors Pin Extraction

For pin orientation of Molex connectors, see To remove a pin from a Molex connector, use
Figure 6-1 on page 6-27. Molex connectors have pin extraction tool P/N 950-026.
pins with locking ears that engage ridges in the 1. Insert the extraction tool over the pin and
plastic connector body. To remove a pin from a push all the way into the connector. This
Molex connector, depress these locking ears far releases the locking ears on the pin.
enough to clear the ridge in the connector. See
2. Pull the wire and pin from the connector.
Figure 7-110.

Figure 7-110. Molex Connector, end view Pin Insertion

Molex.wmf

To insert a pin into a Molex connector, insert

Socket the pin into the back side of the connector and
push the wire all the way in until it clicks. The
locking ears have now engaged the connector.
Pin See Figure 7-111.

Locking
Ears

Figure 7-111. Pin Extraction and Insertion

Molex1.wmf

Top view of
connector Tool inserted over
pin

Extraction
Locking Tool
ears

Side view of
connector

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Electrical Components Wiring and Harness Connectors

AMP Water-Resistant
Connectors
AMP connectors provide water-resistant
connection by the use of seals between wires
and connectors and between the mating
connector halves. See Figure 7-112

Figure 7-112. AMP Water-Resistant Connector

4570_001.tif

Wire Seal

Interface
Seal
Contact
Cavity

Wire Seal Jack

Housing

Pin Contact

Pin Housing

Sealing Plug

To maintain the integrity of water-resistant Figure 7-113. AMP Pin Extraction

seals, use the following procedures when
4570_009.tif

working with AMP connectors. Extraction Tool

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
extraction tool into the contact socket. See Locking
Figure 7-113. Lance
2. Pull the wire gently until you feel the
contact locking lances disengage.
3. Holding the wire seal and connector
housing together, rotate the wire while
pulling it through the wire seal. This
prevents damage to the seal. See
Figure 7-114.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Wiring and Harness Connectors Electrical Components

Figure 7-114. Removing Wire Figure 7-116. Wire Insertion
4570_008.tif 4570_004.tif

Rotate and Pull

Pin Contact

Pin Insertion Seals

1. Make 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 7-115.
Figure 7-115. 2. Plug unused pin positions with sealing
plugs. See Figure 7-117.
Figure 7-115. Wire Seal
4570_002.tif
3. Align the split tapered end of the sealing
Wire Seal plug with the unused opening in the wire
seal. Push the plug through the wire seal
into the connector until it snaps into
position.
4. Remove sealing plugs by pulling with
needle-nose pliers while grasping the wire
seal and connector.
Pin Housing
Figure 7-117. Sealing Plug
4570_005.tif

2. If re-inserting a wire previously removed, Sealing Plug

check the pin contact locking lances to
make sure they are extended to their
original position.
3. Grasp the wire close behind the contact
insulation barrel and push the wire
straight through the wire seal into the
socket until it clicks. Pull back gently to
make sure the contact is locked in place.
See Figure 7-116.

5. Use an interface seal between pin and jack

halves of the connector. To prevent
damage to the seal, use the matching
connector cap to slide the interface seal
over the contact silos on the pin housing.
See Figure 7-118.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Electrical Components Wiring and Harness Connectors

Figure 7-118. Interface Seal
4570_003.tif

Interface
Seal

Pin Housing

6. When mating connectors, make sure

polarized silos are correctly oriented. Push
pin and jack halves of the connector
together until locking latches engage. See
Figure 7-119.

Figure 7-119. Latching AMP Connector

4570_006.tif

Locking
Latches

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Wiring and Harness Connectors Electrical Components

AMP Harness/Power Amp

Connector
Connector Components
Figure 7-120. Power Amp Connector Components
amp006.tif

Power Amp
Connector

JT1
and
JL1

Disassembly (Contact Removal) Contact Insertion

1. Insert a 4.8 mm screwdriver blade between The axial concentricity of the crimped contact
the mating seal and one of the red wedge shall fall into an area defined by a 2 mm
lock tabs. See Figure 7-121. diameter cylinder whose center is the center
2. Pry open the wedge lock to the open line of the contact front end. See Figure 7-122.
position.
3. While rotating the wire back and forth over Assembly
a half turn (1/4 turn in each direction),
gently pull the wire until the contact is Make sure the wedge lock is open.
removed.
1. To insert a contact, push it straight into
the appropriate circuit cavity as far as it
Figure 7-121. AMP Connector (JT1 or JL1)
amp001.tif will go. See Figure 7-122 (a) and (b).
2. Pull back on the contact wire with a force
of 1 or 2 lb. to make sure the retention
fingers are holding the contact. See
Figure 7-122 (c).

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Electrical Components Wiring and Harness Connectors

Figure 7-122. Contact Insertion
amp004.tif,amp005.tif

3. After all contacts are inserted, close the

wedge lock to its locked position. Release
the locking latches by squeezing them
Be very careful when putting the wedge
inward. See Figure 7-123.
lock in the locked position. Forcing the
Figure 7-123. Wedge Lock Latches
wedge lock can cause damage to the
amp003.tif connector. Make sure the wedge lock is
aligned correctly. If resistance is felt,
slightly adjust the wedge lock until it
slides in freely.

4. Slide the wedge lock into the housing until

it is flush with the housing. See
Figure 7-124.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Wiring and Harness Connectors Electrical Components

Figure 7-124. Wedge Lock Flush With Housing
amp002.tif

Testing

Do not pierce wire insulation with a sharp point

while troubleshooting.

The wedge lock has slotted openings in the

forward (mating) end. These slots accommodate
circuit test tabs that are approximately 3.3 by
0.6 mm, that prevent damage to the receptacle.
For circuit testing in the field, use a flat probe
such as a pocket knife blade. Do not use a
probe with a sharp point.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Electrical Components Power Cables

Power Cables Table 7-6. Cable Jacket Strip Length - Short Barrels

AWG Lug P/N Strip Length

Check power cables for: 1/0 1002215/001-004 11/16 in. (17 mm)
• evidence of overheating
2/0 1002215/005-008 13/16 in. (21 mm)
• burned spots in the cable
3/0 1002215/009-012 1 in. (25 mm)
• nicks in the insulation
• damaged or overheated terminal lugs 4/0 1002215/013-015 1-1/16 in. (27 mm)

• damaged mounting hardware or brackets

Table 7-7. Cable Jacket Strip Length - Long Barrels
Replace damaged cables or mounting hardware AWG Lug P/N Strip Length
as necessary.
1/0 1002217/001-003
Power cables are marked on the terminal lug 2/0 1002217/004-006 1-9/16 in. (40 mm)
with the location where they belong. If the
marking is missing or is not readable, remark 3/0 1002217/007-009
the cable with the correct information.
4/0 1002217/010-011 1-11/16 in. (43 mm)
NOTE: Terminal lugs may be replaced in the
field using the appropriate crimping 5. Insert cable into terminal.
tools. Crimping tool, lugs, and
6. Place cable and terminal into tool die and
heat-shrink are available through the
crimp. Refer to pictures below for what
Parts Distribution Center. Failure to use
completed crimps should look like.
correct cables, terminal hardware, and
torque values can result in overheating Figure 7-125. Short Barrel Terminal
and damage to components. 7FIG1_LUGS.jpg

Power Cable Repair

Traditional lug crimping techniques for power
cables on DC motors may not meet the higher
current requirements of AC motors. Use
Manual Crimp Tool (P/N 1069861) when
crimping power cables for all AC motors. This
tool may also be used to repair power cables for
DC motors.
1. Remove the bad cable(s).
2. Using the removed cable(s) for reference,
cut an appropriate amount of replacement
cable of the same gauge.
3. Set the adjustment screw on the manual
crimp tool head to match the cable gauge.
4. Strip the cable jacket to fit the terminal to
be crimped. Refer to Table 7-6 and
Table 7-7.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Power Cables Electrical Components

Figure 7-126. Long Barrel Terminals
7FIG2_LUGS.jpg

7. Apply heat-shrink tubing (P/N 611-035) to

the terminal after crimping.
a. For short barrels, use 1.75 in. (45 mm)
of tubing. Apply 1 in. (25 mm) over the
jacket extending 0.75 in. (19 mm) over
the barrel.
b. For long barrels, use 2.5 in. (64 mm) of
tubing. Apply 1 in. (25 mm) over the
jacket extending 1.5 in. (38 mm) over
the barrel.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Electrical Components Motors

Motors DC Motor Service

Motor Brushes
Power Cable Terminals
Inspection
Table 7-8. Power Cable Terminal Torques

Location/Stud Figure 7-127. Motor Brush Location

Torque Mtrbrush.tif

Size/Type

Traction Motor Top Nut:

204 to 221 in. lb.
Lift Motor (23 to 25 Nm)
Bottom Nut:
128 to 133 in. lb.
(14.5 to 15 Nm)

Steer Motor 17 in. lb. (1.9 Nm)

95 to 104 in. lb.

Power Amplifiers
(10.7 to 11.8 Nm)

Contactor - M6 steel 50 in. lb. (5.6 Nm)

Contactor - M8 steel 180 in. lb. (20.3 Nm)

Contactor - M8
70 in. lb. (7.8 Nm)
brass/copper

DC Motor Troubleshooting Conduct a partial inspection of the motor

during scheduled maintenance. If the truck is
See “DC Motors” on page 5-10. operated in a severe or caustic environment or
is used in an extended duty cycle application,
inspect the motor more frequently.
AC Motor Troubleshooting
Set up and rigidly adhere to a strict inspection
See “AC Motors” on page 5-14.
schedule to obtain the maximum efficiency
from the electrical equipment.

Each partial inspection of the motor must

include:
1. Inspect the brushes for wear and for
correct contact with the commutator.
Record the level of wear on the brushes.
This history provides an indication of
whether a brush must be changed or if it
can wait until the next inspection. Refer to
Table 7-9, “Minimum Brush Length and
Spring Tension,” on page 7-83 for
acceptable brush length.
NOTE: Overloading a unit is ultimately reflected
in the motor and brush wear; therefore,
you must take this into account when
considering brush replacement.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Motors Electrical Components

2. Check brush spring tension. Refer to 4. Remove the sandpaper.

“Motor Brush Spring Tension”. 5. Blow any dust out of the motor with clean,
3. Clean brushes and holders. Wipe the compressed air at a maximum of 30 psi
commutator with a dry, lint-free cloth. Do (207 kPa).
not use lubricants of any kind on or
around the commutator. Motor Brush Spring Tension
4. Check brush holders for a solid connection
to the mounting support. Tighten the Inspection
mounting screws as necessary. 1. Turn the key switch OFF and disconnect
5. Check the cap screws that hold the brush the battery connector.
cross-connectors to the brush holder 2. Remove the operator compartment covers.
body.
3. Slide the brush up slightly in its holder.
6. Make sure the motor terminals are
secured tightly to the motor frame. Use 4. Insert a paper strip between the brush
care not to strip the threads or crush the face and the commutator. See
insulating parts. See “Power Cable Figure 7-128.
Terminals” on page 7-81.
Figure 7-128. Motor Brush Spring Tension Inspection
7. Check all the cap screws around the frame 8b16032s.eps

for tightness. Spring

Scale
8. Keep the outside frame of the motor clean
and free from dirt. Maintain a free air
passage around the motor to permit heat
radiation.

Replacement
NOTE: If one brush needs replacement, always
replace the entire set of brushes.
Leather
Use only genuine Raymond brushes. Using Loop
another type of brush could cause damage to
the commutator or cause excessive brush wear
and voids your warranty.

If the end of the brush is not already contoured

to fit the commutator, seat the brush to the Paper
commutator:
NOTE: If the motor commutator is not
accessible, form the brush contour
using a brush seating stone.
Rotation
1. Move the motor brush springs out of your
Pull paper in direction of rotation
way.
2. Wrap a piece of 00 sandpaper around the 5. Place a small leather loop around the coil
commutator. Do not use emery cloth to spring for the brush. If the brush spring
seat brushes. has a loop at the brush, hook the spring
scale directly to the spring.
3. Move the brushes back down into their
holders. Rotate the armature until the face 6. Attach a 5 lb. (2.27 kilogram) spring scale
of the brushes are contoured to match the to the leather loop.
curve of the commutator.

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Electrical Components Motors

7. While gently pulling the scale outward, 12. Re-install the brake assembly.
slowly pull the paper strip in the direction 13. Connect the new temperature sensor
that the commutator normally rotates. cable.
8. When the paper strip begins to move 14. Install the terminal board and reconnect
freely, the spring scale will read the spring power cables. Torque motor cable securing
brush tension. nuts to 18 ft. lb. (24 Nm).
9. Refer to Table 7-9 for correct spring 15. Reconnect the battery connector and turn
tension. the key switch ON.
Table 7-9. Minimum Brush Length and Spring Tension
Lift Motor
Motor Min. Brush Length Spring Tension 1. Turn the key switch OFF and disconnect
the battery connector.
40 oz.
Lift 0.62 in. (15.7 mm) 2. Disconnect the temperature sensor
(425 grams)
connector.
Aux and 15 oz.
0.50 in. (13 mm) 3. Remove the four bolts that secure the top
Steer (1134 grams)
end bell to the bottom end bell.
4. Remove the top end bell.
10. Repeat steps 3 thru 9 for the remaining
5. Cut the bad temperature sensor cable.
brushes.
6. Install a new temperature sensor with high
temperature silicone P/N 1034060/SIL.
AC Motor Service Mount the sensor close to the location of
the original.
Temperature Sensor Replacement 7. Re-install the top end bell.
Traction Motor 8. Re-install the four bolts that secure the
top end bell to the bottom end bell.
1. Turn the key switch OFF and disconnect
the battery connector. 9. Connect the new temperature sensor
cable.
2. Remove the brake assembly.
10. Reconnect the battery connector and turn
3. Disconnect the temperature sensor
the key switch ON.
connector.
4. Disconnect motor power cables. Note
locations for reassembly later.
5. Remove the terminal board.
6. Remove the four bolts that secure the top
end bell to the bottom end bell.
7. Remove the top end bell using a puller.
8. Cut the bad temperature sensor cable.
9. Install a new temperature sensor with high
temperature silicone P/N 1034060/SIL.
Mount the sensor close to the location of
the original. Secure the cable with a cable
tie to one of the power leads for stress
relief.
10. Re-install the top end bell.
11. Re-install the four bolts that secure the
top end bell to the bottom end bell.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Steer Amplifier (AC Lift) Electrical Components

Steer Amplifier (AC Lift)

Removal
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove covers as required.

Use correct electrostatic discharge

precautions. See “Static Precautions” on
page 2-7.

3. Disconnect wire from TP4.

4. Remove the contactor/fuse panel cover.
5. Disconnect wire STR-1 from the contactor,
removing cable ties as necessary.
6. Open the Traction Motor compartment.
7. Disconnect the steer motor primary power
wires at A1 and A2 on the motor. Cut cable
ties as needed.
8. Remove steer amplifier mounting bolts.

Installation
1. Install steer amplifier to frame.
2. Route steer motor wires to steer 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
cover, primary control handle cover, right
side cover, and front cover. Close the
Traction Motor compartment door.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Electrical Components Cold Storage Conditioning

Cold Storage Treat the following parts to prevent moisture

from entering:
Conditioning • TS3 - located on left side of tractor
bulkhead
NOTE: Conversion of Model 7500/7520 lift • TS2 - located on top of reach carriage
trucks for cold storage operation
• Deadman switch terminals
requires prior Raymond approval via
Form S207. • Proportional valve (SOL2) terminals

Model 7500/7520 lift trucks to be operated in a Corrosion Inhibitor Coating

cold storage environment require the following:
Coat or spray bare metal surfaces listed below
Components with Corrosion Inhibitor Coating (P/N 990-644):

• All-weather hydraulic fluid (P/N 1017238) • Reach cylinder cotter pins

• Main and free lift chain pulleys and shafts
NOTE: Do not add any additives to this
hydraulic fluid. • Main and free lift chain anchors and
threaded pins
• Ambient temperature sensor
• Drive unit dipstick
• Special cold storage control handle
assemblies with heaters
• Wire mesh mast guard
Condensation Drip Guard
• Suggested on fore/aft stance trucks: To add the control handle condensation drip
Condensation drip guard (P/N 1036240) guard (P/N 1036240) to the overhead guard of
• Optional heated floor pad Fore/Aft stance lift trucks, do the following:
1. Remove from the overhead guard the
Lubricants right-hand lower hex head cap screw,
located almost directly above the control
See the “Lubrication Specification Chart” on handle.
page A-2 for special hydraulic fluid and drive 2. Install an M16 flat washer onto the cap
unit lubricants for cold storage operation. screw.
3. Reinstall the cap screw with flat washer
Coat battery roller shafts with all-weather and drip guard. See Figure 7-129.
grease (P/N 1012992).
Figure 7-129. Condensation Drip Guard
Lubricate carriage fittings with all-weather RCH_05_002.tif

grease (P/N 1012992).

Sealing Treatment
Fill sockets and the front and back of both
halves of unsealed connectors with cold storage
sealing compound (P/N 990-445). Connect
wires and connectors. Coat the outside and
where connectors attach to the circuit board.
Coat terminals and terminal strips.
NOTE: Self-sealing AMP connectors (reference
page 7-73) do not need sealing
treatment.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Cold Storage Conditioning Electrical Components

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components

Hydraulic Components
Section 7. Component Procedures

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Hydraulic System Bleeding Hydraulic Components

Hydraulic System Figure 7-131. Bleed Screw, Main Lift Cylinder Piston Cap
7bleederfree.JPG

Bleeding
You must bleed the hydraulic system to remove
any trapped air whenever you: Bleed Screw
• change a hydraulic hose
• disconnect a hydraulic fitting
• remove a hydraulic cylinder
• remove the hydraulic pump
• remove the hydraulic reservoir
Main Lift Cylinder
• notice that the load is bouncing Piston Cap
7. Repeat steps 4 and 5 for each of the two
Procedure free lift cylinders.

1. Elevate the fork carriage past free lift and Figure 7-132. Bleed Screw, Free Lift Cylinder
lower it to the floor. Repeat several times. 7bleederfree.JPG

2. Elevate the forks 2 to 3 in. (5 to 7.5 cm) off

the floor.
3. Turn the key switch OFF and disconnect
the battery connector.
Bleed Screw
4. Loosen (do not remove) the bleed screw at
the top of the main lift cylinder. Hold a rag
close to and beneath the bleed screw to
keep hydraulic fluid from spraying out.

Figure 7-130. Bleed Screw, Main Lift Cylinder 8. Reconnect the battery connector and turn
7bleedermain.JPG
the key switch ON.
9. Lower the forks all the way down to the
floor.
10. Fully extend and retract the reach
mechanism several times.
11. If the truck is equipped with tilt, tilt the
carriage all the way forward and backward
several times.
Bleed Screw
12. If the truck is equipped with sideshift,
shift the carriage all the way to the left and
right several times.
5. When hydraulic fluid starts flowing from 13. DC Lift - Step on the deadman pedal and
the bleed screw hole, securely tighten the turn the steering wheel from stop to stop
bleed screw. for approx. 2 minutes.
6. Repeat steps 4 and 5 for the other main lift 14. Thoroughly clean up any spilled hydraulic
cylinder. fluid.
NOTE: Main lift cylinders also have a bleed 15. Check the hydraulic reservoir level and
screw located in the piston cap at the refill as necessary. Do not overfill the
top of the cylinder. reservoir.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components Hydraulic Filter

Hydraulic Filter 8. Securely install filter housing cap.

DC Lift
AC Lift
1. Remove the top cover. Removal
2. If you have not drained the reservoir, 1. Remove the top cover.
elevate the carriage to lower the hydraulic
2. If you have not drained the reservoir,
fluid level and minimize hydraulic fluid
elevate the carriage to lower the hydraulic
leakage.
fluid level and minimize hydraulic fluid
3. Turn the key switch OFF and disconnect leakage.
the battery connector.
3. Turn the key switch OFF and disconnect
4. Remove filter housing cap. See the battery connector.
Figure 7-133.
4. Remove the plug retaining the hydraulic
Figure 7-133. Filter Housing - AC Lift fluid filter, using a 3/4 in. socket.

Figure 7-134. Filter Plug

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
5. Remove the filter element and filter if necessary.
housing assembly as a unit from the tank.
To ensure contaminants are not Installation
re-introduced to the hydraulic system, DO
1. Install the cartridge core into the manifold
NOT dislodge the filter element from the
making sure the core seats correctly into
housing directly over the reservoir. Allow
the nose of the cavity.
residual oil to drip back into the tank and
move the entire assembly away from the
reservoir.
6. Invert the housing assembly and remove
the filter element.
7. Install the new element. Re-install filter
housing assembly in reservoir.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Hydraulic Filter Hydraulic Components

Figure 7-135. Cartridge Core

2. Install the new filter cartridge onto the

cartridge core.

Figure 7-136. 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.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components Lift Pressure Adjustment

Lift Pressure Adjustment greater than that required to lift the

maximum rated load (the value recorded
in Step 8). Turn the adjusting screw
See Table 7-10 for maximum lift pressures. clockwise to increase pressure,
counterclockwise to decrease pressure.
Table 7-10. Maximum LIft Pressures
For maximum permissible lift pressure,
Model/Mast Maximum Lift Pressure
see Table 7-10.
7500/R35TT 13. Tighten the lock nut on the lift pressure
7500/R45TT 3300 psi (22,753 kPa) relief valve (RV-5).
14. Check the pressure again. If the value has
7520/R45TT
changed, repeat this procedure until the
7500/DR32TT correct pressure reading is obtained.
3600 psi (24,821 kPa) 15. Turn the key switch OFF and disconnect
7520/DR32TT
the battery connector.
16. Remove the pressure gauge from the lift
NOTE: Lift pressure is set by software in AC lift pressure test port and replace the cap.
trucks without regenerative lower. 17. Reinstall the top cover. Reconnect the
battery connector and turn the key switch
AC Lift with Regen Lower ON.

1. Lower the carriage completely. Disable any 18. Enable any lift cutout or lift deceleration
lift cutout or lift deceleration options. options that were disabled in Step 1. Verify
truck operation.
2. Turn the key switch OFF and disconnect
the battery connector.
3. Remove the top cover.
DC Lift
4. Remove the cap from the G1 lift pressure 1. Lower the carriage completely.
test port on the lift/lower manifold. See 2. Turn the key switch OFF and disconnect
page 7-97. the battery connector.
5. Connect a pressure gauge capable of 3. Remove the top cover.
reading at least 5000 psi (34,470 kPa).
4. Remove the cap from the G1 lift pressure
6. Reconnect the battery connector and turn test port on the main manifold. See “Main
the key switch ON. Manifold - DC Lift” on page 7-99.
7. Place the maximum rated load on the 5. Connect a pressure gauge capable of
forks. reading at least 5000 psi (34,470 kPa).
8. Elevate the carriage past free lift (until the 6. Reconnect the battery connector and turn
telescopics begin to lift). Record the the key switch ON.
pressure required to lift the load.
7. Place the maximum rated load on the
9. Lower the carriage and remove the load. forks.
10. Loosen the lock nut on the main lift 8. Elevate the carriage past free lift (until the
pressure relief valve (RV-5) on the telescopics begin to lift). Record the
lift/lower manifold. See page 7-97. pressure required to lift the load.
11. Elevate the carriage until the upper limit is 9. Lower the carriage and remove the load.
reached.
10. Loosen the lock nut on the main lift
12. Continue trying to elevate and turn the pressure relief valve (REL1) on the main
relief valve adjusting screw to obtain a manifold. See “Main Manifold - DC Lift” on
pressure reading 200 psi (1379 kPa) page 7-99.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Lift Pressure Adjustment Hydraulic Components

11. Elevate the carriage until the upper limit is

reached.
12. Continue trying to elevate and turn the
relief valve adjusting screw to obtain a
pressure reading 200 psi (1379 kPa)
greater than that required to lift the
maximum rated load (the value recorded
in Step 8). Turn the adjusting screw
clockwise to increase pressure,
counterclockwise to decrease pressure.

For maximum permissible lift pressure,

see Table 7-10.
13. Tighten the lock nut on the lift pressure
relief valve (REL1).
14. Check the pressure again. If the value has
changed, repeat this procedure until the
correct pressure reading is obtained.
15. Turn the key switch OFF and disconnect
the battery connector.
16. Remove the pressure gauge from the lift
pressure test port and replace the cap.
17. Reinstall the top cover. Reconnect the
battery connector and turn the key switch
ON.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components Manual Lowering of Fork Carriage

Manual Lowering of AC Lift - Regen Lower

Fork Carriage 1. Manually open the needle valve NV-1. See
“Lift/Lower Manifold - AC Lift with Regen
Lower” on page 7-97.
If the fork carriage is hung up and unable to be
2. After making necessary repairs to the lift
lowered normally, use the following procedure
truck, close NV-1.
to lower the carriage.
NOTE: Make sure the forks and carriage are
free from racks and other obstructions
DC Lift
before lowering. 1. Turn the key switch OFF and disconnect
the battery connector.
AC Lift - Standard 2. Loosen and remove the lock nut on the
main relief valve REL1. See “Main Manifold
1. Manually open the load holding valve - DC Lift” on page 7-99. Note the number
SOL1. See “Main Manifold - Standard AC of threads exposed on the lift pressure
Lift” on page 7-96. On the top of SOL1 is a relief valve.
small knurled knob. Depress the knob and
turn counterclockwise until the knob pops 3. Turn the lift pressure adjusting screw
up. slowly counterclockwise until the fork
carriage begins to lower.
2. If there is power on the lift truck, try to
lower by using the lift/lower knob. 4. When you have resolved the cause of the
hung carriage, you must reset the lift
a. If this is successful, go to step 4. pressure.
b. If this is unsuccessful, continue to the 5. Turn the lift pressure adjusting screw
next step. clockwise until the same number of
3. Manually adjust the proportional lift/lower threads are exposed as you noted in
valve SOL2 to cause the carriage to lower. step 2.
a. Loosen the lock nut on top of SOL2. 6. Install, but do not tighten, the lock nut on
the relief valve.
b. Using a hex-key wrench, adjust the
brass adjustment screw clockwise until 7. Perform the procedure to adjust lift
the carriage begins to move. pressure. See “Lift Pressure Adjustment”
on page 7-91.
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 7-94.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Proportional Valve Adjustment Hydraulic Components

Proportional Valve
Adjustment
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 “Main Manifold - Standard AC Lift” on
page 7-96 or “Main Manifold - DC Lift” on
page 7-99. 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 approx. 9 to 10% request.
12. Reinstall the top cover.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components Auxiliary Pressure Adjustment

Auxiliary Pressure
Adjustment
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 (RV-4) on the Main manifold
(non-regen) or Aux manifold (regen lower).
See Figure 7-137 on page 7-96 or
Figure 7-139 on page 7-98.
4. Remove the cap from the G2 test port on
the 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 lock nut 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.

DC Lift
Auxiliary pressure is fixed at 1800 psi
(12,410 kPa) on trucks with DC Lift. There is no
pressure adjustment.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Main Manifold - Standard AC Lift Hydraulic Components

Main Manifold -
Standard AC Lift
The main manifold, located on the tractor deck, controls lift/lower and aux functions. For torque
values, see Table 7-11 on page 7-104.

Figure 7-137. Main Manifold, Standard AC Lift

A1

G2 port
Tank

G1 port
SOL1
(manual lower valve) CV-1

SOL2 RV-4 SOL3

CYL-1 HTI (optional)

CYL-P
A2

LS-1

P1
SOL5

POD-1

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components Lift/Lower Manifold - AC Lift with Regen Lower

Lift/Lower Manifold - AC
Lift with Regen Lower
The main manifold, located on the tractor deck, controls lift/lower functions on trucks equipped
with regenerative lower. For torque values, see Table 7-12 on page 7-104.

Figure 7-138. Main Manifold, AC Lift - Regen Lower

SOL1

CV-6
CYL-P

CYL-1

NV-1
(manual lower valve)

P1
CV-5

G1 port

SOL2

RV-5

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Aux Manifold - AC Lift with Regen Lower Hydraulic Components

Aux Manifold - AC Lift

with Regen Lower
The aux manifold, located above the steer motor, controls aux functions on trucks equipped with
regenerative lower. For torque values, see Table 7-13 on page 7-104.

Figure 7-139. Aux Manifold, AC Lift - Regen Lower

EP-1

G2 port
A1
HTI (optional)
A2

P2 G4 port

SOL5B/SOL5T

RV-4

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components Main Manifold - DC Lift

Main Manifold - DC Lift

The main manifold, located on the tractor deck, controls lift/lower and aux functions. For torque
values, see Table 7-14 on page 7-105.

Figure 7-140. Main Manifold, DC Lift

A2 A1 Hydraulic
CV-2 P2 Fore/Aft
Filter
P2 Dockstance

CYL-1

SOL5
SOL4

SOL2
CV-1

CYL-P

SOL1

LS-1
G2 port
REL-1 (manual lower valve)

S-RET
P2

PWR BYND

TANK

CE-1

HTI CASE DRAIN SOL8 LS-1 SOL5

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Aux Manifold (Standard Reach) Hydraulic Components

Aux Manifold (Standard

Reach)
The aux manifold, located on the fixed portion of the carriage, controls reach, tilt, and sideshift
functions. For torque values, see Table 7-15 on page 7-105.

Figure 7-141. Aux Manifold (Standard Reach)

Sideshift Reach
Solenoid Solenoid

Tilt
Solenoid

SSR

A1

A2

SSL TR

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components Aux Manifold (Standard Reach)

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 cannot 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 approx. 2.5 ft. 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 7-88.
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
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 7-15 on
page 7-105.
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).

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Deep-Reach ® Manifold Hydraulic Components

Deep-Reach ® Manifold
The deep-reach manifold, located on the fixed portion of the carriage, controls the reach function on
Deep-Reach equipped trucks. For torque values, see Table 7-16 on page 7-105.

Figure 7-142. Deep-Reach Manifold

CB-1 CB-2 REL-3

Reach Solenoid

RR

CV-3 RC

Removal 3. Position the manifold and connect all the

hydraulic hoses.
1. Reach the carriage out and lower to the
4. Reconnect the solenoid wires.
floor. Block the reach mechanism so that
the scissors cannot retract. 5. Mount the manifold to the scissors.
2. Turn the key switch OFF and disconnect 6. Reconnect the battery connector and turn
the battery connector. the key switch ON.
3. Remove the two manifold mounting bolts 7. Remove the blocking.
to gain access to all hydraulic fittings. 8. Bleed the hydraulic system. See
4. Label as required all the solenoid wires “Hydraulic System Bleeding” on page 7-88.
and remove. 9. Test the auxiliary functions for correct
5. Disconnect and cap all hydraulic hoses. operation and check connections for leaks.
Note the location of each of the hoses.
6. Remove the manifold from the truck.

Installation
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.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components Tilt/Sideshift Manifold (Deep-Reach ®)

Tilt/Sideshift Manifold
(Deep-Reach ®)
The tilt/sideshift manifold, located on the reach carriage, controls tilt and sideshift functions on
Deep-Reach equipped trucks. For torque values, see Table 7-17 on page 7-105.

Figure 7-143. Tilt/Sideshift Manifold (Deep-Reach)

Tilt
Solenoid

Sideshift
Solenoid

Refer to Parts Manual for “Tilt Only” Manifold

Removal 4. Connect the hydraulic hoses.

5. Connect the wiring to the solenoids.
1. Reach the fork carriage out and fully lower
to the floor. 6. Reconnect the battery connector and turn
the key switch ON.
2. Tilt the forks fully down.
7. Bleed the hydraulic system. See
3. Turn the key switch OFF and disconnect
“Hydraulic System Bleeding” on page 7-88.
the battery connector.
8. Test the auxiliary functions for correct
4. Disconnect the wiring for the solenoids.
operation and check 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
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.
3. Mount the manifold to the carriage.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Manifold Port Torque Specifications Hydraulic Components

Manifold Port Torque

Specifications
Tables 7-11 thru 7-17 provide torque specifications for manifold components.

Table 7-11. Main Manifold - Standard AC Lift Table 7-12. Lift/Lower Manifold - AC Lift with Regen Lower
Solenoid/ Torque Solenoid/ Torque
Attachment/Fitting ft. lb. (Nm) Attachment/Fitting ft. lb. (Nm)

A1 & A2 21 (28) CYL-1 55 (75)

CV-1 Check Valve 50 (68) CYL-P Pressure Transducer 12 (16)

CYL-1 55 (75) CV-5 Check Valve 30 (41)

CYL-P Pressure Transducer 12 (16) CV-6 Check Valve w/locking

50 (68)
tab
G1 & G2 ports 21 (28)
G1 port 21 (28)
HTI Pressure Switch 12 (16)
NV-1 (manual lower) 30 (41)
LS-1 Load Shuttle 20 (27)
P1 55 (75)
P1 55 (75)
RV-5 30 (41)
POD-1 Priority on Demand 35 (47)
SOL1 Load Holding w/locking 50 (68)
REL-2 Aux Relief 25 (34) tab coil nut: 5 (6.8)
Return (Suction) to Pump 55 (75) SOL2 Lift/Lower w/locking 95 (129)
tab coil nut: 0.5 (0.7)
RV-4 25 (34)

S-RET 21 (28)
Table 7-13. Aux Manifold - AC Lift with Regen Lower
SOL1 Load Holding w/locking 50 (68)
Solenoid/ Torque
tab (manual lower) coil nut: 5 (6.8)
Attachment/Fitting ft. lb. (Nm)
SOL2 Lift/Lower Proportional 95 (129)
A1 & A2 21 (28)
(Run Learn Lower) coil nut: 0.5 (0.7)
EP-1
SOL3 Proportional Main 25 (34)
Relief/Dump coil nut: 5 (6.8) G2 and G4 ports 21 (28)
20 (27) HTI Pressure Switch 12 (16)
SOL5B/5T Aux
coil nut: 5 (6.8)
P2 55 (75)
TANK 55 (75)
RV-4 25 (34)

20 (27)
SOL5B/5T Aux
coil nut: 5 (6.8)

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components Manifold Port Torque Specifications

Table 7-14. Main Manifold - DC Lift Table 7-15. Aux Manifold - Standard Reach
Solenoid/ Torque Solenoid/ Torque
Attachment/Fitting ft. lb. (Nm) Attachment/Fitting ft. lb. (Nm)

A1 & A2 21 (28) A1 & A2 15 (20)

Case Drain 12 (16) CV 25 (34)

CE1 Compensating Element 25 (34) 20 (27)

Reach Solenoid
coil nut: 5 (6.8)
CV-1 Check Valve 35 (47)
RC and RR 15 (20)
CV-2 Check Valve 20 (27)
20 (27)
CYL-P Pressure Transducer 12 (16) Tilt Solenoid
coil nut: 5 (6.8)
CYL-1 55 (75) TC and TR 15 (20)
Filter Plug 30 (41) 20 (27)
Sideshift Solenoid
coil nut: 5 (6.8)
G2 port 21 (28)
SSR and SSL 15 (20)
HTI Pressure Switch 12 (16)

LS-1 Load Shuttle 20 (27)

Table 7-16. Deep Reach Manifold
P2
21 (28) Solenoid/ Torque
PWR BYND Attachment/Fitting ft. lb. (Nm)

REL-1 Main Relief 25 (34)

25 (34) Reach Solenoid
(manual lower) coil nut: 5 (6.8)

S-RET 21 (28) RC and RR 15 (20)

35 (47) REL-3 30 (41)

SOL1 Load Holding
coil nut: 5 (6.8)
CV-3 25 (34)
SOL2 Lift/Lower Proportional 95 (129)
CB-1 and CB-2 35 (47)
(Run Learn Lower) coil nut: 0.5 (0.7)

20 (28)
SOL4 2d Pump Table 7-17. Tilt/Sideshift Manifold - Deep Reach
coil nut: 5 (6.8)
Solenoid/ Torque
25 (34)
SOL5B/5T Aux Attachment/Fitting ft. lb. (Nm)
coil nut: 5 (6.8)
A1 & A2 15 (20)
20 (27)
SOL8 Aux Dump
coil nut: 5 (6.8) 20 (27)
Tilt Solenoid
coil nut: 5 (6.8)
TANK 55 (75)
TC and TR 15 (20)

20 (27)
Sideshift Solenoid
coil nut: 5 (6.8)

SSR and SSL 15 (20)

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Manifold Port Torque Specifications Hydraulic Components

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components, Cylinder

Hydraulic Components, Cylinder

Section 7. Component Procedures

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Lift Cylinder, Free Lift, Remove/Install Hydraulic Components, Cylinder

Lift Cylinder, Free Lift, fittings to prevent contamination from

entering the system.
Remove/Install NOTE: Place a pan below the main frame to
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 7-127.
not to damage the hoses and cable.
5. Using a suitable lifting device, lift the 1. Install the flow control, fitting, and feed
carriage to relieve the tension on the lift hose at the bottom of the cylinder.
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
cylinder. 10. Reconnect the battery connector and turn
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
12. Disconnect the hydraulic line at the there is correct clearance between the
bottom of the cylinder. Plug and cap the

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Remove/Install

bracket, hoses/cable, and the front plate NOTE: Place a pan below the main frame to
of the tractor. catch any hydraulic fluid when the line
13. Bleed the hydraulic system. See is disconnected.
“Hydraulic System Bleeding” on page 7-88. 12. Remove the set screw at the bottom of the
14. Check the truck for leaks and correct cylinder.
operation. 13. Position the carriage at an appropriate
15. Install the mast guard. height to permit removal of the cylinder.
14. Using a suitable lifting device, remove the
Right Side Free Lift Cylinder cylinder.

Removal Installation
1. Remove the upper eyelet retainer pin. 1. Position the cylinder into the truck.
2. Install the upper eyelet retainer pin.
NOTE: You can gain easier access by raising the
telescopics. 3. Position and block carriage to permit
access to bottom of the cylinder.
2. Fully lower the forks to the floor.
4. Install the set screw at the bottom of the
3. Turn the key switch OFF and disconnect cylinder.
the battery connector.
5. Connect the hydraulic line at the bottom of
4. Remove the mast guard. the cylinder.
5. Using a suitable lifting device, lift the 6. Lift the carriage assembly to provide slack
carriage to relieve the tension on the lift to install the free lift chain.
chain.
7. Install the ring adapter. Apply
6. Remove the master link from the free lift thread-locking compound (P/N 1013829)
chain at the free lift anchor bolt. to the mounting bolt threads and install
7. Remove and drape the chain over the the pulley bracket assembly to the piston.
carriage assembly. 8. Install the chain pulley and the free lift
NOTE: Twist the pulley assembly to permit the chain.
removal of the chain. 9. Lower the carriage and remove the lifting
8. Remove the chain pulley to access the device.
pulley bracket assembly mounting bolt. 10. Reconnect the battery connector and turn
9. Remove the pulley bracket assembly and the key switch ON.
ring adapter. 11. Bleed the hydraulic system. See
10. Using the lifting device, lift and block the “Hydraulic System Bleeding” on page 7-88.
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.
11. Disconnect the hydraulic line at the
bottom of the cylinder. Plug and cap the
fitting to avoid contamination from
entering the system.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Lift Cylinder, Free Lift, Seal Repacking Hydraulic Components, Cylinder

Lift Cylinder, Free Lift, and lifting the cylinder with the use of a
hoist.
Seal Repacking 10. On a clean work surface, remove the wiper
seal, packing seal, O-rings, and backup
ring from the gland. Note the position and
AC Lift orientation of each when removing.
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
mechanism in the free lift cylinders in addition 12. Clean the gland.
to a cushion at the bottom of the cylinder. 13. Inspect the inside of the housing for
1. Remove the mast guard. damage and clean as required.

2. Lower the carriage onto a suitable block

and fully lower cylinder to relieve the Reassembly
tension on the hoses, cable, and free lift 1. If the piston was removed, install the
chains. piston and the three staging zone
3. Turn the key switch OFF and disconnect mechanism stop screws that were removed
the battery connector. in step 8 of the disassembly procedure.
4. Remove the free lift chain master link at 2. Lubricate the wiper seal, packing seal,
the free lift cylinder anchor bolt and lay O-rings, and backup ring with new
the chain over the carriage. hydraulic fluid and install into their
respective grooves on the gland. Make sure
NOTE: Twist the right side pulley to remove the
they are correctly positioned.
chain from the pulley.
3. Install the pressure ring with the seal
5. Remove the chain pulley to access the towards the open end of the housing. See
pulley bracket mounting bolt. Figure 7-143.
6. Remove the pulley bracket assembly. Set
the left side to one side, keeping the hoses Figure 7-143. Pressure Ring Orientation
7RPIN06005.jpg
and cable in place.
7. For 3 in. 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.
NOTE: Mark the hoses and cable to ensure
correct stretch when re-assembled.
9. Remove the snap ring and gland.
NOTE: When the snap ring is removed, a spring
behind the packing plug should push 4. Apply lubricant (P/N 990-652) to the
the gland out of the housing. outside surface of gland.
5. Lubricate the piston rod with new
NOTE: If necessary, use the piston to extract
hydraulic fluid. Carefully slide the gland
the gland by removing the three staging over it.
zone stop screws and the bleeder screw

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Seal Repacking

6. Using the seal installation driver 5. Remove the chain pulley to access the
(P/N 401-000-051), push the gland into pulley bracket mounting bolt.
the housing and compress the spring. 6. Remove the pulley bracket assembly. Set
7. Apply a film of lubricant (P/N 990-652) to the left side to one side, keeping the hoses
the top of the gland and housing to and cable in place.
prevent moisture entry. 7. For 3 in. lowered height option, remove the
8. Install the snap ring inside the housing. adapter ring.
Make sure that the snap ring is fully 8. Using cylinder end cap tool (P/N A9587),
seated in the groove. remove the end cap (gland).
9. Wipe away any excess hydraulic fluid. 9. On a clean work surface, remove the
10. Tighten the upper OTM retainer, if piston seal, wiper seal, and square seal
previously loosened. from the end cap. Note the position and
11. For 3 in. lowered height option, install the orientation of each when removing.
adapter ring. 10. Inspect the surfaces of the gland for any
12. Apply thread-locking compound scratches or damage. Use fine emery cloth
(P/N 1013829) to the threads of the to remove minor imperfections.
mounting bolt and install the pulley 11. Clean the threads on the gland and the
bracket assembly. cylinder.
13. Install the chain pulley and the free lift 12. Inspect the inside of the housing for
chain. damage and clean as required.
14. Reconnect the battery connector and turn
the key switch ON. Reassembly
15. Remove the block from beneath the 1. Lubricate with new hydraulic fluid, the
carriage. piston seal, wiper seal, and square seal
16. Bleed the hydraulic system. See and install into their respective grooves on
“Hydraulic System Bleeding” on page 7-88. the gland. Make sure they are correctly
17. Check the truck for leaks and correct seated within the grooves and not twisted.
operation. 2. Apply thread-locking compound
18. Install the mast guard. (P/N 990-571) to the threads of the gland.
3. Lubricate the piston rod with new
hydraulic fluid, and carefully install the
DC Lift gland.
4. Torque the end cap to 200 ft. lb. (271 Nm).
Disassembly
5. For 3 in. lowered height option, install the
1. Remove the mast guard. adapter ring.
2. Lower carriage onto a suitable block and 6. Apply thread-locking compound
fully lower cylinder to relieve tension on (P/N 1013829) to the threads of the
the hoses, cable, and free lift chains. mounting bolt and install the pulley
3. Turn the key switch OFF and disconnect bracket assembly.
the battery connector. 7. Install the chain pulley and the free lift
4. Remove the free lift chain master link at chain.
the free lift cylinder anchor bolt and lay 8. Reconnect the battery connector and turn
the chain over the carriage. the key switch ON.
NOTE: Twist the right side pulley to remove the 9. Remove the block from beneath the
chain from the pulley. carriage.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Lift Cylinder, Free Lift, Seal Repacking Hydraulic Components, Cylinder

10. Bleed the hydraulic system. See

“Hydraulic System Bleeding” on page 7-88.
11. Check the truck for leaks and correct
operation.
12. Install the mast guard.

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Models 7500/7520 Reach-Fork ® Trucks 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
Left Side Main Lift Cylinder cylinder from the truck.

Removal Installation
1. Remove mast guard, top cover, and left
1. Install the fitting and feed hose at the
front cover.
bottom of the cylinder.
2. Remove the retainer bolt at the bottom of
2. Attach the mast guard bracket onto the
the cylinder.
cylinder.
3. Place a block approx. 18 in. long between
3. Position the cylinder into the truck.
the inner telescopic crosstie and the outer
telescopic crosstie. Place a block approx. 4. Apply thread-locking primer
12 in. (305 mm) in length between the (P/N 990-666) to both the right and left
outer telescopic crosstie and the main mast mounting bolt threads and the hole
frame crosstie. threads. Permit to dry for several minutes.
Apply thread-locking compound
NOTE: This provides the necessary hose/cable (P/N 990-544) to the threads of the mast
slack and clearance to remove the mounting bolts. Install the mast connector
cylinder. and torque the bolts to 160/170 ft. lb.
4. Fully lower the carriage. (217/230 Nm).
5. Turn the key switch OFF and disconnect 5. Install the mast connector snap ring.
the battery connector. Remove battery. 6. Remove the jack.
6. Remove the bolt, washer, and spacer at the 7. Connect the feed hose at the bulkhead
top of the piston. fitting.
7. Remove the cylinder mounting 8. Attach the OTM hose/cable retainer
L-bracket(s). bracket to the cylinder.
NOTE: Models with an OACH of 131 in. 9. Install the cylinder mounting L-bracket(s)
(333 cm) and above have two brackets. with sleeves and bolts. Do not tighten at
this time.
8. Remove the OTM hose/cable retainer
bracket from the cylinder. 10. Install battery. Reconnect the battery
connector and turn the key switch ON.
9. Place a pan below the tractor and
disconnect the cylinder feed hose at the 11. Carefully rotate the lift knob to raise the
tractor bulkhead fitting. piston to the telescopic crosstie.

NOTE: The feed hose can remain connected to 12. Install the bolt, washer, and spacer at the
the bottom of the cylinder to assist in crosstie to the top of the piston.
removal. 13. Apply thread-locking compound
(P/N 1013829) to the threads and tighten,
10. From inside the battery compartment,
leaving a 0.12 in. (3 mm) gap between the
loosen the right side mast connector
head of the bolt and the washer.
mounting bolts.
14. Tighten the cylinder mounting L-bracket
11. Remove the left side mast bolts and the
bolts to 55 ft. lb. (75 Nm).
mast connector snap ring.
15. Remove the blocks from the telescopics
and the main frame.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

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 page 7-88. 12. Remove the connector.
18. Check for leaks and correct operation. 13. Using a suitable lifting device, remove the
19. Install the mast guard, top cover, and left cylinder from the truck.
front cover.
Installation
Right Side Main Lift Cylinder NOTE: The right side main lift cylinder houses
a flow limiter located in the manifold
Removal block at the bottom of the cylinder. See
“Flow Limiter, Main Lift” on page 7-125.
1. Remove mast guard, top cover, and right
front cover. 1. Install the flow control, fitting, and feed
hose at the bottom of the cylinder.
2. Elevate telescopics and remove the
retainer bolt at bottom of cylinder. 2. Attach mast guard bracket to cylinder.

3. Place a block at least 12 in. (305 mm) in 3. Position the cylinder into the truck.
length between the main frame and the 4. Apply thread-locking primer
outer telescopic crosstie and fully lower (P/N 990-666) to mast mounting bolt
the carriage. threads and the hole threads. Permit to
dry for several minutes. Apply
NOTE: This length provides the clearance
thread-locking compound (P/N 990-544)
required to remove the cylinder.
to the threads of the mast mounting bolts.
4. Fully lower the carriage. Install the mast connector and torque the
5. Turn the key switch OFF and disconnect bolts to 160/170 ft. lb. (217/230 Nm).
the battery connector. 5. Install the mast connector snap ring.
6. Remove the bolt, washer, and spacer at the 6. Remove the jack from the truck.
top of the piston and outer telescopic 7. Connect the feed hose at the tractor
crosstie. bulkhead fitting.
7. Remove the cylinder mounting 8. Install the cylinder mounting L-bracket(s)
L-bracket(s). with sleeves and bolts. Do not tighten at
NOTE: Models with an OACH of 131 in. this time.
(333 cm) and above have two upper 9. Install the retainer bolt at the bottom of
brackets. the cylinder.
8. Place a pan below the tractor. Disconnect 10. Reconnect the battery connector and turn
the cylinder feed hose at the tractor the key switch ON.
bulkhead. Plug and cap the fittings to 11. Carefully rotate the lift knob to raise the
prevent contamination from entering the piston to the telescopic crosstie.
system.
12. Install the bolt, washer, and spacer at the
NOTE: The feed hose can remain connected to crosstie to the top of the piston.
the cylinder to assist in removal of the
cylinder. NOTE: Install thread-locking compound
(P/N 1013829) to bolt threads and
9. From inside the battery compartment, tighten, leaving a 0.12 in. (3 mm) gap
loosen the left side mast bolts. between head of the bolt and washer.
10. Remove the right side mast bolts and the 13. Tighten the cylinder mounting L-bracket
mast connector snap ring. bolts to 55 ft. lb. (75 Nm).

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components, Cylinder Lift Cylinder, Main, Remove/Install

14. Remove the block from between the

telescopic and the main frame.
15. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on page 7-88.
16. Check the truck for leaks and correct
operation.
17. Install the mast guard, top cover, and right
front cover.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Lift Cylinder, Main, Seal Repacking Hydraulic Components, Cylinder

Lift Cylinder, Main, Seal 6. Carefully rotate the lift knob to raise the
piston to the telescopic crosstie.
Repacking 7. Install the bolt, washer, and spacer at the
crosstie to the top of the piston.

Disassembly NOTE: Apply thread-locking compound

(P/N 1013829) to the threads of the bolt
1. Slightly elevate the mast and place a block and tighten, leaving a 0.12 in. (3 mm)
between the outer telescopic crosstie and gap between the head of the bolt and the
the main frame. washer.
2. Fully lower the carriage. 8. Remove the block from between the outer
3. Turn the key switch OFF and disconnect telescopic crosstie and the main frame.
the battery connector. 9. Bleed the hydraulic system. See
4. Remove the bolt, washer, and spacer at the “Hydraulic System Bleeding” on page 7-88.
top of the piston and the outer telescopic 10. Check the truck for leaks and correct
crosstie. operation.
5. Retract the piston into the housing enough
to allow the removal of the end cap (gland).
6. Using cylinder end cap tool (P/N A9587),
remove the end cap (gland).
7. On a clean working surface, remove the
packing seal, wiper seal, and square seal
from the end cap. Note position and
orientation of each when removing.
8. Inspect the surfaces of the gland for any
scratches or damage. Remove minor
imperfections using fine emery cloth.
9. Inspect the inside of the housing for
damage and clean as required.
10. Clean the threads on the gland and the
cylinder.

Reassembly
1. Lubricate with new hydraulic fluid, the
packing seal, wiper seal, and square seal,
and install into their respective grooves on
the gland. 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.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components, Cylinder Lift Cylinder Lowering Cushion

Lift Cylinder Lowering 4. Compress the spring and hold it in place

with a drill bit or drift pin inserted in one
Cushion of the hydraulic fluid ports in the cushion
housing.
5. Install the snap ring.
Main Lift Cylinders 6. Carefully release cushion pressure.
7. Reassemble the cylinder. See “Lift
Removal
Cylinder, Main, Seal Repacking” on
1. Remove the main lift cylinder. Refer to page 7-116.
page 7-113. 8. Install the cylinder. Refer to page 7-113.
2. Remove the piston rod from the cylinder.
See “Lift Cylinder, Main, Seal Repacking” Free Lift Cylinders - AC Lift
on page 7-116.
3. Place the piston rod on a clean padded Removal
working surface.
4. Compress the spring and hold it in place Trucks with AC lift have a staging zone
with a drill bit or drift pin inserted in one mechanism in the free lift cylinders in addition
of the hydraulic fluid ports in the cushion to a cushion at the bottom of the cylinder.
housing.
1. Using an eye bolt and hoist, remove the
piston rod from the cylinder.
2. Perform steps 1 thru 9 of “Lift Cylinder,
When the snap ring is removed, the Free Lift, Seal Repacking”, “AC Lift”,
cushion spring ejects the cushion from “Disassembly” on page 7-110.
the piston. Keep body away from the 3. Place the piston rod on a clean padded
piston end when performing this working surface.
procedure.
4. Compress the spring and hold it in place
5. Remove the snap ring from inside of the with a drill bit or drift pin inserted in one
cylinder. of the hydraulic fluid ports in the cushion
housing.
6. Release the cushion slowly.
7. Remove the ring retainer and seal from the
cushion.
When the snap ring is removed, the
8. Replace the cushion, spring, seal, and/or
cushion spring ejects the cushion from
retainer components as necessary. If
the piston. Keep body away from the
replacing the cushion, install the cap
piston end when performing this
screw in the end of the cushion.
procedure.

Reassembly 5. Remove the snap ring from inside of the

cylinder.
1. Lubricate the inside of the piston surface
with clean hydraulic fluid. 6. Release the cushion slowly.
2. Lubricate the seal with clean hydraulic 7. Remove the retaining ring and the two
fluid and install on the cushion. Install the O-rings on the inside and outside of the
retainer ring on the cushion. ring.
3. Insert and seat the cushion spring in the 8. Remove the spring and decel piston.
center of the piston. Insert and seat the 9. Remove the decel bearing and piston ring
cushion on the end of the cushion spring. from the decel piston.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Lift Cylinder Lowering Cushion Hydraulic Components, Cylinder

10. Remove the spring and plug from the 4. Compress the cushion to relieve the
cushion housing (piston plug). pressure on the snap ring.
11. Remove the O-ring from the plug. 5. Compress the spring and hold it in place
with a drill bit or drift pin inserted in one
Reassembly of the hydraulic fluid ports in the cushion
housing.
1. Lubricate new O-rings, piston ring, and
decel bearing with clean hydraulic fluid.
2. Install the new piston ring and decel
When the snap ring is removed, the
bearing in the decel piston.
cushion spring ejects the cushion from
3. Lubricate the inside of the piston surface the piston. Keep body away from the
with clean hydraulic fluid. piston end when performing this
4. Install the new O-ring in the groove in the procedure.
plug and install the plug in the cushion
housing. 6. Remove the snap ring from inside of the
cylinder.
5. Seat the plug in the housing by inserting
the spring and the decel piston in the 7. Release the cushion slowly.
cushion housing. 8. Remove the ring retainer and seal from the
6. Install the other spring. cushion.
7. Install new O-rings on the inside and 9. Replace the cushion, spring, seal, and/or
outside of the retaining ring. retainer components as necessary. If
replacing the cushion, install the cap
8. Install the retaining ring on the shaft of
screw in the end of the cushion.
the decel piston.
9. Compress the spring and hold it in place
with a drill bit or drift pin inserted in one
Reassembly
of the hydraulic fluid ports in the cushion 1. Lubricate the inside of the piston surface
housing. with clean hydraulic fluid.
10. Install the snap ring in the cushion 2. Lubricate the seal with clean hydraulic
housing. fluid and install on the cushion. Install the
11. Release the cushion slowly. retainer ring on the cushion.
12. Reassemble the cylinder. Perform steps 2 3. Insert and seat the cushion spring in the
thru 14 of “Lift Cylinder, Free Lift, Seal center of the piston. Insert and seat the
Repacking”, “AC Lift”, “Reassembly” on cushion on the end of the cushion spring.
page 7-110. 4. Compress the spring and hold it in place
with a drill bit or drift pin inserted in one
Free Lift Cylinders - DC Lift of the hydraulic fluid ports in the cushion
housing.
Removal 5. Install the snap ring.
6. Carefully release cushion pressure.
1. Using an eye bolt and hoist, remove the
piston rod from the cylinder. 7. Reassemble the cylinder. Perform steps 3
thru 12 of “Lift Cylinder, Free Lift, Seal
2. Perform steps 1 thru 8 of “Lift Cylinder, Repacking”, “DC Lift”, “Reassembly” on
Free Lift, Seal Repacking”, “DC Lift”, page 7-111.
“Disassembly” on page 7-111.
3. Place the piston rod on a clean padded
working surface.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components, Cylinder Reach Cylinder

Reach Cylinder 10. Slide the piston assembly off the end of the
rod.
11. Slide the cushion sleeve off the rod. Note
Removal the direction of the taper.
1. Remove the mast guard. 12. Remove the head assembly.
2. Raise the carriage until the reach cylinder 13. Remove the head static seal O-rings,
is accessible from the operator’s backup washers, rod inside diameter
compartment. dynamic seal, and the rod wiper. Use care
to avoid scratching the groove.
3. Fully retract the carriage.
14. Remove the O-ring and backup washers
4. Block the carriage.
from the piston assembly.
5. Turn the key switch OFF and disconnect
the battery connector.
Reassembly
6. Place a pan below the reach cylinder.
1. Remove any burrs or sharp edges caused
7. Remove and cap the reach hoses at the
from disassembly before installing the new
reach cylinder.
seals.
8. Remove the screw and cotter pin holding
2. Clean all parts with solvent. Lubricate
the piston yoke in place.
parts with petroleum jelly or clean
9. Remove the clevis pin and spacers. hydraulic fluid as indicated.
10. Remove the screw and cotter pin at the 3. Lubricate and install the new rod,
housing end. dynamic seal, and rod wiper in their
11. While supporting the cylinder, remove the respective inside grooves of the head
clevis pin and spacers holding the cylinder assembly.
in place. 4. Lubricate and install the new head static
seal O-rings and head static seal backup
Disassembly washers on the outside grooves of the head
assembly.
1. With the cylinder removed, drain all 5. Lubricate the head assembly inside seals
hydraulic fluid from the cylinder assembly. and carefully slide the head assembly onto
2. Clamp the cylinder base end in a bench the rod assembly.
vise. Cover the ports with a clean rag.
3. Remove the external lock ring.
4. Push the head assembly into the tube
assembly approx. 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).
9. Clamp the rod at the wrench flats or clevis
in a soft-jawed vise. Loosen the retaining
nut on the piston assembly.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Reach Cylinder Hydraulic Components, Cylinder

Figure 7-144. Reach Cylinder (Deep-Reach shown)
7R1022181_B.cgm
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. Unblock the carriage.
5. Reconnect the battery connector and turn
the key switch ON.
6. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on page 7-88.
7. Adjust the reach cylinder. See “Adjustment
Procedure” on page 7-121.
8. Check the truck for leaks and correct
operation.
9. Install the mast guard.

Adjustment
6. Install the piston O-ring and backup
washers in the outside groove of the piston The top of the scissor roller must not protrude
assembly. more than 0.90 in. (22.8 mm) from the top of
7. Slide the cushion sleeve onto the rod. the roller channel on the fork carriage. This
takes precedence over the extended dimension.
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 approx. 3/4 in. (19 mm).
11. Install a new internal lock ring in the
groove in the tube assembly bore.
12. Grip the rod firmly and pull outward until
the head assembly is tight against the lock
ring.
13. Install the spacer and external lock ring in
the head assembly.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components, Cylinder Reach Cylinder

Figure 7-145. Scissor Roller Dimension 2. Remove the pin that secures the yoke to
7rchadj1.jpg
the carriage.
3. Turn the yoke to obtain the correct
dimension.
4. Install the pin to secure the yoke to the
carriage.
5. Apply thread-locking compound
(P/N 1013829) to the threads on the
piston and torque the jam nut to 175 ft. lb.
(237 Nm).

Retract Adjustment

Model 7500 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
When the reach is fully extended, the
gap between the plastic block and the metal
dimension from the front of the main frame to
block (Deep-Reach) or fixed carriage (Standard
the face of the forks when level should be:
Reach). This is a backup stop only. Shim the
plastic block to produce a gap of:
Carriage Dimension

R35TT 28.25 in. (717.6 mm) Carriage Gap

R45TT 28.38 in. (720.00 mm) Standard Reach 0.125 to 0.250 in.
(3.2 to 6.4 mm)
DR32TT 53.40 in. (1356.4 mm)
Deep-Reach 0.125 to 0.375 in.
(3.2 to 9.5 mm)
Figure 7-146. Reach Fully Extended Dimension
7rchadj2.jpg

Reach Scissor Roller Shimming

Make sure at least half of the thickness of the

scissor roller is running on the roll plate wear
bar. Shim as needed between the shoulder of
the scissor arm stud and the bearing inner
race. See Figure 7-147.

NOTE: The face of the fork to the front of the

load wheel (or wheel box) should be a
minimum of 0.50 in. (13 mm). If not,
perform the adjustment procedure that
follows.

Adjustment Procedure
1. Loosen the jam nut that holds the piston
to the yoke.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Reach Cylinder Hydraulic Components, Cylinder

Figure 7-147. Reach Scissor Roller Bearing Shimming
7RSB05013.jpg

Shim Here

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components, Cylinder Tilt Cylinder

Tilt Cylinder Figure 7-148. Tilt Cylinder, Disassembly

7cylassy.wmf

Head Static Seal

Backup Washer
Removal Internal Lock
Head Static Ring
1. Extend and block the scissor assembly so Seal O-ring
it cannot retract. Spacer
2. Position and block the carriage at a
External Lock
comfortable working height. Ring
3. Spread the forks on the carriage to gain
complete access to the tilt cylinder. Rod Wiper
4. Tilt the forks completely up. Rod Wear
5. Turn the key switch OFF and disconnect Ring
the battery connector. Rod Dynamic
Tube Seal
6. Remove the snap rings from the tilt pin. Assembly
7. Place a block between the fork carriage Piston
and the carriage frame. Assembly
Head Assembly
8. Remove the tilt pin.
9. Place a pan below the tilt cylinder and
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
Base
End
Disassembly
Rod
With the cylinder removed, drain all hydraulic
fluid from the cylinder assembly. Clamp the
cylinder at the base end in a bench vise. Cover
the ports with a clean rag. Refer to Figure 7-148 Piston
for the following steps. Wear
Ring
1. Remove the external lock ring.
2. Remove the spacer.
Piston
3. Push the head assembly into the tube Seal
assembly approx. 3/4 in. (19 mm).
4. Remove the internal lock ring.
5. Important: Remove the sharp edge from the Rod Piston
back corner of the internal lock ring O-Ring
groove. 8. Loosen the piston assembly with a
6. Grip the rod through the hole in the pin spanner wrench. Unthread the piston
and pull the rod assembly out of the tube assembly from the rod.
assembly. 9. Slide the head assembly off the rod from
7. Clamp the rod in a bench vise at the pin the piston end.
hole end. 10. Clean the male threads of the rod. Remove
the rod piston O-ring.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Tilt Cylinder Hydraulic Components, Cylinder

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 backup 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 page 7-88.
8. Apply red thread-locking compound
(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.
10. Push the head assembly into the tube
assembly approx. 3/4 in. (19 mm).
11. Install a new internal lock ring in the
groove in the tube assembly bore.
12. Grip the rod through the pin hole and pull
outward until the head assembly is tight
against the lock ring.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components, Cylinder Flow Limiter, Main Lift

Flow Limiter, Main Lift Figure 7-150. Flow Limiter Location - Model 7520
7mainlimiter.jpg

The main lift cylinder flow limiters restrict

lowering flow to 15 gpm (57 lpm). These flow Left Side Main
limiters can be replaced without removing the Lift Cylinder
cylinder.

Main lift cylinder flow limiter(s) are located at

the bottom of the main lift cylinder(s). Main Lift Flow Limiter

Figure 7-149. Flow Limiter Location - Model 7500

7mainlimiter.jpg

Main Lift Flow Limiter

Note: Model 7520 trucks have a flow limiter in

both main lift cylinders.

Left Side Main Removal

Lift Cylinder 1. Fully lower the carriage to the floor.
2. Turn the key switch OFF and disconnect
the battery connector.
Note: Trucks with an OACH above 146 in. have
a flow limiter in both main lift cylinders. 3. Remove the front cover(s).
4. Place a pan below the baseleg at the left
side main lift 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.

Installation
1. Install the flow limiter. Make sure the
arrow points in the up direction.
2. Install the fitting in the manifold block.
3. Reconnect the hose to the cylinder.
4. Reconnect the battery connector and turn
the key switch ON.
5. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on page 7-88.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Flow Limiter, Main Lift Hydraulic Components, Cylinder

6. Check the truck for leaks and correct

operation.
7. Install the front cover(s).

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Hydraulic Components, Cylinder Flow Limiter, Free Lift

Flow Limiter, Free Lift Figure 7-151. Free Lift Flow Limiter (Model 7500 shown)
7mainlimiter.jpg

Flow
The free lift flow limiter is located in the SAE Limiter
fitting at the bottom of the left side free lift
cylinder on a Model 7500 and at the bottom of
the right side free lift cylinder on a Model 7520.

Removal
1. Remove the mast guard.
2. Raise the telescopics until the bottom of
the left free lift cylinder is accessible from
the operator’s compartment.
3. Place a block of sufficient length (approx.
24 in./610 mm) between the outer
telescopic crosstie and the main frame to
hold the position in step 2.
4. Fully lower the carriage.
Installation
5. Extend the reach mechanism to allow
easier removal of the free lift lines and 1. Install the flow limiter fitting in the
fittings. manifold block.
6. Turn the key switch OFF and disconnect 2. Install the set screw at the bottom of the
the battery connector. cylinder.
7. Place a pan below the baseleg at the left 3. Reconnect the hydraulic line at the bottom
free lift cylinder. of the cylinder.
8. Remove and cap the hydraulic line at the 4. Reconnect the battery connector and turn
bottom of the free lift cylinder. See the key switch ON.
Figure 7-151. 5. Remove the block between the outer
9. Remove the set screw at the bottom of the telescopic and main frame.
free lift cylinder to permit the cylinder to 6. Bleed the hydraulic system. See
rotate for the removal of the fitting. “Hydraulic System Bleeding” on page 7-88.
10. Remove the fitting from the manifold 7. Check the truck for leaks and correct
block. operation.
11. Remove the flow limiter noting the 8. Install the mast guard.
direction of the arrow.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Flow Limiter, Free Lift Hydraulic Components, Cylinder

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable

Mast, Chain, Hose, Cable

Section 7. Component Procedures

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Reach Carriage Bearings Mast, Chain, Hose, Cable

Reach Carriage Bearings 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
5. Repeat steps 1 thru 4 for the five
accessible when the carriage is elevated. The
remaining bearings.
reach carriage must be removed to access the
middle and lower bearings. The bearings are 6. Clean and re-grease the telescopic
shimmed at the factory to a 0.00 ±0.010 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 7-133.
and inserted in the outer telescopic. Inspect
8. Test the reach/retract function of the
bearings for damage or wear and replace as
carriage.
required.

Removal Adjustment
1. Remove the carriage. See “Carriage” on Test reach carriage operation. If there is any
page 7-133. kick or if the forks are not level, adjust the
2. Remove the socket head cap screw and eccentric pins as necessary. Start with lower
washer on the end of the bearing. carriage roller bearing pins.

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./0.25 mm)
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./0.25 mm) 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.
4. If the inner race of the bearing does not
protrude past the end of the shaft when

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast Shimming

Mast Shimming 8. Shim the outer telescopic upper bearing

set to 0.000 ±0.010 in. overall
interference with the inner telescopic after
Shimming a mast makes a smooth running unit the top main frame bearings have been
that is not too tight or too loose. If you find any correctly shimmed.
marks within the telescopics or main frame
9. Shim the inner telescopic lower bearing set
where the rollers have been running, remove
to 0.030 ±0.010 in. overall interference
them using a sanding disc and 80 grit paper. Do
with the outer telescopic after the outer
not attempt to remove all marks, only the
telescopic lower bearings have been set.
ridges. Shim the bearings to the tightest spot on
the assembly (as the rollers run up and down 10. Install or remove the required amount of
the rail). Buff small areas that are slightly shims.
higher than the rest of the web to avoid 11. Install the bearing on the shaft.
shimming the major portion of the rail too loose.
12. Apply thread-locking compound
The shims used under each roller bearing come
(P/N 990-536) to the socket head cap
in the following sizes: thin, medium and thick.
screw and fasten the screw and washer in
Although you can use different combinations of
place.
shims to obtain the correct adjustment, you
should try to maintain equal shim thickness on 13. If the inner race of the bearing does not
each side of the mast. protrude past the end of the bearing stud
when the bearing is fully seated, bend the
flat washer to contact the bearing to
Shimming Procedure prevent the bearing from walking on the
1. Elevate the mast to gain access to the stud shaft.
bearings.
Figure 7-152. Inner Race
2. Place a block between the outer telescopic 7mastbearshim1.jpg

crosstie and the main frame.

3. Fully lower the carriage.
4. Turn the key switch OFF and disconnect
the battery connector.
NOTE: When removing the upper bearings, use
caution not to let the bearing fall down
into the mast assembly. If the bearings
are worn or damaged, replace them.
5. Remove the bolt and roller stud sleeve
securing the roller bearing to the
respective mast or telescopic.
6. Remove the bearing.
NOTE: It may be necessary to drive a wedge 14. Install the bearing assembly into its
between the respective telescopics to respective mast or telescopic. Make sure
provide clearance for removal and that the flat spot of the bearing stud aligns
installation. with the welded stop on the mast or
telescopic.
7. Remove the socket head cap screw and
washer retaining the bearing on the stud. 15. Install the roller stud sleeve.

NOTE: Shim the main frame top bearing and 16. Apply thread-locking compound
the outer telescopic lower bearing set to (P/N 1013829) to the threads of the
a 0.030 ±0.010 in. overall interference. mounting bolt and torque to 260 ft. lb.
(352.5 Nm).

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast Shimming Mast, Chain, Hose, Cable

17. Reconnect the battery connector and turn

the key switch ON.
18. Remove the block from between the outer
telescopic and the main frame.
19. Test the operation of the elevating
assembly.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Bow Pads - Model 7500

Bow Pads - Model 7500 Figure 7-154. Inner Telescopic Bow Pads
7RPINRCH06R008_img006.jpg

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 7-156 on page 7-132.
2. R35TT: Elevate the mast to expose the bow
pads mounted on the outside of the inner
telescopic and the outside of the outer
telescopic. Pads are on both leading and
trailing edges of the rail. See Figure 7-156
on page 7-132. 4. Shim as required to obtain a gap of 0.03 to
0.09 in. (0.8 to 2.3 mm). On the R35TT
3. DR32TT, R45TT, and R35TT: Examine each mast, measure the gaps between the outer
bow pad and measure its thickness. If the telescopic and main frame by elevating the
thickness is <0.187 in. (4.75 mm), replace mast so that the pads are at the top of the
the pad. Lower the mast. Using a suitable main frame.
feeler gauge, check the clearance gap of
the bow pads between the inner telescopic Figure 7-155. Outer Telescopic Bow Pads Model 7500
and the outer telescopic. R35TT Mast
7RPINRCH06R008_img010.jpg

Figure 7-153. Inner Telescopic Bow Pads Model 7500

R45TT/R45TT/DR32TT Mast
7RPINRCH06R008_img002.jpg

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Bow Pads - Model 7500 Mast, Chain, Hose, Cable

Figure 7-156. Bow Pad Locations
1043120_C12.cgm,1043120_C13.cgm,1043786_A5.cgm

R35TT Mast R45TT/DR32TT Mast

2 Bow Pads on each leading and trailing

edge of inner and outer telescopic —
total of 16 pads

3 Bow Pads on each leading

edge of inner telescopic —
total of 6 pads

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Carriage

Carriage NOTE: Twist the left side free lift pulley to allow
the carriage stop mounting block to
clear.
The carriage is removed through 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 approx. 880 lb. (363 kg). A appropriate height and reconnect free lift
Deep-Reach ® carriage without forks chains to the anchors.
weighs approx. 1100 lb. (500 kg).
3. Connect the OTM hoses to the auxiliary
manifold.
Removal 4. Remove the lifting device.
1. Remove mast guard and top cover. 5. Connect the cable to JS2 at carriage and
2. Remove forks. TS3 in tractor.
3. Remove the mounting bolts from the 6. Attach the manifold cover to the carriage.
hose/cable guide and retainer at the back Apply thread-locking compound
of the carriage. (P/N 1013829) to the mounting bolts and
torque to 30 ft. lb. (42 Nm).
4. Retract scissor assembly.
7. Mount the auxiliary manifold to the
5. Disconnect the OTM cable at TS3 in the
carriage. Apply thread-locking compound
tractor.
(P/N 990-536) to the mounting bolts and
6. Remove the auxiliary manifold cover and torque to 21 ft. lb. (29 Nm).
disconnect the Over-The-Mast (OTM) cable
8. Extend the reach. Block the carriage at an
at TS2. Remove the auxiliary manifold
appropriate height to relieve the tension
mounting screws.
on the OTM hoses and cable to install the
7. Elevate the carriage to gain access from hose/cable guide retainer at the back of
the operator’s compartment to the carriage the carriage.
stops and the OTM hose fittings at the
9. Apply thread-locking compound
auxiliary manifold.
(P/N 1013829) to the mounting bolts and
8. Turn the key switch OFF and disconnect install the hose/cable guide retainer at the
the battery. back of the carriage.
9. Remove the OTM hoses from the carriage 10. Install the carriage stops.
manifold. Cap hoses and plug the fittings.
11. Install the forks.
10. Remove the carriage stops.
12. Check the tension of the hoses, cable, and
11. Using a suitable lifting device, lift the free lift chains and adjust as required.
carriage assembly to relieve the tension
13. Bleed the hydraulic system. See
from the free lift chains.
“Hydraulic System Bleeding” on page 7-88.
12. Remove the master link from the free lift
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.
14. Carefully lift the carriage assembly out of
the mast assembly.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Chain Anchors Mast, Chain, Hose, Cable

Chain Anchors Figure 7-158. Upper Main Lift Chain Anchor Removal
7chain2.jpg

Main Lift Chain Anchors

Preparation for Removal
1. Place a block between the outer telescopic
crosstie and the main frame crosstie and a
slightly longer block between the inner
telescopic crosstie and the outer telescopic
crosstie. This provides the required slack
in the chains. See Figure 7-157.

Figure 7-157. Blocking Telescopics

7DSCF1361.JPG

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
(1 1/16 in.), an M8 x 50 mm bolt, and
washers to act as a pulling device. See
Figure 7-159.

Figure 7-159. Anchor Pin Removal

7chain3.jpg

Blocking

2. Lower the carriage and block at a height

that allows 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

1. Remove the chain anchor bolt and the
anchor pin retainer. See Figure 7-158.
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

1. Install the mast stop to the chain anchor.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Chain Anchors

2. Attach the chain anchor to the lift chain, Figure 7-160. Lower Main Lift Chain Anchor, Model 7500
7chain1.jpg
making sure that the two holes in the
anchor are facing towards the outside.
3. Remove the locking pliers, position the
chain anchor and install the anchor pin.
You can install the chain anchor bolt Master Link
temporarily to assist in the installation of
Cotter
the pin.
Pin
4. Install the chain anchor pin retainer. Chain
Apply thread-locking compound Anchor
(P/N 1013829) to the threads of the
anchor bolt and torque to 130 ft. lb.
Chain Anchor
(174 Nm). Block
5. Reconnect the battery connector and turn
the key switch ON. Adjusting
6. Remove the blocks from between the Nut
telescopic crossties.
Cotter Pin
7. Adjust the lift chains until there is a
0.25 in. (6.4 mm) gap at the narrowest
point between the inner and outer
telescopics when the carriage is fully
lowered. Make sure there is equal tension
Lower Chain Anchor Installation
on the lift chains after the adjustment. 1. Reinstall the master link to the lift chain
8. Test the truck for correct operation. and chain anchor.
2. Install the chain anchor into the chain
Lower Chain Anchor Removal anchor block and thread the adjusting nut
on to the distance recorded earlier. Install
1. Disconnect the lift chain master link from the cotter pin at the end of the chain
the chain anchor at the bottom of the anchor.
inner telescopic.
3. Reconnect the battery connector and turn
2. Note the distance of the adjusting nut. the key switch ON.
This distance is used as a preliminary
4. Remove the blocks from between the
adjustment when re-installing.
telescopic crossties.
3. Remove the cotter pin and chain anchor
5. Adjust the lift chains until there is a
adjusting nut.
0.25 in. (6.4 mm) gap at the narrowest
4. Remove the chain anchor from the point between the inner and outer
telescopic. 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.

Free Lift Chain Anchors

Upper Chain Anchor Removal
1. Elevate and block the carriage at a
convenient working height.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Chain Anchors Mast, Chain, Hose, Cable

2. Lower the carriage to relieve tension on the 7. Remove blocking from carriage.
chains. 8. Test the truck for correct operation.
3. Turn the key switch OFF and disconnect
the battery connector. Lower Chain Anchor Removal
4. Remove the mast guard.
NOTE: Right side lower free lift chain anchors
5. Left side only: Remove the hose/cable are welded to the carriage. Use the
retaining block. following procedure to remove the left
6. Disconnect the lift chain master link from side chain anchor.
the chain anchor.
1. Elevate and block the carriage at a
7. Note the distance of the adjusting nut. convenient working height.
This distance is used as a preliminary
2. Lower the carriage to relieve tension on the
adjustment when re-installing.
chains.
8. Remove the nut from the chain anchor
3. Turn the key switch OFF and disconnect
bolt. Remove anchor from anchor block.
the battery connector.
Figure 7-161. Upper Free Lift Chain Anchor, Model 7500 4. Remove the mast guard.
7R1022604_A4.cgm
5. Disconnect the lift chain master link from
the chain anchor.
6. Unscrew the anchor from the anchor
block.

Figure 7-162. Lower Free Lift Chain Anchor

7R1022604_A1.cgm

Master Link

Master Link
Chain Anchor

Chain Anchor Chain Anchor

Block
Chain Anchor
Adjusting Nut Block

Upper Chain Anchor Installation

1. Insert the chain anchor in the chain
anchor block. Lower Chain Anchor Installation
2. Install a new master link to the lift chain 1. Screw the chain anchor into the chain
anchor and secure with a new cotter pin. anchor block.
3. Thread the adjusting nut on the chain 2. Attach a new master link to the chain
anchor bolt to the distance recorded anchor and secure with a new cotter pin.
earlier. 3. Reinstall the mast guard.
4. Left side only: Reattach the hose/cable 4. Reconnect the battery connector and turn
retaining block. the key switch ON.
5. Reinstall the mast guard. 5. Remove blocking from carriage.
6. Reconnect the battery connector and turn 6. Test truck for correct operation.
the key switch ON.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Lift Chains

Lift Chains chain anchor bolt temporarily to assist in

the installation of the pin.
4. Install the anchor pin retainer. Apply
Chains, Main Lift thread-locking compound (P/N 1013829)
to the threads of the anchor bolt and
Removal torque to 130 ft. lb. (174 Nm).
5. Attach the chain and the lower chain
1. Place a block between the outer telescopic anchor, using a new master link and cotter
crosstie and the main frame crosstie and a pin.
slightly longer block between the inner
telescopic crosstie and the outer telescopic 6. Remove the blocks between the telescopics
crosstie. This provides the required slack and the main frame and fully lower the
in the chains for their removal. See forks to the floor.
Figure 7-157 on page 7-134. 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
lowered. Make sure there is equal tension
3. Turn the key switch OFF and disconnect
on the lift chains after the adjustment.
the battery connector.
8. Lubricate the chains and test the truck
4. Disconnect the lift chain master link from operation.
the lower chain anchor at bottom of inner
telescopic.
5. Remove the chain anchor bolt and the
Chains, Free Lift
anchor pin retainer. See Figure 7-159 on
page 7-134. Removal
6. Grasp the chain and remove the anchor 1. For easy access to the lift chain master
pin. links at the carriage anchor blocks, elevate
NOTE: You can remove the pin by using a slide the carriage to a convenient working
hammer or by using a large socket height. Using a suitable hoist or stand,
(1 1/16 in.), an M8 x 50 mm bolt and secure the carriage at this height.
washers to act as a pulling device.
Figure 7-163. Carriage Chain Anchor
1. Remove the chain anchor and chain from 7flchain1.jpg

the telescopic.
2. Remove the master link between chain
and chain anchor.

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. 2. Activate “lower” to relieve the tension on
3. Position the upper chain anchor and the free lift chains.
install the anchor pin. You can install the

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Lift Chains Mast, Chain, Hose, Cable

3. Turn the key switch OFF and disconnect 7. Remove the hoist.
the battery connector. 8. Fully lower the carriage.
4. Remove the mast guard. 9. With the reach mechanism retracted, forks
5. Remove the master links at the adjustable level with the floor, and the key switch
chain anchors. OFF, adjust the anchor nuts equally until
6. Remove the master links at the carriage the forks are approx. 3 in. (76 mm) off the
chain anchors. The right side requires the floor (or just touching the floor with the
removal of a retainer tab and pin rather floor lower height option). Make sure there
than a cotter pin. is equal pressure on the chains when the
carriage is fully lowered.
Figure 7-164. Retainer Tab (right side)
7flchain2.jpg

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.
2. 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.
3. 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.
4. Reinstall the mast guard.
5. Reconnect the battery connector and turn
the key switch ON.
6. Slowly raise the carriage, using the lift
button to place the weight of the carriage
on the free lift chains.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Hose, Main Lift

Hose, Main Lift

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.
4. Position and reinstall the display and Lift
Motor mounting bolts.
5. Reinstall battery.
6. Reconnect the battery connector and turn
the key switch ON.
7. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on page 7-88.
8. Check the truck for leaks and correct
operation.
9. Install the top cover and the right and left
front cover.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Hose and Cable, Over-the-Mast Mast, Chain, Hose, Cable

Hose and Cable, Figure 7-166. Over-the-Mast Hose/Cable - Right Side

(Model 7500 shown)
Over-the-Mast 7R1018766_C03.cgm

Figure 7-165. Over-the-Mast Hose/Cable - Left Side (Model

7500 shown)
7R1018766_C1.cgm

Main Lift
Cylinder Upper Free Lift
Hose/Cable Cylinder
Retainer Hose/Cable
Retainer

Carriage
Hose/Cable
Retainer

Lower Free Lift

Cylinder NOTE: For replacement of the over-the-mast
Hose/Cable electrical cable only, see “Cable,
Retainer Over-the-Mast” on page 7-146.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Hose and Cable, Over-the-Mast

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 7-167.
8. Reconnect the battery connector and turn
Figure 7-167. Blocking Scissor Assembly the key switch ON.
7OTM_1.jpg
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 7-169.

Figure 7-169. Hose/Cable Retainer on Carriage

7OTM_2.jpg

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. Disconnect the over-the-mast
cable at terminal strip TS2.
See Figure 7-168.

Figure 7-168. Auxiliary Manifold access

7DSC_0942a.jpg
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 7-166 on
page 7-140.
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
lift cylinder and the retainer on the
telescopic from the tractor side. Place a
6. Remove auxiliary manifold mounting
hardwood block of sufficient length
screws to permit access to the
between the outer and inner telescopics.
over-the-mast hose fittings at the
This removes tension from the
manifold.
over-the-mast hoses and the lift hose and
makes the removal and installation of the

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Hose and Cable, Over-the-Mast Mast, Chain, Hose, Cable

retainers easier. Carefully lower the mast Figure 7-171. Positioning Hose Retainer
7OTM_4.JPG
until you have the desired tension. See
Figure 7-170.

Figure 7-170. Blocking Telescopics

7OTM_3.JPG

NOTE: OTM hose lengths on Model 7500 lift

trucks are equal. Reference
Figure 7-194 on page 7-157 for correct
hose/cable routing.
17. Turn the key switch OFF and disconnect
the battery connector. 1. While observing correct routing, connect
18. Remove the lower free lift cylinder hoses to auxiliary manifold at carriage and
hose/cable retainer and the hose/cable the cable to terminal strip TS2.
retainer from the bottom of the inner 2. Mount auxiliary manifold to carriage.
telescopic. Apply thread-locking compound
19. Feed hoses and cable through pulley at (P/N 990-536) to mounting bolt threads
top of inner telescopic. and torque to 21 ft. lb. (29 Nm).
20. Remove hose/cable retainer at left main 3. Reconnect the battery connector and turn
lift cylinder. the key switch ON.
21. Reconnect the battery connector and turn 4. Carefully elevate and block carriage high
the key switch ON. enough to access the hose/cable retainer
and guide at the back of the carriage.
22. Carefully elevate telescopics and remove
blocking. 5. Turn the key switch OFF and disconnect
the battery connector.
23. Fully lower mast and carriage.
6. Feed hoses and cable through guide and
24. Turn the key switch OFF and disconnect retainer.
the battery connector.
7. Remove slack from hoses and cable
25. Disconnect and plug/cap hoses and
between retainer and manifold. Adjust and
fittings at A1 and A2 on the main
tension the cable to allow the cable to loop
manifold.
away at the bottom edge of the hose/cable
26. Feed hoses and cable through opening in bracket on the carriage. This loop should
tractor bulkhead. be 0.75 in. ±0.25 in. below the bracket.
Make sure the cable is long enough to
Installation remove the auxiliary manifold cover and
access TS2. Tighten the retainer. See
NOTE: To help install the retainers, use two Figure 7-172.
modified (M6-1 x 70) bolts to locate and
support the retainer during assembly.
See Figure 7-171.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Hose and Cable, Over-the-Mast

Figure 7-172. Carriage Hose/Cable Retainer Figure 7-173. Free Lift Pulley Routing of Hoses and Cable
71045742_D6.cgm 71045742_B7.jpg

Aux Hose A2

Aux Hose A1

Electrical
Cable
Electrical Cable

Aux Hose A1

Aux Hose A2

13. Install hoses, cable, and retainer at top of

free lift cylinder. See Figure 7-174.

8. Attach manifold cover to carriage. Apply Figure 7-174. Upper Hose/Cable Retainer, Main Lift and
thread-locking compound (P/N 990-536) Free Lift Cylinders
71045742_D8.cgm
to the mounting bolt threads and torque to
30 ft. lb. (42 Nm).
Main Lift
9. Reconnect the battery connector and turn
Retainer
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
other. The electrical cable is in the
left-hand position.
Free Lift
Retainer
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 7-18
on page 7-145. Measure and mark hoses
above the upper free lift cylinder retainer,
using the L2 value. L2 equals the length
the hoses are to be stretched over the free
lift cylinder. See Figure 7-175.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Hose and Cable, Over-the-Mast Mast, Chain, Hose, Cable

Figure 7-175. Marking L2 Dimension side. Make sure hoses and cable do not
7OTM_5.jpg
cross each other.
stretch 24. Install over-the-mast hoses, lift hose, and
cable in retainer at left main lift cylinder.
25. Remove slack from hoses and cable.
Adjust cable grip and spring so that spring
is stretched to an overall length of
L2 dimension 1.75 ±0.12 in. (44.5 ±3 mm) across the
coils. 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 retainer.
26. Measure and mark the lift hose above the
retainer with the appropriate L3 value
16. Reconnect the battery connector and turn from Table 7-18 on page 7-145. Measure
the key switch ON. and mark the over-the-mast hoses above
17. Place block under carriage and lower the retainer with the appropriate L1 value
carriage to relieve tension on hoses. from Table 7-18 on page 7-145.
18. Pull down on the hoses until marks are 27. Repeat step 17 of the installation
flush with top of retainers. Tighten the procedure.
four retainer bolts. Do not tighten the 28. Pull down on the hoses until marks are
lower clamp bolts on the retainer assembly flush with the top of the retainers. Tighten
yet. retainers.
19. Install hoses, cable, retainer, and clamp at 29. Reconnect the battery connector and turn
bottom of free lift cylinder and inner the key switch ON. Remove blocking from
telescopic. Carefully elevate the telescopics telescopics. Turn the key switch OFF and
high enough to access the lower retainer disconnect the battery connector.
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
between the outer and inner telescopics. 31. Secure hoses and cable to the free lift
Carefully lower the mast until you have cylinder with cable ties every 16 to 24 in.
the desired tension. Observe correct (40 to 60 cm).
routing to make sure hoses and cable have 32. Route hoses and cable through the tractor
sufficient clearance. See Figure 7-170 on opening, along the tractor bulkhead, and
page 7-142. attach with the hose/cable clamps. See
20. Turn the key switch OFF and disconnect Figure 7-176.
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.
22. Reconnect the battery connector and turn
the key switch ON. Remove blocking from
telescopics. Turn the key switch OFF and
disconnect the battery connector.
23. Feed hoses and cable through pulleys at
top of telescopic, from fork side to tractor

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Hose and Cable, Over-the-Mast

Figure 7-176. Hose/Cable Retainer Clamps on Tractor Table 7-18. Over-the-Mast Hose Stretch Values
7R1018766_C7.cgm

L1 L2 L3
(OTM hoses (over free (lift hose
OACH over tele) lift cyl) 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) 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) 1.18 (30) 2.68 (68.1)

33. Observing correct routing, connect
131 2.61 (66.3) 1.20 (30.5) 2.77 (70.4)
over-the-mast hoses to A1 and A2 at the
main manifold. Connect the over-the-mast 133 2.67 (67.8) 1.21 (30.7) 2.83 (71.9)
cable to connector JPS3.
135 2.73 (69.3) 1.23 (31.2) 2.89 (73.4)
34. Reconnect the battery connector and turn
the key switch ON. Test the lift truck for 138 2.82 (71.6) 1.25 (31.8) 2.98 (75.7)
correct operation and check for leaks.
141 2.91 (73.9) 1.27 (32.3) 3.07 (78)
35. Cycle all auxiliary functions several times
to purge air from the hydraulic system. 143 2.97 (75.4) 1.29 (32.8) 3.13 (79.5)

36. Check hydraulic fluid level and add fluid 146 3.09 (78.5) 1.31 (33.3) 3.25 (82.6)
as required.
37. Install mast guard and covers.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Cable, Over-the-Mast Mast, Chain, Hose, Cable

Cable, Over-the-Mast cylinder pulley. See Figure 7-166 on

page 7-140.
10. Position the cable grip onto the
Over-the-Mast Cable replacement cable so that the spring
Replacement anchor end of the cable grip is oriented
towards the TS2 end of the cable and the
This procedure describes the installation of the loop is approx. 20 in. (51 cm) from the end
new cable as the old one is being removed. of the cable. See Figure 7-178.
1. Mark the OTM hoses at all the hose/cable Figure 7-178. Cable Grip on TS2 end of OTM cable
retainers to ensure the correct stretch
when reassembled. (If required, use
Table 7-18, “Over-the-Mast Hose Stretch
Values,” on page 7-145.)
2. Remove the top cover, left front cover, and
mast guard.
11. If installing bulk cable, strip 3 in. (76 mm)
3. Turn the key switch OFF and disconnect
of insulation from cable, strip wires, and
the battery connector.
attach spade lugs.
4. Disconnect the OTM cable at TS3 on the
12. Attach a cable tie around the braided end
tractor.
of the cable grip to prevent the grip from
5. Remove the auxiliary manifold cover from slipping. Do not tighten at this time.
the carriage and disconnect the OTM cable
13. Install the new cable in the carriage
at TS2.
retainer/guide and route to TS2.
6. Reconnect battery connector and turn key
switch ON. NOTE: Position the hoses using the marks
made in step 1 and make sure that there
7. Elevate and block the carriage at an is enough slack in the cable for the
appropriate height to access the installation and removal of the auxiliary
hose/retainer and guide at the back of the manifold cover.
carriage from the operator compartment.
This also relieves tension on the hoses for 14. Reconnect battery connector and turn key
easier assembly. See Figure 7-177. switch ON. Remove blocking and lower the
carriage. Turn key switch OFF and
Figure 7-177. Blocking the Carriage disconnect battery connector.
15. Connect cable spade lugs to TS2.
16. Attach aux manifold cover to carriage.
17. Reconnect the battery connector and turn
the key switch ON. Elevate and block
carriage as in step 7. Turn the key switch
OFF.
18. Tighten the carriage hose and cable
retainer.
19. Turn the key switch ON. Remove blocking
and lower the carriage. Turn the key
switch OFF.
20. Feed the cable through the free lift pulley
8. Turn the key switch OFF and disconnect
and position it in the upper free lift
the battery connector.
cylinder retainer. Do not tighten at this
9. Remove the cable from the retainer/guide time.
at the back of the carriage and the free lift

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Cable, Over-the-Mast

NOTE: Remove all twist from the cable when 25. Turn the key switch ON. Carefully elevate
installing. the telescopics high enough to access the
lower retainer on the free lift cylinder and
21. Turn the key switch ON. Elevate and block
the retainer on the telescopic from the
carriage. Turn the key switch OFF.
operator’s compartment.
22. Adjust and tension the cable to allow the
26. Place a hardwood block of sufficient length
cable to loop away at the bottom edge of
(approx. 30 in.) between the outer and
the hose/cable bracket on the carriage.
inner telescopics. This removes the
This loop should be 0.75 in. ±0.25 in.
tension from the OTM hoses and the lift
below the bracket. See Figure 7-179.
hose to make the removal and installation
Figure 7-179. Service Loop (Standard Carriage shown) of the retainers easier. Carefully lower the
mast until you have the desired tension.
See Figure 7-180.

Figure 7-180. Blocking Telescopics

Carriage Hose/
Cable Guide

27. Turn the key switch OFF.

Service Loop
28. Remove and install the cable at the lower
free lift cylinder and bottom inner
Tension Spring telescopic hose/cable retainers. Observe
correct routing to make sure hoses and
cable have sufficient clearance. Tighten
23. Position the hoses and cable using the the retainers.
marks made in step 1 and tighten the 29. Remove and feed the cable through the
upper 4 bolts, but not the bottom 2 bolts pulley at the top of the inner telescopic.
of the upper free lift cylinder retainer. Observe correct routing and make sure the
24. Set the tension on the spring at the cable is not twisted.
carriage by sliding the cable grip to 30. Remove the old cable and insert the new
produce a length of 1.75 ±0.12 in. cable through the passage hole.
(44.5 ±3.0 mm) across the coils. Do not
over tension. Tighten the cable tie on the 31. Reassemble the retainer, aligning witness
cable grip. See Figure 7-179. marks on the hoses, and tighten the bolts.
Insert the new cable through the passage
NOTE: Orient the loop of the cable grip fore-aft hole.
so, as the cable passes through the loop
32. If installing bulk cable, install cable grip
of the cable grip and the latch of the
with the loop pointing down towards the
cable tie, it does not interfere with the
tractor.
free lift cylinder mounting pin.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Cable, Over-the-Mast Mast, Chain, Hose, Cable

33. Turn the key switch ON. Remove the Figure 7-182. Cabling at Terminal Strip
blocking between the inner and outer
telescopic.
34. Tighten the bottom two bolts of the free lift
cylinder hose/cable retainer.
35. Secure hoses and cable to the free lift
cylinder with cable ties every 16 to 24 in.
(40.6 to 60.9 cm) as you lower the carriage
all the way. Turn the key switch OFF.
36. If installing exact replacement cable, pull
the cable through the main lift cylinder
retainer until all slack is removed. Mark
the cable at the top of the retainer. Tighten
the retainer bolts.
42. Install the mast guard and covers.
37. Set the tension on the spring at the
43. Turn the key switch ON. Elevate the
carriage by sliding the cable grip to
carriage and place a hardwood block
produce a length of 1.75 ±0.12 in.
between the inner and outer telescopic.
(44.5 ±3.0 mm) across the coils. Do not
Carefully lower the carriage to relieve the
over tension. Tighten the cable tie on the
hose and cable tension. Turn the key
cable grip.
switch OFF.
Figure 7-181. Main Lift Cylinder Retainer Cable Spring 44. Position the cable so that the mark on the
Tension cable is 0.5 in. (13 mm) above the retainer.
45. Position the OTM hoses and the lift hose
as marked in step 1 of the Over-the-Mast
Cable Replacement procedure. Tighten the
retainer.
46. Turn the key switch ON. Remove the block
between the inner and outer telescopic.
47. Lower the carriage. Turn the key switch
OFF.
48. Remove and route the cable along the
tractor bulkhead and attach with the
hose/cable clamps.

38. Cut the OTM cable 20 in. (508 mm) past

the bottom of the main lift cylinder
retainer.
39. Strip 3 in. (76 mm) of insulation from the
cable, strip the wires, and attach spade
lugs.
40. Connect the wires to the terminal strip.
NOTE: Colors will not match at TS2.
41. Attach cable to frame with a cable tie and
self-adhesive cable tie anchor. See
Figure 7-182.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Hose/Tubing, Free Lift Feed

Hose/Tubing, Free Lift Figure 7-183. Free Lift Feed Hose/Tube (Model 7500
shown)
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 main
frame to hold the position in step 2.
4. Fully lower the carriage.
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 7-183.

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 main frame.
4. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on page 7-88.
5. Check the truck for leaks and correct
operation.
6. Install the mast guard.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7500 (Complete Disassembly) Mast, Chain, Hose, Cable

Mast, Model 7500 blocked where it meets the mast before

loosening the mast mounting bolts.
(Complete Disassembly) 13. Place blocks snugly under the tractor near
the mast.
Separation of Tractor and Mast 14. Attach a lifting strap around the top
crossties of all three mast sections. Draw
• Do this procedure with a minimum tight with hoist. Make sure the weight of
of two technicians in a shop the mast is supported by the hoist.
equipped with a suitable hoist. 15. Use an impact wrench to remove the mast
• Do not permit observers to stand mounting bolts inside the battery
nearby. compartment, four on the top, eight on the
• Wear gloves, safety glasses, bottom.
steel-toed safety boots, and a safety 16. Using a lift truck, carefully separate the
helmet (hard hat). tractor about 6 in. (15 cm).
1. Lower and retract the fork carriage
17. Remove the hose/cable retaining bracket
completely.
on the front of the tractor bulkhead.
2. Turn the key switch OFF and disconnect 18. Remove the hose/cable retainer on the
the battery connector. Remove battery main lift cylinder.
gates. Using a suitable battery removal
device, remove the battery. 19. Reinstall mast mounting bolts and
washers and tighten lightly (to prevent
3. Remove the top cover and the left and right misplacing them).
front covers.
4. Remove the mast guard.
Hose/Cable, Free Lift Cylinder,
5. Secure a hoist strap around the overhead
guard. Take the weight off the guard.
and Carriage Removal
Remove mounting bolts. Remove the 1. Remove the auxiliary manifold cover from
guard. the carriage. See Figure 7-184 on
6. Disconnect and cap right side main lift page 7-151.
hose at the tractor bulkhead fitting. 2. Disconnect the wires of the over-the-mast
7. Disconnect the ambient temperature cable from the terminal strip, labeling as
sensor connector JPA on the tractor deck. needed for re-connection.
8. Disconnect the mast switch connector 3. Remove auxiliary manifold mounting
JPS4 (near the lift pump). Feed harness screws to permit access to the OTM hose
through tractor opening at left side. fittings at the manifold.
9. Disconnect over-the-mast cable connector NOTE: There may be shims between the
JPS3 on the tractor deck. manifold and carriage.
10. Disconnect the hose/cable retaining
clamp from the left front corner of the
tractor near the opening in the bulkhead.
11. 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.
12. Disconnect the main lift hose fitting at the
left side of the tractor.
NOTE: Make sure the weight of the mast is fully
supported by the hoist and the tractor is

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast, Model 7500 (Complete Disassembly)

Figure 7-184. Auxiliary Manifold Access 17. Disconnect and cap the hose to the left
main lift cylinder.
18. 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

1. Rig a lifting strap of one hoist around the
lower crosstie of the main frame (the one
where the overhead guard attaches).
2. Rig a lifting strap of another hoist around
the top crossties of both inner and outer
4. 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
ensure correct re-connection. 3. Remove chain anchor bolt and access
cover from sides of main frame.
5. Remove cable ties on upper hose retaining
block. Loosen upper and lower hose/cable 4. Remove the chain anchor pin by using a
retaining blocks. slide hammer or by using a large socket
(1 1/16 in.), an M8 x 50 mm bolt, and
6. Jack carriage up about 3 in. (7.6 cm). washers to act as a pulling device. See
Remove master links on free lift chains. Figure 7-185 and Figure 7-159 on
Feed free lift chains through pulleys and page 7-134.
drape over front of carriage.
7. Remove hose/cable retaining block on Figure 7-185. Main Lift Chain Upper Chain Anchor
back of carriage. Bolt
8. Remove hoses and cable from guide at
back of carriage. Cover

9. Remove upper and lower hose/cable

retainers from free lift cylinder.
Pin
10. Feed hoses and cable through right side
free lift cylinder pulley.
11. Remove tee tubing from free lift cylinders. Chain
Anchor
12. Remove set screws from bottom of right
free lift cylinders. Lift each free lift cylinder
off the mounting hook at the top and the
mounting block at the bottom. Install set
screws so they are not misplaced. 5. Pull the chain anchor/mast stop out of the
main frame.
13. Remove carriage stops from back of
carriage. 6. Feed main lift chains from inside to
outside over the chain sheave.
14. Remove the lower hose/cable pulley from
the top of the outer telescopic.
15. Remove the upper hose/cable pulley from
Separation of Telescopics
the top of the outer telescopic. 1. Using the hoists, carefully lower the mast
16. Disconnect the tee tubing to the right side to a horizontal position on jack stands.
main lift cylinder. 2. Loosen the L-bracket bolts holding the
main lift cylinders to the telescopic.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7500 (Complete Disassembly) Mast, Chain, Hose, Cable

3. Remove the top mounting bolt, washer, Figure 7-188. Outer Telescopic Lower Bearing and
and sleeve holding the main lift cylinder to Anti-Rattle Pads
the outer telescopic. See Figure 7-186.

Figure 7-186. Main Lift Cylinder Mounting Hardware

Mounting Bolt

Washer

Sleeve

Shims

Pad
Outer
Telescopic
6. Remove anti-rattle pads and shims from
bottom of inner telescopic. See
Figure 7-189.
4. Remove main lift chain sheaves from top of
outer telescopic. Sheaves attach with a pin Figure 7-189. Inner Telescopic Lower Bearing and
and a set screw on the inside. See Anti-Rattle Pads
Figure 7-187.

Figure 7-187. Main Lift Chain Sheave Shim

Pad
Chain

Spacer
Sheave

Spacer

Pin

Set Screw

Shims

5. Remove anti-rattle pads and shims from

bottom of outer telescopic. See Pad
Figure 7-188.
7. Using a suitable hoist, pull the inner
telescopic halfway out of the outer
telescopic.
8. Remove the upper roller bearings and
shims from the top of the outer telescopic.
See Figure 7-190.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast, Model 7500 (Complete Disassembly)

Figure 7-190. Outer Telescopic Upper Bearing

Sleeve

Stud

Shims

Bearing

9. Remove the lower roller bearings and

shims from the bottom of the inner
telescopic. See Figure 7-189.
10. Using a suitable hoist, remove the inner
telescopic from the outer telescopic.
11. Using a suitable hoist, pull the outer
telescopic halfway out of the main frame.
12. Remove the upper roller bearings and
shims from the main frame. See
Figure 7-191.

Figure 7-191. Main Frame Upper Bearing

Bolt
Stud

Shims

Bearing

13. Remove the lower roller bearings and

shims from the outer telescopic. See
Figure 7-188.
14. Using a suitable hoist, remove the outer
telescopic from the main frame.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7500 (Complete Assembly) Mast, Chain, Hose, Cable

Mast, Model 7500 Figure 7-192. Inner Race

(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 9. Using the hoist, slide the outer telescopic
important because the correct bearing the entire length of the main frame,
alignment is canted with respect to the checking for binding. The tightest spots
channel. See Figure 7-188. are generally at the crossties. Add or
3. Using a suitable hoist, insert the outer remove shims as necessary to maintain a
telescopic into the main frame as far as snug but free-running fit.
the crosstie.
4. Attach the lower roller bearing to the other
Upper Bearings of Main Frame
side of the outer telescopic. 1. With the outer telescopic inserted halfway
5. Using a pry bar, move the outer telescopic into the main frame, attach the upper
and bearing to one side. roller bearing to one side of the main
frame. Make sure the flat spot on the
6. Use spare shims as a gauge to determine
bearing outer stud is correctly positioned
the amount of shims required to cause the
against the mast. See Figure 7-191.
roller bearing to contact the main frame.
2. Attach, but do not tighten, the upper roller
7. Remove both lower bearings. Install one
bearing to the other side of the main
half of the total shim thickness required to
frame.
each roller bearing. Reinstall the bearings.
Apply thread-locking compound 3. Use spare shims as a gauge to determine
(P/N 990-536) to the bearing mounting the amount of shims required to cause the
bolt and torque to 260 ft. lb. (352 Nm). roller bearing to contact the outer
telescopic.
8. If the inner race of the bearing does not
protrude past the end of the bearing stud 4. Remove both upper bearings. Install one
when the bearing is fully seated, bend the half of the total shim thickness required to
flat washer to contact the bearing to each roller bearing. Reinstall the bearings.
prevent the bearing from walking on the Apply thread-locking compound
stud shaft. See Figure 7-192. (P/N 990-536) to the bearing mounting
bolt and torque to 260 ft. lb. (352 Nm).
5. 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
flat washer to contact the bearing to
prevent the bearing from walking on the
stud shaft. See Figure 7-192.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast, Model 7500 (Complete Assembly)

6. Using the hoist, slide the outer telescopic as necessary to maintain a snug but
the entire length of the main frame, free-running fit.
checking for binding. Add or remove shims
as necessary to maintain a snug but Upper Bearings of Outer Telescopic
free-running fit.
1. With the inner telescopic inserted halfway
7. R35TT mast only: Check the clearance
into the main frame, attach the upper
gap of the bow pads between outer
roller bearing to one side of the outer
telescopic and main frame. Shim as
telescopic. Make sure the flat spot on the
required to obtain a gap of 0.03 to 0.09 in.
bearing outer stud is correctly positioned
(0.8 to 2.3 mm).
against the mast. See Figure 7-190.
2. Attach, but do not tighten, the upper roller
Assembling and Shimming bearing to the other side of the outer
Inner Telescopic to Outer telescopic.
Telescopic 3. Use spare shims as a gauge to determine
the amount of shims required to cause the
Lower Bearings of Inner Telescopic roller bearing to contact the inner
telescopic.
1. Attach the lower roller bearing to one side
of the inner telescopic. Make sure the flat 4. Remove both upper bearings. Install one
spot on the bearing outer stud is correctly half of the total shim thickness required to
positioned against the mast. See each roller bearing. Reinstall the bearings.
Figure 7-189. Apply thread-locking compound
(P/N 990-536) to the bearing mounting
2. Using a suitable hoist, insert the inner bolt and torque to 260 ft. lb. (352 Nm).
telescopic into the outer telescopic as far
as the crosstie. 5. If the inner race of the bearing does not
protrude past the end of the bearing stud
3. Attach the lower roller bearing to the other when the bearing is fully seated, bend the
side of the inner telescopic. flat washer to contact the bearing to
4. Using a pry bar, move the inner telescopic prevent the bearing from walking on the
and bearing to one side. stud shaft. See Figure 7-192.
5. Use spare shims as a gauge to determine 6. Using the hoist, slide the inner telescopic
the amount of shims required to cause the the entire length of the outer telescopic,
roller bearing to contact the outer checking for binding. Add or remove shims
telescopic. as necessary to maintain a snug but
6. Remove both lower bearings. Install one free-running fit.
half of the total shim thickness required to 7. 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 in. (0.8 to 2.3 mm).
bolt and torque to 260 ft. lb. (352 Nm).
7. If the inner race of the bearing does not Main Lift Chain Installation
protrude past the end of the bearing stud
when the bearing is fully seated, bend the 1. Install anti-rattle pads and shims at
flat washer to contact the bearing to bottom of inner and outer telescopics.
prevent the bearing from walking on the Shim so pads are snug against mast. See
stud shaft. See Figure 7-192. Figure 7-188 and Figure 7-189.
8. Using the hoist, slide the inner telescopic 2. Install the main lift chain sheaves to the
the entire length of the outer telescopic, top of the outer telescopic. Sheaves install
checking for binding. Add or remove shims with a large pin and a set screw on the
inside. See Figure 7-187.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7500 (Complete Assembly) Mast, Chain, Hose, Cable

3. Install but do not tighten a new sleeve and Shimming Carriage to Inner
collar, washer, and mounting bolt through
the telescopic crosstie and into the
Telescopic
cylinder housing of each main lift cylinder. 1. Drape the free lift chains forward over the
See Figure 7-186. carriage backrest. Rig lifting straps around
4. Rig lifting straps around the upper the carriage.
crossties of all three mast sections. 2. Install the lower set of roller bearings,
5. Using a suitable hoist, raise the mast to a without shims, in the carriage.
vertical position. 3. Using a hoist, carefully lift the carriage
6. Rig a lifting strap of one hoist around the and insert it into the inner telescopic until
lower crosstie of the main frame (the one the bearings just enter the telescopic.
where the overhead guard attaches). 4. Using a pry bar, move the carriage
7. Rig a lifting strap of another hoist around bearings to one side.
the top crossties of both inner and outer 5. Use spare shim(s) as a gauge to determine
telescopics. Using the hoist, lower the the amount of shims required to remove
telescopics to about 10 in. (25 cm) from side play.
the floor.
6. Remove the carriage from the inner
8. Make sure the two holes in the upper telescopic far enough to expose the
chain anchor block are towards the bearings being shimmed.
outside. Feed the main lift chain from the
7. Remove the bearings being shimmed from
outside to the inside over the chain
the carriage. Install one half of the total
sheave.
shim thickness required to each roller
9. Feed the upper chain anchor block down bearing.
between the main frame and outer
8. Using the hoist, reinsert the carriage into
telescopic until holes are aligned between
the inner telescopic. Check for tight areas
block and main frame. Insert the chain
while moving the carriage to the bottom of
anchor bolt (without the access cover) and
the inner telescopic.
lightly tighten the bolt to draw the chain
anchor block to the main frame. 9. Remove the carriage from the inner
telescopic far enough to expose the
10. Thread a bolt into the hole in the chain
bearings being shimmed.
anchor retaining pin. Insert the pin and
drive it in. Remove the bolt from the pin. 10. Remove the bearings being shimmed from
the carriage.
11. Remove the chain anchor bolt. Apply
thread-locking compound (P/N 990-544) NOTE: The carriage may have to be removed
to bolt threads. Install access cover and several times to obtain the correct fit.
torque bolt to 130 ft. lb. (174 Nm).
11. Install the center set of roller bearings,
12. Lower the telescopics into the main frame without shims, in the carriage.
approx. 3 in. (7.6 cm) from the floor.
12. Repeat steps 4 thru 10 for the center set of
13. Install master links to attach the main lift bearings.
chains to the lower chain anchor blocks.
13. Install the upper set of roller bearings,
Lower the telescopics completely. Tighten
without shims, in the carriage.
the chain anchor nuts until the inner
telescopic just lifts off its stops. 14. Repeat steps 4 thru 10 for the upper set of
bearings.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast, Model 7500 (Complete Assembly)

Carriage, Free Lift Cylinder, and 6. Reference Figure 7-194 for the following
steps, that route the hoses/cable.
Hose/Cable Installation
1. Drape the free lift chains forward over the Figure 7-194. OTM Hose and Cable Installation
carriage backrest. Rig lifting straps around
the carriage. Using a hoist, carefully lift
the carriage, insert it into the inner
telescopic, and lower the carriage to about
3 in. (7.6 cm) above the floor.
2. Route cable and hoses around upper
pulleys. Attach upper hose/cable pulley to
the top of the outer telescopic. Apply
thread-locking compound (P/N 1013829)
to the threads of the studs and torque as
shown in Figure 7-193.
3. Route auxiliary hoses around lower
pulleys. Attach lower hose pulley to the
top of the outer telescopic. Apply
thread-locking compound (P/N 1013829)
to the threads of the studs. See
Figure 7-193.

Figure 7-193. OTM Hose/Cable Pulleys

4. Install carriage stops. Apply

thread-locking compound (P/N 990-536)
to mounting bolts and torque to 35 ft. lb.
(47.5 Nm).
5. Remove set screws from free lift mounting
blocks. Lift each free lift cylinder into place 7. Connect hose and crossover tube to free
over the mounting hook at the top and the lift cylinders. See Figure 7-195.
mounting block at the bottom. Apply
thread-locking compound (P/N 990-403)
to set screw threads and install set screws
in mounting blocks.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7500 (Complete Assembly) Mast, Chain, Hose, Cable

Figure 7-195. Free Lift Cylinder Crossover Tube Figure 7-197. Lower Hose/Cable Retainer, Free Lift
Cylinder

8. 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 7-196.

Figure 7-196. OTM Hoses and Cable at Free Lift Pulley

10. Assemble, but do not tighten, the

hose/cable retainer at the top of the free
lift cylinder. See Figure 7-198.

Figure 7-198. Upper Hose/Cable Retainer, Free Lift

Cylinder

Electrical Cable

Aux Hose A1

Aux Hose A2

9. Attach, but do not tighten, the hose/cable

retainer bracket at the bottom of the free
lift cylinder. See Figure 7-197.

11. 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. (19 mm) gap between
the over-the-mast electrical cable and the
bottom of the hose guide. See
Figure 7-199.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast, Model 7500 (Complete Assembly)

Figure 7-199. Hose/Cable Guide on Carriage 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).
20. Assemble, but do not tighten, the
hose/cable retainer on the left side main
lift cylinder. See Figure 7-198.
21. 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).
22. Tighten the hose/cable retainer on the left
Gap side main lift cylinder.
23. Lower the inner telescopic.

Mating Mast to Tractor

1. 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.
2. Attach the hose/cable retaining bracket on
12. Feed the free lift chains over free lift the front (mast side) of the tractor
pulleys, from forks side to tractor side. bulkhead. See Figure 7-200.
Install master links to attach the free lift
chains to the chain anchor blocks.
13. Take slack out of hoses and cable. Make
sure hoses do not cross each other.
14. Install hose/cable retainer on carriage.
See Figure 7-199.
15. Lower the carriage all the way to the floor.
16. Tighten the upper and lower hose/cable
retainers on the free cylinders. Attach two
cable ties on the upper retainer.
17. With the auxiliary manifold removed from
the carriage, connect auxiliary hydraulic
hoses to the manifold, making sure to
observe correct labeling.
18. Attach the manifold to the carriage. Apply
thread-locking compound (P/N 990-536)
to the mounting bolt threads and torque to
21 ft. lb. (29 Nm).
19. Connect the over-the-mast cable wires to
the terminal block on the auxiliary

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7500 (Complete Assembly) Mast, Chain, Hose, Cable

Figure 7-200. Hose/Cable Retainer Clamps on Tractor 6. Thread four mounting bolts and washers
through the top of the tractor frame into
the mast.
7. Tighten lower mast mounting bolts 1 thru
4 and torque to 130 ft. lb. (176 Nm) in the
sequence shown in Figure 7-201. Check
for a gap between the mast plate and the
tractor mounting plate at bolt #5.
a. If gap is less than 0.010 in. (0.25 mm),
tighten bolts 5 thru 8 to 130 ft. lb.
(176 Nm).
b. If gap is more than 0.010 in. (0.25 mm),
install shim(s) as needed to reduce gap
to 0.010 in. (0.25 mm) or less. Torque
bolts 5 thru 8 to 130 ft. lb. (176 Nm).

Figure 7-201. Tightening Lower Mast Mounting Bolts - First

Torque Sequence
#1 #3 #7 #5

View from inside battery compartment

#2 #4 #8 #6

Install shim(s) between mast and tractor mounting plates at bolts 5 and 6
3. With the mast secured by a hoist, use a lift
truck to mate the tractor to the mast. 8. Torque bolts 1 thru 8 to 170 ft. lb.
(230 Nm) in the sequence shown in
4. Apply thread-locking compound
Figure 7-202.
(P/N 990-544) around the first 2 to 3
threads of the mast mounting bolts.
Figure 7-202. Tightening Lower Mast Mounting Bolts -
5. From the battery compartment, thread Second Torque Sequence
eight mounting bolts and washers through #1 #3 #5 #7
bottom of the tractor frame into the mast.

#2 #4 #6 #8

View from inside battery compartment

9. Tighten four upper mast mounting bolts

and torque to 170 ft. lb. (230 Nm).
10. Connect the main lift hose fitting at the left
side of the tractor.
11. Route the auxiliary hoses and electrical
cable through the tractor opening. Secure
hoses and cable with retainer clamps. See
Figure 7-200.
12. Install the battery connector bracket.
13. Connect auxiliary hoses A1 and A2 at the
main manifold, observing labels.
14. Connect over-the-mast cable connector
JPS3 on the tractor deck. See
Figure 7-164.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast, Model 7500 (Complete Assembly)

15. 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.
16. Connect the ambient temperature sensor
cable connector JPA on the tractor deck.
17. Connect HTI encoder to JP13 and JPS11.
18. Connect the right side main lift hose to the
fitting on the tractor bulkhead.
19. 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.
20. Apply thread-locking compound
(P/N 990-536) to the mounting bolt
threads. Install mounting bolts and torque
to 130 ft. lb. (174 Nm).
21. Install the mast guard.
22. Using a suitable battery moving device,
install the battery. Install battery gates.
23. Install covers.
24. Make sure all hoist straps and blocks are
removed.
25. Reconnect the battery connector and turn
the key switch ON.
26. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on page 7-88.
27. Test all lift truck functions.
28. Apply thread-locking compound
(P/N 990-536) and tighten main lift
cylinder L-bracket mounting bolts to 55 ft.
lb. (74.5 Nm).
29. Using a work basket and lift truck, grease
the channels of all sections of the mast.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7520 (Complete Disassembly) Mast, Chain, Hose, Cable

Mast, Model 7520 12. Place blocks snugly under the tractor near
the mast.
(Complete Disassembly) 13. Attach a lifting strap around the top
crossties of all three mast sections. Draw
tight with hoist. Make sure the weight of
Separation of Tractor and Mast the mast is supported by the hoist.
• Do this procedure with a minimum 14. Remove the battery connector bracket to
of two technicians in a shop permit access to the top right mast
equipped with a suitable hoist. mounting bolts.
• Do not permit observers to stand 15. Use an impact wrench to remove the mast
nearby. mounting bolts inside the battery
• Wear gloves, safety glasses, compartment, four on the top, eight on the
steel-toed safety boots, and a safety bottom.
helmet (hard hat). 16. Using a lift truck, carefully separate the
1. Lower and retract the fork carriage tractor about 6 in. (15 cm).
completely. 17. Reinstall mast mounting bolts and
2. Turn the key switch OFF and disconnect washers and tighten lightly (to prevent
the battery connector. Remove battery misplacing them).
gates. Using a suitable battery removal
device, remove the battery. Hose/Cable, Free Lift Cylinder,
3. Remove the top cover and the left and right and Carriage Removal
front covers.
4. Remove the mast guard. 1. Remove the auxiliary manifold cover from
the carriage. See Figure 7-203 on
5. Secure a hoist strap around the overhead page 7-163.
guard. Take the weight off the guard.
Remove mounting bolts. Remove the 2. Disconnect the wires of the over-the-mast
guard. cable from terminal strip TS-2, labeling as
needed for re-connection.
6. Disconnect and cap right side main lift
3. Remove auxiliary manifold mounting
hose at the tractor bulkhead fitting.
screws to permit access to the
7. Disconnect the ambient temperature over-the-mast hose fittings at the
sensor connector JPA on the tractor deck. manifold.
8. Disconnect the mast switch connector
NOTE: There may be shims between the
JPS4 (near the lift pump). Feed harness
manifold and carriage.
through tractor opening at right side.
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
needed for correct reassembly. Feed hoses
through opening in tractor bulkhead.
11. Disconnect the main lift hose fitting at the
left side of the tractor.
NOTE: 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.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast, Model 7520 (Complete Disassembly)

Figure 7-203. Auxiliary Manifold Access Figure 7-205. U-clamp, OTM Electrical Cable
7DSC_0942a.jpg 71066854_B2.cgm

U-clamp

4. Disconnect and plug/cap the

over-the-mast hoses and fittings at the
auxiliary manifold. Label as needed to
ensure correct re-connection.
5. Place a chalk witness mark on the hoses to 8. Cut cable ties on hose clamps on left side
aid in reassembly. free lift cylinder.
6. Remove hose retaining clamp near top of 9. Loosen the hose retaining clamp on the
the left side free lift cylinder. See carriage near the bottom of the left side
Figure 7-204. free lift cylinder. Slide clamp inward to free
the hoses. See Figure 7-206.
Figure 7-204. Hose Retaining Clamp, Left Free Lift Cylinder
71066854_B11.cgm
Figure 7-206. Hose Retaining Clamp, Left Free Lift Cylinder,
Bottom
71066854_B13.cgm

7. Loosen the U-clamp on the right side free

lift cylinder and feed the over-the-mast 10. Feed hoses and cable through free lift
(OTM) cable through. See Figure 7-205. cylinder pulleys.
11. Jack carriage up about 3 in. (7.6 cm) to
provide slack in chains. Remove master
links on free lift chains. Feed free lift

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7520 (Complete Disassembly) Mast, Chain, Hose, Cable

chains through pulleys and drape over Figure 7-207. Free Lift Cylinder Mounting Stud and Pin
71051676_D.cgm
front of carriage.
12. Remove carriage stops at the top of the Free Lift Cylinder
inner telescopic. Mounting Stud

13. 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.
14. Disconnect and plug the hydraulic supply
hose at the bottom of the free lift cylinders.
15. Disconnect the free lift crossover hose and
cap both cylinders.
16. Remove the nylon locking nut from the
mounting stud on the free lift cylinder. Lift
each free lift cylinder off the mounting
stud at the top and off the pin at the
bottom. See Figure 7-207. Free Lift Cylinder
Mounting Pin

Main Lift Chain Removal

1. Rig a lifting strap of one hoist around the
lower crosstie of the main frame (the one
where the overhead guard attaches).
2. 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).
3. Remove the kickback block, pads, and
shims at the bottom of the inner
telescopic. See Figure 7-208.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast, Model 7520 (Complete Disassembly)

Figure 7-208. Inner Telescopic Kickback Block, Pad, Shims
71051418_E8.cgm
Separation of Telescopics
1. Using the hoists, carefully lower the mast
to a horizontal position on jack stands.
Kickback 2. Loosen the L-bracket bolts holding the
Block main lift cylinders to the telescopic.
3. Remove the top mounting bolt, washer,
Mounting and sleeve holding the main lift cylinder to
Screws the outer telescopic. See Figure 7-210.

Figure 7-210. Main Lift Cylinder Mounting Hardware

71051674_B.cgm

Shim Mounting Bolt

Kickback
Pad
Washer

Sleeve
4. Remove the chain anchor retaining nut
from the chain anchor block at the bottom
of the inner telescopic.
5. Remove the bolt and access cover to the
upper chain anchor at the sides of main
frame. See Figure 7-209.
6. Remove the chain anchor pin by using a Outer
slide hammer or by using a large socket Telescopic
(1 1/16 in.), an M8 x 50 mm bolt, and
4. Remove main lift chain sheaves from top of
washers to act as a pulling device.
outer telescopic. Sheaves attach with a pin
See Figure 7-209 and Figure 7-159 on
and a retaining screw on the front. See
page 7-134.
Figure 7-211.
Figure 7-209. Main Lift Chain Upper Chain Anchor
7R1020561_A1.cgm
Figure 7-211. Main Lift Chain Sheave
71051418_E6.cgm

Bolt
Sheave
Cover
Spacer Chain

Pin Bearing

Chain Snap Ring

Anchor
Pin

Retaining Screw
7. Pull the chain anchor/mast stop out of the
main frame.
5. Remove anti-rattle pads and shims from
8. Feed main lift chains from inside to
bottom of outer telescopic. See
outside over the chain sheave.
Figure 7-212.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7520 (Complete Disassembly) Mast, Chain, Hose, Cable

Figure 7-212. Outer Telescopic Lower Bearing and Figure 7-214. Main Frame Upper Bearing
Anti-Rattle Pads 71051418_E5.cgm

71051418_E7.cgm

Bolt

Stud

Bearing
Retaining
Shim Screw and
Washer
Bearing

Pad Shim Cover 12. Remove the lower roller bearings and
shims from the outer telescopic. See
6. Using a suitable hoist, pull the inner
Figure 7-212.
telescopic halfway out of the outer
telescopic. 13. Using a suitable hoist, remove the outer
telescopic from the main frame.
7. Remove the upper roller bearings and
shims from the top of the outer telescopic.
See Figure 7-213.

Figure 7-213. Outer Telescopic Upper Bearing

71051418_E6.cgm

Stud
Shim

Bearing

Bearing Retaining
Screw and Washer
8. Remove the lower roller bearings and
shims from the bottom of the inner
telescopic. See Figure 7-208.
9. Using a suitable hoist, remove the inner
telescopic from the outer telescopic.
10. Using a suitable hoist, pull the outer
telescopic halfway out of the main frame.
11. Remove the upper roller bearings and
shims from the main frame. See
Figure 7-214.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast, Model 7520 (Complete Assembly)

Mast, Model 7520 Figure 7-215. Inner Race

7mastbearshim1.jpg

(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
9. Using the hoist, slide the outer telescopic
important because the correct bearing
the entire length of the main frame,
alignment is canted with respect to the
checking for binding. The tightest spots
channel. See Figure 7-212.
are generally at the crossties. Add or
3. Using a suitable hoist, insert the outer remove shims as necessary to maintain a
telescopic into the main frame as far as snug but free-running fit.
the crosstie.
4. Attach the lower roller bearing to the other Upper Bearings of Main Frame
side of the outer telescopic.
1. With the outer telescopic inserted halfway
5. Using a pry bar, move the outer telescopic into the main frame, attach the upper
and bearing to one side. roller bearing to one side of the main
6. Use spare shims as a gauge to determine frame. Make sure the flat spot on the
the amount of shims required to cause the bearing outer stud is correctly positioned
roller bearing to contact the main frame. against the mast. See Figure 7-214.
7. Remove both lower bearings. Install one 2. Attach but do not tighten the upper roller
half of the total shim thickness required to bearing to the other side of the main
each roller bearing. Reinstall the bearings. frame.
Apply thread-locking compound 3. Use spare shims as a gauge to determine
(P/N 990-536) to the bearing mounting the amount of shims required to cause the
bolt and torque to 260 ft. lb. (352 Nm). roller bearing to contact the outer
8. If the inner race of the bearing does not telescopic.
protrude past the end of the bearing stud 4. Remove both upper bearings. Install one
when the bearing is fully seated, bend the half of the total shim thickness required to
flat washer to contact the bearing to each roller bearing. Reinstall the bearings.
prevent the bearing from walking on the Apply thread-locking compound
stud shaft. See Figure 7-215. (P/N 990-536) to the bearing mounting
bolt and torque to 260 ft. lb. (352 Nm).
5. 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
flat washer to contact the bearing to
prevent the bearing from walking on the
stud shaft. See Figure 7-215.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7520 (Complete Assembly) Mast, Chain, Hose, Cable

6. Using the hoist, slide the outer telescopic roller bearing to one side of the outer
the entire length of the main frame, telescopic. Make sure the flat spot on the
checking for binding. Add or remove shims bearing outer stud is correctly positioned
as necessary to maintain a snug but against the mast. See Figure 7-208.
free-running fit. 2. Attach but do not tighten the upper roller
bearing to the other side of the outer
Assembling and Shimming telescopic.
Inner Telescopic to Outer 3. Use spare shims as a gauge to determine
Telescopic the amount of shims required to cause the
roller bearing to contact the inner
telescopic.
Lower Bearings of Inner Telescopic
4. Remove both upper bearings. Install one
1. 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 7-208. bolt and torque to 260 ft. lb. (352 Nm).
2. Using a suitable hoist, insert the inner 5. 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
3. 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
stud shaft. See Figure 7-214.
4. Using a pry bar, move the inner telescopic
and bearing to one side. 6. Using the hoist, slide the inner telescopic
the entire length of the outer telescopic,
5. 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.
6. Remove both lower bearings. Install one 7. 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 in. (0.8 to 2.3 mm).
(P/N 990-536) to the bearing mounting
bolt and torque to 260 ft. lb. (352 Nm).
7. If the inner race of the bearing does not
Main Lift Chain Installation
protrude past the end of the bearing stud 1. 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 7-212 and Figure 7-208.
stud shaft. See Figure 7-215.
2. Install the main lift chain sheaves to the
8. Using the hoist, slide the inner telescopic top of the outer telescopic. Sheaves install
the entire length of the outer telescopic, with a large pin and a retaining screw on
checking for binding. Add or remove shims the front. See Figure 7-211.
as necessary to maintain a snug but
3. Install, but do not tighten, a new sleeve
free-running fit.
and collar, washer, and mounting bolt
through the telescopic crosstie and into
Upper Bearings of Outer Telescopic the cylinder housing of each main lift
cylinder. See Figure 7-210.
1. With the inner telescopic inserted halfway
into the main frame, attach the upper

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast, Model 7520 (Complete Assembly)

4. Rig lifting straps around the upper 3. Using a hoist, carefully lift the carriage
crossties of all three mast sections. and insert it into the inner telescopic until
5. Using a suitable hoist, raise the mast to a the bearings just enter the telescopic.
vertical position. 4. Using a pry bar, move the carriage
6. Rig a lifting strap of one hoist around the bearings to one side.
lower crosstie of the main frame (the one 5. Use spare shim(s) as a gauge to determine
where the overhead guard attaches). the amount of shims required to remove
7. Rig a lifting strap of another hoist around side play.
the top crossties of both inner and outer 6. 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. 7. Remove the bearings being shimmed from
8. 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 8. Using the hoist, reinsert the carriage into
sheave. the inner telescopic. Check for tight areas
9. 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 9. 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. 10. Remove the bearings being shimmed from
the carriage.
10. 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.
11. Remove the chain anchor bolt. Apply 11. 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 12. Repeat steps 4 thru 10 for the center set of
torque bolt to 130 ft. lb. (174 Nm). bearings.
12. Lower the telescopics into the main frame 13. Install the upper set of roller bearings,
approx. 3 in. (7.6 cm) from the floor. without shims, in the carriage.
13. Insert chain anchor bolts into chain 14. Repeat steps 4 thru 10 for the upper set of
anchor blocks. Lower the telescopics bearings.
completely. Tighten the chain anchor nuts
until the inner telescopic is 3/8 in.
(9.5 mm) off of the outer telescopic. Carriage, Free Lift Cylinder, and
Hose/Cable Installation
Shimming Carriage to Inner 1. Drape the free lift chains forward over the
Telescopic carriage backrest. Rig lifting straps around
the carriage. Using a hoist, carefully lift
1. Drape the free lift chains forward over the the carriage and insert it into the inner
carriage backrest. Rig lifting straps around telescopic and lower the carriage to about
the carriage. 3 in. (7.6 cm) above the floor.
2. Install the lower set of roller bearings, 2. Route lift hose and cable around upper
without shims, in the carriage. pulleys. See Figure 7-216.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7520 (Complete Assembly) Mast, Chain, Hose, Cable

3. Route auxiliary hoses around lower

pulleys. See Figure 7-216.

Figure 7-216. Over-the-Mast Hose/Cable Pulleys

71045742_D2.cgm

Cable
Main Lift

Aux

4. 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).
5. Lift each free lift cylinder into place over
the mounting stud at the top and the pin
at the bottom. See Figure 7-207 on
page 7-164.
6. Refer to Figure 7-217 for the following
steps to route the hoses/cable.

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast, Model 7520 (Complete Assembly)

Figure 7-217. Over-the-Mast Hose and Cable Installation 7. Connect supply hose and crossover tubing
71066854_B2.cgm
to free lift cylinders. See Figure 7-218.

Figure 7-218. Free Lift Cylinder Hose Connection

71066854_B9.cgm

Crossover Tubing

8. Attach and tighten the hose retainer

bracket at the bottom of the free lift
cylinder. See Figure 7-219.

Figure 7-219. Lower Hose/Cable Retainer, Free Lift

Cylinder
71066854_B4.cgm

9. Feed hydraulic hoses and electrical cable

through the free lift pulleys, from tractor
side to forks side. See Figure 7-220.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7520 (Complete Assembly) Mast, Chain, Hose, Cable

Figure 7-220. OTM Hoses and Cable at Free Lift Pulley 20. Connect the over-the-mast cable wires to
71066854_B3.cgm
the terminal block on the auxiliary
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).

Mating Mast to Tractor

1. 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.
2. With the mast secured by a hoist, use a lift
truck to mate the tractor to the mast.
3. Apply thread-locking compound
(P/N 990-544) around the first 2 to 3
threads of the mast mounting bolts.

10. Attach and tighten the hose retaining

clamp on the carriage near the bottom of
the left side free lift cylinder. See
Figure 7-206 on page 7-163.
11. Replace cable ties on hose clamps on left
side free lift cylinder.
12. Feed the OTM electrical cable through the
U-clamp on the right side free lift cylinder.
See Figure 7-217 on page 7-170.
13. Attach and tighten the hose retaining
clamp near top of the left side free lift
cylinder. See Figure 7-204 on page 7-163.
14. 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.
15. Take slack out of hoses and cable.
16. Lower the carriage all the way to the floor.
17. Tighten the upper and lower hose clamps
on the free lift cylinders.
18. With the auxiliary manifold removed from
the carriage, connect auxiliary hydraulic
hoses to the manifold, making sure to
observe correct labeling.
19. Attach the manifold to the carriage. Apply
thread-locking compound (P/N 990-536)
to the mounting bolt threads and torque to
21 ft. lb. (29 Nm).

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Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures

Mast, Chain, Hose, Cable Mast, Model 7520 (Complete Assembly)

4. From the battery compartment, thread Figure 7-222. Tightening Lower Mast Mounting Bolts -
eight mounting bolts and washers through Second Torque Sequence
bottom of the tractor frame into the mast. #1 #3 #5 #7

View from inside battery compartment

#2 #4 #6 #8

8. Tighten four upper mast mounting bolts

and torque to 170 ft. lb. (230 Nm).
9. Connect the main lift hose fitting at the left
side of the tractor.
10. Install the battery connector bracket.
11. Connect auxiliary hoses A1 and A2 at the
main manifold, observing labels.
12. Connect over-the-mast cable connector
JPS3 on the tractor deck. See &IGURE 
13. 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.
14. Connect the ambient temperature sensor
5. Thread four mounting bolts and washers
cable connector JPA on the tractor deck.
through the top of the tractor frame into
the mast. 15. Connect HTI encoder to JP13 and JPS11.
6. Tighten lower mast mounting bolts 1 thru 16. Connect the right side main lift hose to the
4 and torque to 130 ft. lb. (176 Nm) in the fitting on the tractor bulkhead.
sequence shown in Figure 7-221. Check 17. Secure a hoist strap around the overhead
for a gap between the mast plate and the guard or position a lift truck with pallet
tractor mounting plate at bolt #5. under the overhead guard. Lift the guard
a. If gap is less than 0.010 in. (0.25 mm), into position at the lower crosstie of the
tighten bolts 5 thru 8 to 130 ft. lb. main frame.
(176 Nm). 18. Apply thread-locking compound
b. If gap is more than 0.010 in. (0.25 mm), (P/N 990-536) to the mounting bolt
install shim(s) as needed to reduce gap threads. Install mounting bolts and torque
to 0.010 in. (0.25 mm) or less. Torque to 130 ft. lb. (174 Nm).
bolts 5 thru 8 to 130 ft. lb. (176 Nm). 19. Install the mast guard.

Figure 7-221. Tightening Lower Mast Mounting Bolts - First

20. Using a suitable battery moving device,
Torque Sequence install the battery. Install battery gates.
21. Install covers.
#1 #3 #7 #5
22. Make sure all hoist straps and blocks are
View from inside battery compartment
removed.
#2 #4 #8 #6
Install shim(s) between mast and tractor mounting plates at bolts 5 and 6 23. Reconnect the battery connector and turn
the key switch ON.
7. Torque bolts 1 thru 8 to 170 ft. lb. 24. Bleed the hydraulic system. See
(230 Nm) in the sequence shown in “Hydraulic System Bleeding” on page 7-88.
Figure 7-222.
25. Test all lift truck functions.

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Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks

Mast, Model 7520 (Complete Assembly) Mast, Chain, Hose, Cable

26. Apply thread-locking compound and

tighten main lift cylinder L-bracket
mounting bolts to 55 ft. lb. (74.5 Nm).
27. Using a work basket and lift truck, grease
the channels of all sections of the mast.

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Section 8. Theory of Operation

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Traction System Functional Operation

Traction System RELAY_ENABLE at JPC14-6 taking the

relay coils for K1, K2, K3, and K4 to B–
Functional Operation internal to the VM. The VM also uses this
input to calculate BSOC and compares it
to the last battery voltage in its memory.
Battery Connected The VM then determines if the display
requires updating.
When the battery is connected, the truck has • The tips of K1, K2, K3, and K4 close,
B+ and B– supplied to the following points: supplying B+ to the following:
• B+ to JPF4-3 and 4-4 through FU7 and to • B+K3 at JPT1-1 and JPL1-1 are used
the normally open tips of K1 relay and by the amplifiers to power their internal
JPF4-15. circuitry that includes power supplies.
• B+ to JPF4-1 and 4-2 through FU5 to the The power supplies provide 12V to the
normally open tips of K2, K3, K4, the K4 velocity sensors (encoders) and
coil, and the key switch S1. JPF4-1 and temperature sensors for the Traction
JPF4-2 also supply the VM with Motor and the Lift Motor.
BATTERY_SENSE_IN at JPC24-24. It is • B+K3 at JPT1-12 and JPL1-11 to
protected by a thermistor for overcurrent establish whether the amp is a traction
conditions caused by shorts in the wiring. amp or a lift amp.
• B+ to the normally open tips of the Steer, • All hydraulic solenoids, Nested Switch,
Main (AC lift), and Traction (DC lift) Horn, Brake, and FAN-T, -FW, -FW2,
contactors. LM, and -DU are supplied by B+K2.
• B– is supplied to all points labeled B–, B–F, • connections for optional devices at
any sensor connection with a (–) negative JPF2-9 by B+K1.
label and DGND.
• B+ is supplied to the VM by B+K4. It is
used to power the heaters on trucks
Key Turned ON with the Cold Storage option.
• With all microprocessors powered up,
When the key switch is turned ON, B+ is SelfTest continues:
supplied to the following points:
• the VM checks to make sure its power
• through the EPO switch to the coils of K1, supplies are within range.
K2, and K3.
• the VM checks the BUS to make sure
• to JPC14-12 at the VM as B+ Key. This, communications are functioning with
internal to the VM, activates the power all other devices (DISPLAY, LPA, and
supply circuits that supply all 12V and 5V TPA).
outputs from the VM and activates the
microprocessor in the VM. The power • the amplifiers check the pre-charge
supply’s maintain a steady output as long circuit voltages to make sure they are
as battery voltage remains above 17V. in range. If not, a message is sent over
With the power supplies activated, 12V is the BUS to the VM and a code is
supplied to the display. The display displayed.
contains a microprocessor that requires • on trucks with AC lift, the VM checks
firmware updates any time the VM is the status of the MPC and STR
updated. contactors to make sure they are open.
• The processor in the VM looks at On trucks with Regen Lower, it also
BATTERY_SENSE_IN (JPC24-24) and checks the AUX contactor. On trucks
verifies it is within the required with DC lift, the VM checks the LPC,
parameters for the amps, 28 to 45V. If it is, TPC, and STR.
there is an output from the processor to

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Traction System Functional Operation

• The VM activates the circuitry to close • the VM checks to make sure the
the contactors. The contactors are Ambient Temperature Sensor is within
checked to make sure power is supplied the acceptable range.
through the contactor tips using the • the VM checks its memory for all
sense lines. previously logged faults that have not
• the VM verifies the EPO switch is closed been cleared.
using EPO_SENSE. • after SelfTest is complete, the MPC
• the software and configured parameters contactor remains energized for approx.
are checked in the LPA, TPA, Display, 30 seconds. If no function requests are
and VM to make sure they are within made by the operator, it opens. On
limits and correct. trucks with DC lift, the TPC remains
• the amplifiers check to make sure there closed for approx. 30 seconds and the
are no shorts in the power circuits. LPC contactor opens after circuits are
tested. The STR contactor opens on
• the VM checks to make sure the both trucks as soon as the circuits are
Deadman Switch is open. tested. The VM also monitors the
• the VM checks to make sure the Steer temperature inputs from the TPA and
Tiller Encoder is connected. LPA. Anytime one of the readings goes
• the VM checks to make sure the lift above the limits defined in the Analog
potentiometer (VR2) and throttle Tests, the VM turns on fans T, FW,
potentiometer (VR1) are within 0.2V of FW2, DU, and closes the Aux contactor.
the learned neutral position and are not
outside the allowable minimum and Deadman Pedal Depressed
maximum voltages. They are
continuously monitored and messages When the deadman pedal is depressed, the
are displayed if activated prior to Deadman Switch (DS1) is closed, supplying the
closing the deadman switch. VM with B– through JPC22-8, DEADMAN DS1.
• the TPA is commanded to activate the This activates circuitry that informs the VM the
Traction Motor to make sure current is switch is closed.
seen and there are no motor velocity
sensor (encoder) inputs. This is to make With the Deadman Switch closed, the VM tells
sure the power circuits are functional the LPA and TPA it is closed and commands the
and the brake is applying resistance to MPC and STR contactors to be closed on trucks
the Traction Motor. with AC lift and the AUX contactor on trucks
with Regen Lower. Trucks with DC lift do not
• the VM checks the state of the control
close the LPC until there is a lift request seen by
handle switches to make sure they are
the VM. The VM now reacts to any request from
in the open position. They are
control pots or switches for lift/lower, travel,
continuously monitored and messages
and aux functions. When the Deadman Switch
are displayed if activated prior to
is opened again, the MPC remains energized for
closing the deadman switch.
30 seconds with no functions commanded and
• the VM checks the information from the then opens. On trucks with Regen Lower, the
TPA and LPA to make sure the motor Aux contactor remains closed for 25 seconds,
temperature sensor readings are within then opens. The STR contactor remains
range and determines if speed limiting energized for 3 seconds and then opens. The
is required. Deadman Switch then must close again for the
• the VM checks pressure transducer contactors to energize.
readings to make sure they are within
range. With the Deadman Switch closed, the TPA
continuously monitors the input from the
Traction Motor Encoder (TME). If no travel

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Traction System Functional Operation

request is seen from the control handle and verify the encoder is functioning correctly. Once
inputs are seen from the sensor, the TPA this information is processed, the VM sends out
powers the Traction Motor as required to keep a chopped DC voltage to the Steer Amplifier
the truck in the same position. This prevents over CCW_PWM or CW_PWM. CCW_PWM is a
unwanted movement on uneven surfaces, dock request for the drive unit to be turned in the
plates or ramps, or if placing a pallet in the rack counterclockwise direction and CW_PWM is a
system. command to turn in the clockwise direction.
Based on the OFF time between the square
waves, the Steer Amplifier determines the speed
Electric Steering 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 that has positive voltage
Steering, the VM reverses the CW and applied to it, MS-A1 or MS-A2. The VM then
CCW commands to the Steer Amplifier. monitors the inputs from the Steer Motor
It also looks for feedback from the Steer Encoder to determine the direction and speed
Motor Encoder in the opposite direction. the motor is turning and compares it to the
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
monitor the inputs from the Steer Amplifier, Motor is approx. 100 amps and is controlled by
Steer Tiller Encoder, and the Steer Motor the Steer Amplifier. The VM uses this input
Encoder. The VM is looking for a current draw when checking the steering system for shorts or
on the 12V lines that power the two Steer Tiller opens in the power circuit. The VM also
Encoders. With no steer requests from the Steer monitors the input from the END OF STEER
Tiller Encoder, the VM looks for an input from ROTATION SWITCH (S11), mounted next to the
the Steer Amplifier on JPC6-1, 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 the drive unit. As the drive unit nears the end of
connected and powered up. The its rotation, the metal ring is no longer under
NEUTRAL_PULSE is created by the VM sending the proximity switch and the switch opens prior
a very low steering command over the CCW and to hitting the drive unit’s mechanical stop.
CW wires to the Steer Amplifier. These When the input to the VM goes high at
commands are alternated back and forth JPC22-22 STEER_LIMIT, the VM no longer
between CCW and CW. This creates a toggling sends out a steer command in that direction. It
high/low input on the NEUTRAL_PULSE line only sends out commands when there is a
that changes about 10 times a second. When a request in the opposite direction from the
steer command is present, this input does not operator. This prevents the steering system
toggle as fast and the VM ignores it. When the from being held in current limit.
operator turns the steering wheel, a set of
square wave voltages (chopped DC voltage) is Travel Request
sent to the VM on Channels A _1, B_1, A _2, and
B_2. The VM looks at the square waves as sets.
A _1 and B_1 are one set and A _2 and B_2 are Primary Control Handle
another set. Based on which channel of the set
is seen first, A or B, the VM determines the With the Deadman Switch (DS1) closed, the VM
direction the operator has requested the drive constantly sends an RPM request that causes
unit to turn. The VM determines the requested the TPA to maintain the speed requested by the
speed by the amount of time between the operator. With the Primary Control Handle in
square waves. Less OFF time between them neutral, the request is always at 0 RPM. When
means a faster rotation was requested. Two sets the VM sees a change in the learned neutral
are used so the VM can compare them and voltage from the Primary Control Handle travel

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Traction System Functional Operation

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 TPA
over the BUS as a command to travel in the
appropriate direction at the RPM to obtain the
requested speed. The TPA then determines the
correct sequence to energize the motor leads (U,
V, and W) to move the truck in the correct
direction. The TPA also determines the required
amount of voltage to send through the motor
leads based on the acceleration parameters
programmed and the requested RPM. The TPA
then monitors the feedback from the TME to
adjust the voltage to the Traction Motor to
maintain the requested RPM and direction. Any
conditions that prevent the TPA from
maintaining these requests are sent over the
BUS to the VM. The VM tells the Display, via
the BUS, to display a message informing the
operator. The VM also invokes any system shut
down or limitations based on the information
from the TPA.

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
to 1 mph (1.6 km/h).

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Cold Storage

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 switch is turned OFF,
K1, K2, and K3 all open because they are
powered from 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 Cold
Storage option. 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 are operable
until the key is turned ON and the truck is
powered up.

On Regen Lower trucks equipped with the Cold

Storage option, cooling fans are powered on
below 51°F (10.5°C).

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Hydraulic System Functional Operation (AC Lift Without Regen Lower)

Hydraulic System Sideshift Cylinder

Functional Operation The sideshift cylinder is a double-acting

hydraulic cylinder used to shift the load left and
(AC Lift Without Regen right with respect to the mast.

Lower) Tilt Cylinder

System Components The tilt cylinder is a double-acting hydraulic

cylinder used to tilt the forks up and down.
Main Lift/Aux Pump (P1)
Load Holding Valve (SOL1)
Pump P1 is a positive displacement gear pump
that rotates clockwise from the shaft end. P1 is The load holding valve is a normally closed
used for all lift and aux functions. solenoid valve used to hold the carriage and
telescopics in an elevated position. It
incorporates an override to allow lowering the
Main Lift System carriage and telescopics manually.

The main lift system consists of four single

acting hydraulic cylinders. Hydraulic fluid flows Proportional Lower Valve (SOL2)
from the main manifold through a tee-fitting in
the tractor, through fittings in the left and right The proportional lower valve is a pressure
front of the tractor bulkhead. The right side compensated flow control solenoid valve used to
hose feeds the right side main lift cylinder. The lower the carriage and telescopics. As the
left side divides again at a tee-fitting, supplying voltage to the valve increases, the flow through
both the left side main lift cylinder and the free the valve increases, regardless of the pressure.
lift cylinders. At the bottom of the free lift
cylinders, another tee-fitting divides the flow Proportional Relief (SOL3/Dump)
between left and right free lift cylinders. A flow
limiter is installed at one of the free lift and one SOL3 is a proportional solenoid valve used as a
or both of the main lift cylinders. system relief. In addition, SOL3 is used to divert
hydraulic fluid from Pump P1 back to the
When the operator requests lift, the entire lift reservoir after a lift is stopped and the pump is
system is pressurized. Since the carriage still spinning. It also acts as a valve to port
weighs less than the carriage plus telescopic, excess hydraulic fluid back to the reservoir from
the free lift cylinders extend first, elevating the the auxiliary functions.
carriage. When they reach the limit of their
travel, the main lift cylinders extend, elevating SOL5B/SOL5T
the telescopics.
SOL5 is a directional solenoid valve providing
Reach/Retract Cylinder directional control to the reach, tilt, and
sideshift functions. De-energized, flow is
The reach/retract cylinder is a double-acting blocked to the aux functions and directed to the
hydraulic cylinder used for extending and reservoir. When SOL5B is energized, flow is
retracting the forks from the mast. directed to port A1 for tilt up, sideshift right, or
retract. When SOL5T is energized, flow is
directed to port A2 for tilt down, sideshift left, or
reach.

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Hydraulic System Functional Operation (AC Lift Without Regen Lower)

Reach/Retract Solenoid (REACH SOL) Lift Motor Encoder

REACH SOL is a normally closed solenoid valve The Lift Motor Encoder is a two-channel
used to block (de-energized) or allow (energized) encoder. It provides the lift power amplifier with
fluid flow to and from the reach cylinders. motor speed for motor speed regulation during
lift and aux functions.
Sideshift Solenoid (SIDESHIFT SOL)
Lift Motor Temperature Sensor
SIDESHIFT SOL is a normally closed solenoid
valve used to block (de-energized) or allow The Lift Motor Temperature Sensor is mounted
(energized) fluid flow to and from the sideshift internally in the Lift Motor. Its purpose is to tell
cylinder. the lift power amplifier the temperature of the
lift motor.
Tilt Solenoid (TILT SOL)
Load Shuttle (LS-1)
TILT SOL is a normally closed solenoid valve
used to block (de-energized) or allow (energized) The load shuttles are 2-input, pressure
fluid flow to and from the tilt cylinder. activated, 2-position valves. In each shuttle, the
higher of the input pressures passes through
the valve at the pressure out port. The output
Flow Limiter Valve
port provides flow used to operate pressure-
activated devices such as piloted relief or
Flow limiter valves are used to limit the
metering valves. The load shuttles provide
maximum lower speed of the forks. A pilot port
pressure feedback to the pilot line of the POD
forces restricted flow through the restricted
valve to allow it to position itself for correct
portion of the valve during lower. A spring and
auxiliary and lift function operation.
pilot port keeps the restricted portion of the
valve closed, allowing free flow during lift.
Priority On Demand (POD) Valve
Aux Relief Valve (RV4)
This is a pilot operated spring return valve that
divides flow between the lift and auxiliary
RV4 is a relief valve used to protect auxiliary
functions as required. It also provides a path to
system components against excessive pressure.
the reservoir for excess hydraulic fluid from P1.
It is factory-adjusted to 2000 psi (13790 kPa). A
manual adjustment knob can be turned
clockwise to increase the relief pressure, or Theory of Lift/Aux Functions
counterclockwise to decrease the relief
pressure. Lift

Hydraulic Filter Lift speed varies directly with Lift Motor rpm.
The voltage supplied to the Lift Motor is
The hydraulic system has one filter in the proportional to the amount of lift request from
reservoir. All hydraulic fluid is filtered on the VR2 (faster lift = higher motor voltage).
return to the reservoir. Maximum lift speed for a given weight load is
governed by software.
Lift Motor (LM)
Weight is calculated from inputs to the VM from
The Lift Motor is a brushless, three-phase the pressure transducer. Weight of the empty
internally delta connected variable-speed AC carriage and telescopic is calculated during
motor. Learn Mode.

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Hydraulic System Functional Operation (AC Lift Without Regen Lower)

Prior to requesting a lift, all valves are in the energized SOL2. After fluid exits these valves, it
de-energized state. returns to the tank via the hydraulic fluid filter.

When VR2 is moved to request lift, a voltage is

sent to the VM at JPC12-2. The VM sees a
Auxiliary Functions
voltage different from the “learned” neutral
voltage, and sends an RPM request to the lift Tilt
power amplifier via BUS+/BUS– (JPC14-11 and
JPC14-4 through the Operator Display to Fork tilt allows the operator to raise or lower the
JPL1-23 and JPL1-35). tips of the forks. Standard fork tilt is 5° up and
2° down.
The VM supplies B– to the Main Pump
Contactor (MPC) coil at JPC18-8, that closes the When the deadman pedal is depressed, the VM
normally open contactor tips. sends a command via BUS+/BUS– to the LPA.
The VM supplies B– to the MPC coil at JPC18-8,
The MPC coil is energized by depressing the closing the normally open contactor tips.
Deadman Switch (DS1).
The Tilt Up Switch (S6) is depressed,
When the MPC is energized, the contactor tips completing a circuit between JPC12-5 and
close, allowing B+ to be supplied to the LPA, JPC12-12 at the VM.
that supplies voltage to the Lift Motor to make it
rotate. The VM energizes the following solenoids:
• SOL3 (Dump) at JPC20-12
The POD valve (POD-1) receives pressure at
• SOL5B at JPC20-20
port 4, placing pressure on the pilot line of the
valve. This pressure moves the spool in the • TILT SOL at JPC18-15
valve to allow flow out port 2 to CV1, the
de-energized Load Holding Solenoid (SOL1), Pump P1 rotates at a speed predetermined in
through the flow limiters in the base of the lift software. Flow is ported to the POD valve at port
cylinders, and into the lift cylinders, producing 3 and out at port 4. Fluid then flows through
lift. SOL5B or SOL5T, depending on the direction of
the function requested. SOL5 is a proportional
When the lift knob is returned to neutral, the solenoid, but the VM sends a fixed voltage to it,
Lift Motor is ramped down. SOL3 opens to regulating the speed of the requested function.
relieve any pressure spikes in the system. If more oil than is needed flows to SOL5, back
pressure is present at port 4 of the POD valve.
This shifts the spool of the POD valve and sends
Lower
the excess oil to SOL3 via port 2. SOL3 opens to
allow the excess oil to flow back to the filter and
Lowering is accomplished via the proportional
reservoir. After leaving SOL5, the oil flows to the
valve SOL2 (L/L). Lowering Speed is not a
LS-1. The LS-1 ports oil back to the POD valve
function of weight on the forks. An increasing
at port 1 to help regulate the flow to the
voltage increases the flow through the valve
auxiliary function. From LS-1, the fluid flows to
regardless of the pressure in the system. When
the Tilt Solenoid (TILT SOL) on the carriage. The
VR2 is moved to request Lower, a voltage is sent
TILT SOL allows fluid flow to the requested
to the VM at JPC12-2. The VM sees a voltage
function.
different from the “learned” neutral voltage. The
VM energizes SOL1 at JPC18-10. SOL2 opens NOTE: LS-1 also supplies a pilot pressure to
proportionally to the requested rate of lower via REL2 to open the auxiliary relief if
a voltage from the VM at JPC20-16. With SOL1 pressure gets too high.
energized, fluid flows out of the lift cylinders,
through the regulated portion of the flow Fluid flows through the energized TILT SOL and
limiters, through SOL1, and then through then to the tilt cylinder.

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Hydraulic System Functional Operation (AC Lift Without Regen Lower)

Reach/Retract the POD valve (at port 1) to help regulate the

flow to the auxiliary function. From LS-1, the
Reach extends the forks away from the mast fluid flows to the reach solenoid on the carriage.
assembly. The reach/retract function can be The Reach/Retract Solenoid allows fluid flow to
configured to have single speed reach/retract or the requested function.
two speed reach/retract. Single speed moves at NOTE: LS-1 also supplies a pilot pressure to
the speed of high-speed set in Config. REL2 to open the auxiliary relief if
pressure gets too high.
To use two speed reach, depress S5 after
depressing S4. Doing this switches from low Fluid flows through the energized
speed to high-speed reach. For high speed Reach/Retract Solenoid and then to the reach
retract, depress S5, then S4. cylinder.

High-speed or single-speed reach/retract

Sideshift
When the deadman pedal is depressed, the VM
sends a command via BUS+/BUS– to the LPA. Sideshift allows the operator to move the fork
The VM supplies B– to the MPC at JPC18-8, carriage to the left or right relative to the mast.
which closes the normally open contactor tips. The amount of sideshift is 2 or 4 in. (5 or 10 cm)
depending on the baseleg opening.
When the Reach Switch (S4) or the Retract
Switch (S5) is depressed, a circuit is completed When the deadman pedal is depressed, the VM
to the VM. sends a command via BUS+/BUS– to the LPA.
The VM supplies B– to the MPC at JPC18-8,
On lift trucks with two speeds selected, the VM closing the normally open contactor tips.
activates high speed when the other switch is
also depressed. When the Sideshift Right Switch (S9) is
depressed, a circuit is completed between
NOTE: To change reach speed (high speed JPC12-9 and JPC12-12 at the VM.
versus low speed), the VM adjusts the
voltage to SOL5 to regulate the valve for The VM energizes the following solenoids:
more or less flow.
• SOL3 (Dump) at JPC20-12
The VM energizes the following solenoids: • SOL5B at JPC20-20 or SOL5T at
JPC20-18, depending on direction
• SOL3 (Dump) at JPC20-12
• SIDESHIFT SOL at JPC18-14
• SOL5B at JPC20-20 SOL5T at JPC20-18
• REACH SOL at JPC18-12 Pump P1 rotates at a speed predetermined in
software. Flow is ported to the POD valve at port
Pump P1 rotates at a speed predetermined in 3 and out at port 4. Fluid then flows through
software. Flow is ported to the POD valve at port SOL5B or SOL5T, depending on the direction of
3 and out at port 4. Fluid then flows through the function requested. SOL5 is a proportional
SOL5B or SOL5T, depending on the direction of solenoid, but the VM sends a fixed voltage to it,
the function requested. SOL5 is a proportional regulating the speed of the requested function.
solenoid, but the VM sends a fixed voltage to it, If more oil flows to SOL5 than is needed, back
regulating the speed of the requested function. pressure is present at port 4 of the POD valve.
If more oil flows to SOL5 than is needed, back This shifts the spool of the POD valve and sends
pressure is present at port 4 of the POD valve. the excess oil to SOL3 via port 2. SOL3 is
This shifts the spool of the POD valve and sends opened to allow the excess oil to flow back to
the excess oil to SOL3 via port 2. SOL3 is the filter and reservoir. After leaving SOL5, the
opened to allow the excess oil to flow back to oil flows to the LS-1. The LS-1 ports oil back to
the filter and reservoir. After leaving SOL5, the the POD valve (at port 1) to help regulate the
oil flows to the LS-1. The LS-1 ports oil back to

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Hydraulic System Functional Operation (AC Lift Without Regen Lower)

flow to the auxiliary function. From LS-1, the With the valve in this position, fluid flows to
fluid flows to the Sideshift Solenoid on the Check Valve 1 (CV1). Fluid flows through CV1
carriage. The Sideshift Solenoid allows fluid and passes through the free flow portion of the
flow to the requested function. flow limiters (located in the base of the lift
cylinders) and into the lift cylinders.
NOTE: LS-1 also supplies a pilot pressure to
REL2 to open the auxiliary relief if
SOL3 (Dump) is used as a proportional relief to
pressure gets too high.
limit system pressure to a safe level. With this
valve: 0V = 3500 psi (24132 kPa). The pressure
Lift while using Aux Functions
relief is set by the VM and firmware at approx.
2V, which equals 3200 (22063 kPa) psi.
The MPC is energized by depressing the
Deadman Switch (S2).
The POD valve also meters fluid to the
requested aux function. As the metered flow
The VM internally supplies B– to the MPC at
enters SOL5B or SOL5T (depending on the
JPC18-8, which closes the normally open
direction of function requested), the voltage
contactor tips.
applied to the valve by the VM causes it to open.
When the MPC coil is energized, the contactor
SOL5 is a proportional solenoid. The VM sends
tips close, allowing B+ to be supplied to the
a fixed voltage to it to open it a specific amount,
LPA, which supplies voltage to the Lift Motor.
depending on the function requested.
When VR2 is moved to request lift, a voltage is
The load shuttle sends pressure to the pilot line
sent to the VM at JPC12-2. The VM sees a
of the POD valve to allow the valve to correctly
voltage different from the “learned” neutral
divide the fluid between lift and auxiliary.
voltage, and sends a request to the LPA via
BUS+/BUS– (JPC14-11 and JPC14-4 to
When using auxiliary functions only (no lift),
JPL1-23 and JPL1-35).
the speed of the motor is approx. 400 rpm. If
slow lift is used along with an auxiliary
The voltage supplied to the Lift Motor is
function, the motor/pump speed may increase
proportional to the amount of lift requested
due to the need for more fluid to the functions.
from VR2 (faster lift = higher motor voltage).
NOTE: The Lift Motor/pump is variable speed.

In order to operate reach or retract, S4 or S5 is

used to send an input to the VM at JPC12-4 or
JPC12-11.

When the request to lift and reach is made, the

VM energizes the following solenoids:
• SOL3 (Dump) at JPC20-12
• SOL5B at JPC20-20 or SOL5T at
JPC20-18, depending on direction
• REACH SOL at JPC18-12

As Pump P1 begins to rotate, fluid flows into the

POD valve at port 3. The POD valve is used to
bias flow between lift and aux. Port 3 is
connected to port 4. With pressure at port 4,
the pilot line moves the spool to allow flow to
both lift and aux.

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Hydraulic System Functional Operation (AC Lift With Regen Lower)

Hydraulic System Sideshift Cylinder

Functional Operation The sideshift cylinder is a double-acting

hydraulic cylinder used to shift the load left and
(AC Lift With Regen right with respect to the mast.

Lower) Tilt Cylinder

System Components The tilt cylinder is a double-acting hydraulic

cylinder used to tilt the forks up and down.
Main Lift/Lower Pump (P1)
Load Holding Valve (SOL1)
Pump P1 rotates clockwise and counter-
clockwise and is used to control the speed for The load holding valve is a normally closed
all lift and lower functions. solenoid valve used to hold the carriage and
telescopics in an elevated position.
Aux Pump (P2)
Proportional Lower Valve (SOL2)
The aux pump rotates clockwise and supplies
oil flow and pressure for the aux functions. The proportional lower valve is a pressure
compensated flow control solenoid valve used to
lower the carriage and telescopics.
Main Lift System

The main lift system consists of four single SOL5B/SOL5T

acting hydraulic cylinders. Hydraulic fluid flows
from the main manifold through a tee-fitting in SOL5 is a directional solenoid valve providing
the tractor, through fittings in the left and right directional control to the reach, tilt, and
front of the tractor bulkhead. The right side sideshift functions. De-energized, flow is
hose feeds the right side main lift cylinder. The blocked to the aux functions and directed to the
left side divides again at a tee-fitting, supplying reservoir. When SOL5B is energized, flow is
both the left side main lift cylinder and the free directed to port A1 for tilt up, sideshift right, or
lift cylinders. At the bottom of the free lift retract. When SOL5T is energized, flow is
cylinders, another tee-fitting divides the flow directed to port A2 for tilt down, sideshift left, or
between left and right free lift cylinders. A flow reach.
limiter is installed at one of the free lift and one
or both of the main lift cylinders. Aux Dump Solenoid (SOL6)

When the operator requests lift, the entire lift SOL6 is a two position normally open solenoid.
system is pressurized. Since the carriage Its purpose is to provide a path for oil from P2
weighs less than the carriage plus telescopic, back to the reservoir when Aux functions are
the free lift cylinders extend first, elevating the not being used.
carriage. When they reach the limit of their
travel, the main lift cylinders extend, elevating
the telescopics.
Reach/Retract Solenoid (REACH
SOL)
Reach/Retract Cylinder REACH SOL is a normally closed solenoid valve
used to block (de-energized) or allow (energized)
The reach/retract cylinder is a double-acting fluid flow to and from the reach cylinders.
hydraulic cylinder used for extending and
retracting the forks from the mast.

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Hydraulic System Functional Operation (AC Lift With Regen Lower)

Sideshift Solenoid (SIDESHIFT SOL) Aux Motor

SIDESHIFT SOL is a normally closed solenoid The Aux Motor is a single speed DC motor that
valve used to block (de-energized) or allow is turned ON when there is a request for an aux
(energized) fluid flow to and from the sideshift function.
cylinder.
Lift Motor (LM)
Tilt Solenoid (TILT SOL)
The Lift Motor is a brushless, three-phase
TILT SOL is a normally closed solenoid valve internally delta connected variable-speed AC
used to block (de-energized) or allow (energized) motor.
fluid flow to and from the tilt cylinder.
Lift Motor Encoder
Flow Limiter Valve
The Lift Motor Encoder is a two-channel
Flow limiter valves are used to limit the encoder. It provides the lift power amplifier with
maximum lower speed of the forks. A pilot port motor speed for motor speed regulation during
forces restricted flow through the restricted lift, lower, and aux functions.
portion of the valve during lower. A spring and
pilot port keeps the restricted portion of the Lift Motor Temperature Sensor
valve closed, allowing free flow during lift.
The Lift Motor Temperature Sensor is mounted
Aux Relief Valve (RV4) internally in the Lift Motor. Its purpose is to tell
the lift power amplifier the temperature of the
RV4 is a relief valve used to protect auxiliary lift motor.
system components against excessive pressure.
It is factory-adjusted to 2000 psi (13790 kPa). A Check Valve 1 (CV1)
manual adjustment knob can be turned
clockwise to increase the relief pressure, or CV1 acts as a suction line to the pump and
counterclockwise to decrease the relief routes lowering return oil through the hydraulic
pressure. filter.

Hydraulic Filter Check Valve 2 (CV2)

The hydraulic system has one filter in the CV2 prevents aux system return oil from
reservoir. All hydraulic fluid is filtered on the entering the lift system. It also maintains a
return to the reservoir. There is no internal system pressure of 15 psi (103 kPa) when a
bypass. lower request is removed for pump
pre-pressurization.
EP-1 Valve
Check Valve 3 (CV3)
EP-1 is a normally closed pilot operated valve.
When operating an aux function, the pressure CV3 allows oil to return to the reservoir on
at port 1 opens the valve, allowing oil to exit at Deep-Reach trucks if the forks hit an
port 2 and return to the reservoir, reducing the obstruction when reach is extended.
system pressure.
Check Valve 5 (CV5)

CV5 allows pre-pressurization of the system to

transition from a lower to a lift command.

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Hydraulic System Functional Operation (AC Lift With Regen Lower)

Check Valve 6 (CV6) With the pump turning, oil is drawn from the
reservoir, opening CV-1. The pressure caused
CV6 allows oil to bypass SOL1 and SOL2 during by the pump moves the spool in the valve to
lift to reduce flow resistance. allow flow through CV-6, SOL2, and SOL4,
through the flow limiters in the base of the lift
cylinders, and into the lift cylinders, producing
Check Valve 7 (CV7)
lift.
CV7 (located in the oil filter) opens when there
When the lift knob is returned to neutral, the
is approx. 44 psi (303 kPa) on the oil filter to
Lift Motor is ramped down. When the pump
allow return oil to bypass the filter so hydraulic
stops turning, CV-1 and CV-6 return to their
function speeds are not reduced and the filter is
normally closed state.
not ruptured.

Lower
Theory of Lift/Aux Functions
When VR2 is moved to request lower, a voltage
Lift is sent to the VM at JPC12-2. The VM sees a
voltage different from the “learned” neutral
Lift speed varies directly with Lift Motor rpm. voltage, and determines how to respond. If the
The voltage supplied to the Lift Motor is request is for less than ½ speed lower, the VM
proportional to the amount of lift request from energizes SOL1 and varies the voltage to SOL2
VR2 (faster lift = higher motor voltage). to control the lowering speed. Once the
Maximum lift speed for a given weight load is requested speed is greater than ½ of full
governed by software. lowering speed, SOL2 is opened fully and
lowering speed is controlled by the Lift Motor
Weight is calculated from inputs to the VM from rpm. The voltage supplied to the Lift Motor is
the pressure transducer. Weight of the empty proportional to the amount of lower request
carriage and telescopic is calculated during from VR2. The VM sends a request to the lift
Learn Mode. power amplifier via BUS+/BUS– (JPC14-11 and
JPC14-4 through the Operator Display to
Prior to requesting a lift, all valves are in the JPL1-23 and JPL1-35). The VM supplies B– to
de-energized state. the Main Pump Contactor Coil (MPC) at
JPC18-8, closing the normally open contactor
When VR2 is moved to request lift, a voltage is tips.
sent to the VM at JPC12-2. The VM sees a
voltage different from the “Learned” neutral The MPC is energized by depressing the
voltage, and sends an RPM request to the lift Deadman Switch (DS1). When the MPC is
power amplifier via BUS+/BUS– (JPC14-11 and energized, the contactor tips close, allowing B+
JPC14-4 through the Operator Display to to be supplied to the LPA, supplying voltage to
JPL1-23 and JPL1-35). the Lift Motor to make it rotate at the requested
speed.
The VM supplies B– to the Main Pump
Contactor (MPC) coil at JPC18-8, that closes the Oil flows from the lift cylinders through the now
normally open contactor tips. energized SOL1 and SOL2, through the lift
pump (spinning the lift motor backwards),
The MPC coil is energized by depressing the through CV2, and back to the reservoir. When
Deadman Switch (DS1). the lower request is removed, SOL1 and SOL2
are de-energized. When system pressure
When the MPC is energized, the contactor tips reaches approximately 15 psi (103 kPa), CV2
close, allowing B+ to be supplied to the LPA, returns to its normally closed state, keeping
that supplies voltage to the Lift Motor to make it 15 psi (103 kPa) at the lift pump to ensure the
rotate. lift pump remains full of oil. The 15 psi

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Hydraulic System Functional Operation (AC Lift With Regen Lower)

(103 kPa) is enough to keep CV5 open. It will High-speed or single-speed reach/retract
remain open until a lift request is made and it is
forced closed by the lift pump spinning. When the Reach Switch (S4) is depressed,
completing a circuit between JPC12-4 and
JPC12-12, the VM energizes the following
Auxiliary Functions components:
• AUX Contactor at JPC18-9
Tilt
• SOL5B at JPC20-20 or SOL5T at
Fork tilt allows the operator to raise or lower the JPC20-18, depending on direction
tips of the forks. Standard fork tilt is 5° up and • REACH SOL at JPC18-12
2° down. When the Tilt Up Switch (S6) is
• SOL6 at JPC20-12
depressed, completing a circuit between
JPC12-5 and JPC12-12, the VM energizes the
Pump P2 rotates at full speed. Fluid then flows
following components:
through SOL5B or SOL5T, depending on the
• AUX Contactor at JPC18-9 direction of the function requested. SOL5 is a
• SOL5B at JPC20-20 or SOL5T at proportional solenoid, but the VM sends a fixed
JPC20-18, depending on direction voltage to it, regulating the speed of the
requested function. If more oil than is needed
• TILT SOL at JPC18-15
flows to SOL5, back pressure is present at
• SOL6 at JPC20-12 port 1 of the EP-1 valve. This shifts the spool of
the valve and sends the excess oil via port 2
Pump P2 rotates at full speed. Fluid then flows back to the reservoir. After leaving SOL5, the oil
through SOL5B or SOL5T, depending on the flows to the reach solenoid on the carriage. The
direction of the function requested. SOL5 is a reach solenoid allows fluid flow to the cylinder.
proportional solenoid, but the VM sends a fixed On trucks with two speeds selected, the VM
voltage to it, regulating the speed of the activates high speed when the other switch is
requested function. If more oil than is needed also depressed.
flows to SOL5, back pressure is present at
port 1 of the EP-1 valve. This shifts the spool of NOTE: To change reach speed (high speed
the valve and sends the excess oil, via port 2, versus low speed), the VM adjusts the
back to the reservoir. After leaving SOL5, the oil voltage to SOL5 to regulate the valve for
flows to the Tilt Solenoid (TILT SOL) on the more or less flow.
carriage. The TILT SOL allows fluid flow to the
cylinder. Sideshift

Reach/Retract Sideshift allows the operator to move the fork

carriage to the left or right relative to the mast.
Reach extends the forks away from the mast The amount of sideshift is 2 or 4 in. (5 or 10 cm)
assembly. The reach/retract function can be depending on the baseleg opening.
configured to have single speed reach/retract or
two speed reach/retract. Single speed moves at When the Sideshift Switch (S9) is depressed,
the speed of high-speed. completing a circuit between JPC12-9 and
JPC12-12, the VM energizes the following
To use two speed reach, depress S5 after components:
depressing S4. Doing this switches from low • AUX Contactor at JPC18-9
speed to high-speed reach. For high speed • SOL5B at JPC20-20 or SOL5T at
retract, depress S5, then S4. JPC20-18, depending on direction
• SIDESHIFT SOL at JPC18-12
• SOL6 at JPC20-12

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Hydraulic System Functional Operation (AC Lift With Regen Lower)

Pump P2 rotates at full speed. Fluid then flows

through SOL5B or SOL5T, depending on the
direction of the function requested. SOL5 is a
proportional solenoid, but the VM sends a fixed
voltage to it, regulating the speed of the
requested function. If more oil than is needed
flows to SOL5, back pressure is present at
port 1 of the EP-1 valve. This shifts the spool of
the valve and sends the excess oil via port 2
back to the reservoir. After leaving SOL5, the oil
flows to the sideshift solenoid on the carriage.
The sideshift solenoid allows fluid flow to the
cylinder.

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Hydraulic System Functional Operation (DC Lift)

Hydraulic System Lift/Lower System

Functional Operation System Components
(DC Lift) Load Holding Valve (SOL1)

Steering System The Load Holding Valve is a normally closed

solenoid valve used to hold the carriage in an
elevated position. It incorporates an override to
System Components allow lowering the carriage manually.

Steer Valve Proportional Lift/Lower Valve (SOL2)

The Steer Valve is an orbital type, rotary flow The Proportional Lift/Lower Valve is a pressure
valve with an auxiliary port. When no steering compensated solenoid valve used to lift and
is requested, fluid flows through the auxiliary lower the carriage. As the voltage to the valve
port (E). When steering is requested, fluid flows increases, the flow through the valve increases,
first through the steer valve, hydraulic motor, regardless of the pressure.
and the steer return port (T). Any excess flow
exits through the Power Beyond port. Second Stage Solenoid (SOL4)

Theory of Steering Function SOL4 is a two position normally open solenoid

whose function is to feed oil from Pump P2 to
When the operator presses the deadman pedal, the lift cylinders for high speed lift. When
a circuit is completed at the VM between de-energized, oil is ported from P2 to the
JPC22-8 and JPC18-7. The VM energizes the reservoir.
STR contactor by way of JPC18-11. With the
STR contactor energized, current flows to the Proportional Directional Solenoid
Aux Motor, causing it to run. (SOL5B/SOL5T)

The steering system has priority over all other SOL5 is a proportional directional solenoid
auxiliary functions. Pressurized hydraulic fluid valve providing directional control to the reach,
from the Steer Pump flows to the Steering tilt, and sideshift functions. De-energized, flow
Orbitrol. Turning the steering wheel directs is blocked to the aux functions and directed to
hydraulic fluid to one side of the Steer Motor. the reservoir. When SOL5B is energized, flow is
Turning the steering wheel in the opposite directed to port A1 for tilt up, sideshift right, or
direction directs fluid to the other side of the reach. When SOL5T is energized, flow is
motor. directed to port A2 for tilt down, sideshift left, or
retract.
When steering is requested, oil leaving the
steering valve returns to the reservoir via the Aux Dump (SOL8)
S-RET line. Maximum hydraulic pressure in the
steering system is limited by the pressure relief SOL8 is a two position, normally open solenoid.
valve. The relief is located on the steer valve. Its purpose is to provide a path for oil from P3
Relief pressure is set at approx. 1600 psi back to the reservoir when aux functions are
(11,031 kPa). not being used.

Reach/Retract Solenoid (REACH)

REACH SOL is a normally closed solenoid valve

used to block (de-energized) or allow (energized)
fluid flow to and from the reach cylinders.

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Hydraulic System Functional Operation (DC Lift)

Sideshift Solenoid (SIDESHIFT SOL) • Initially, the VM commands the SOL2 to

move to the full open position (back to
SIDESHIFT SOL is a normally closed solenoid tank), then positions it proportionally to
valve used to block (de-energized) or allow the output request of VR2. For a slow lift
(energized) fluid flow to and from the sideshift rate, the proportional valve opens more,
cylinder. allowing more fluid to return to the
reservoir than it would for faster lifting
Tilt Solenoid (TILT SOL) rates. Lift Motor voltage is monitored at
JPC22-20 FU3_Sense. The weight of the
TILT SOL is a normally closed solenoid valve load on the forks is determined by inputs
used to block (de-energized) or allow (energized) to the VM from the pressure sensor at
fluid flow to and from the tilt cylinder. JPC24-18. PP is used for Pump Pressure
and G1 is used to check the pressure in
Brush Wear Indicators the system.

The brush wear indicators are located on the High-Speed Lift (lift trucks with dual lift
Lift Motor. Their purpose is to provide an pump)
indication when the motor brushes are worn
and need replacement. High speed lift (SOL4), is activated when the
voltage from VR2 is at least 90% of the
Lift Motor Temperature Sensor maximum Learned value for Lift. When this
voltage is reached, SOL4 is energized, stopping
The Lift Motor Temperature Sensor is a oil from the second Lift Pump (P2) from going to
thermistor used to indicate the temperature of the reservoir. Hydraulic flow from both sections
the Lift Motor. It is mounted in the outer case of of the lift pump is sent to the lift cylinder.
the motor.
High speed lift operating parameters vary for
Hydraulic Filter different mast configurations.

The hydraulic system has one filter in the main SOL2 is electrically positioned by the following:
manifold. All hydraulic fluid is filtered on the • Voltage generated by VR2 is sent to and
return to the reservoir. processed by the VM.
• A voltage from the VM drives L/L.
Theory of Lift/Lower Function
• Voltage across the coil of L/L is initially
When the key switch is turned ON, the L/L approx. 19V and decreases as the
proportional valve moves to the full open lift/lower control moves to faster lift
position. This relieves any pressure in the positions. This causes L/L to be fully
hydraulic line by diverting any residual fluid opened at maximum voltage and fully
back to the tank. The L/L proportional valve closed at minimum voltage.
then closes.
When VR2 returns to the neutral position, the
With the key switch ON, moving the lift/lower lift contactor is immediately de-energized; but
control on the control handle to lift causes: L/L is kept energized until the Lift Motor stops
turning. This is done because a spinning motor
• VR2 output voltage to become lower than does not stop instantly; the motor rotation is
when in the neutral position. sensed at JPC22-20. If L/L was de-energized at
• The VM senses the decrease in voltage at the same time as the motor, the fork carriage
JPC12-2. The VM energizes the LPC coil at would jump. Leaving L/L open until the motor
JPC18-9. This closes the contactor tips stops diverts any excess hydraulic fluid back to
and starts the Lift Motor (LM). the reservoir.

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Hydraulic System Functional Operation (DC Lift)

The VM monitors vehicle operation and controls Auxiliary System

performance as required to ensure safe
operation and prevent damage to various
systems of the lift truck. A temperature sensor
System Components
on the Lift Motor detects overheating of the
motor. The output of the temperature sensor is Load Shuttle (LS-1)
fed into the VM. As the temperature rises in the
Lift Motor, the VM cuts out power to the SOL4, The LS-1 is a two input, pressure activated, two
controlling the second Lift Pump (P2), thus position valve. In the shuttle, the higher of the
diverting the hydraulic fluid coming from P2 input pressures passes through the valve at the
back to the reservoir. The temperature that P2 pressure out port. While the output port gives
diverts fluid back to the reservoir is approx. no usable flow, it is used to operate
240°F (115°C). This decreases the load on the pressure-activated devices such as other
motor and should cool it down. If the shuttles, piloted check valves, or piloted
temperature continues to rise (greater than metering valves. In this application, LS-1 reacts
262°F/128°C), the VM cuts out lift entirely. to the pressure applied from SOL5B or SOL5T
to the auxiliary functions and applies a
NOTE: On trucks equipped with dual pumps, pressure feedback to a pilot on the logic
the maximum lift speed may be reduced element in the auxiliary manifold.
(SOL4 disabled) when forks travel above
free lift (S10 opens) and the load exceeds Logic Element (CE-1)
a specified weight, as determined by the
pressure transducer. The Logic Element is a metering valve that uses
manifold pressure input from the supply side of
Lower the hydraulic circuit (Pilot 1), pressure feedback
from load shuttles in the load side of the circuit
Lowering is accomplished via the proportional (Pilot 3), and a calibrated spring to meter
valve SOL2 (L/L). Lowering speed is not a hydraulic fluid flow to the auxiliary functions.
function of weight on the forks. An increasing Fluid not needed for the selected function is
voltage increases the flow through the valve returned back to the reservoir through port 2.
regardless of the pressure in the system.
Theory of Auxiliary Functions
When VR2 is moved to request Lower, a voltage
is sent to the VM at JPC12-2. The VM sees a Reach
voltage different from the “learned” neutral
voltage. Reach extends the forks away from the mast
assembly. The reach/retract function can be
The VM energizes SOL1 at JPC18-10. SOL2 configured to have single speed reach/retract or
opens proportionally to the requested rate of two speed reach/retract. Single speed reach
lower via a voltage from the VM at JPC20-16. moves at the speed of high-speed reach.

With SOL1 energized, fluid flows out of the lift In order to use two speed reach, depress S5
cylinders, through the regulated portion of the after depressing S4. Doing this switches from
flow limiters, through SOL1, and then through low speed to high-speed reach. Speed of the
energized SOL2. After fluid exits these valves, it reach is dependent on how it is configured.
returns to the tank via the hydraulic fluid filter.
High-speed or single-speed reach: When the
Deadman pedal is depressed, the VM completes
the path to the STR contactor coil at JPC18-11.
This causes the STR contactor tips to close,
making the Steer Motor (MS) rotate and causing
Pump P3 to pump oil. When S4 is depressed, a

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Hydraulic System Functional Operation (DC Lift)

circuit is completed between JPC12-4 and The amount of sideshift is 2 or 4 in. (5 or 10 cm)
JPC12-12 at the VM. depending on the baseleg opening.

On lift trucks with two speed reach, when S5 is In the following discussion, the fork carriage is
also depressed, a circuit is completed between sideshifted to the right.
JPC12-11 and JPC12-12 at the VM.
When the deadman pedal is depressed, the VM
P3 is used for steering and auxiliary functions. energizes the STR contactor coil by supplying
Because steering is not requested, oil enters the B– to the coil at JPC18-11, which closes the
steer valve at port P and exits at port E. From normally open contactor tips.
there, it flows through the Power Beyond (Pwr
Bynd) port to SOL5. Depending on the direction When S9 is depressed, a circuit is completed
of the function requested, either SOL5B or between JPC12-9 and JPC12-12 at the VM.
SOL5T is energized by the VM at JPC20-2
(SOL5B) or JPC20-17 (SOL5T). SOL5 is a P3 is used for steering and auxiliary functions.
proportional solenoid. The VM sends a fixed Because steering is not requested, oil enters the
voltage to it, depending on the function steer valve at port P and exits at port E. From
requested. In order to keep all of the oil being there, it flows through the Power Beyond (Pwr
dumped from returning to the reservoir, SOL8 Bynd) port to SOL5. Depending on the direction
(Aux Dump) is energized by the VM at of the function requested, either SOL5B or
JPC20-12. SOL5T is energized by the VM at JPC20-2
(SOL5B) or JPC20-17 (SOL5T). SOL5 is a
With SOL8 closed, oil flows to the proportional solenoid. The VM sends a fixed
Compensator/Logic Element (CE-1). The voltage to it, depending on the function
amount that CE-1 opens depends on the requested. In order to keep all of the oil being
pressure at port 1 of CE-1. With SOL5 dumped from returning to the reservoir, SOL8
energized, fluid flows to the LS-1. LS-1 sends its (Aux Dump) is energized by the VM at
pilot pressure out of port 2 to CE-1 at port 3. JPC20-12.
CE-1 has an internal calibrated spring. The
pilot pressure at port 3 aids the spring to With SOL8 closed, oil flows to the
regulate how much oil flows back to the Compensator/Logic Element (CE-1). The
reservoir in order to keep the function operating amount that CE-1 opens depends on the
at the correct speed. Once the oil passes LS-1, it pressure at port 1 of CE-1. With SOL5
exits the main manifold and flows to the Reach energized, fluid flows to LS-1. LS-1 sends its
Solenoid, that is energized by the VM at pilot pressure out of port 2 to CE-1 at port 3.
JPC18-12. CE-1 has an internal calibrated spring. The
pilot pressure at port 3 aids the spring to
Low-Speed (or two-speed) Reach: Low-speed regulate how much oil flows back to the
reach is activated by depressing the S4 only, reservoir. Once the oil has passed LS-1, it exits
when configured for two-speed reach. the main manifold, and flows to the sideshift
solenoid, that is energized by the VM at
Low-speed reach is accomplished by opening JPC18-14.
SOL5B or SOL5T, thus providing less oil flow to
the reach cylinders. Since SOL5 is a Tilt
proportional solenoid, a lower voltage to the
solenoid results in the lower speed. Fork tilt allows the operator to raise or lower the
tips of the forks. Standard fork tilt is 5° up and
Sideshift 2° down.

Sideshift allows the operator to move the fork When the Deadman pedal is depressed, the VM
carriage to the left or right relative to the mast. completes the path to the STR (steer and aux)
contactor coil at JPC18-11. This causes the

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Hydraulic System Functional Operation (DC Lift)

STR contactor tips to close, making the Steer

Motor (MS) rotate, and causing Pump P3 to
pump oil. When switch S6 (Tilt Up) is
depressed, a circuit is completed between
JPC12-5 and JPC12-12 at the VM.

Pump P3 is used for steering and auxiliary

functions. Because steering is not 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, however,
sends a fixed voltage to it. 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 closed, oil flows to the

Compensator/Logic Element (CE-1). The
amount that CE-1 opens depends on the
pressure at port 1 of CE-1. With SOL5
energized, fluid flows to the Load Shuttle (LS-1).
The LS-1 sends its pilot pressure out of port 2
to CE-1 at port 3. CE-1 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 passes LS-1,
it exits the main manifold, and flows to the Tilt
Solenoid, that is energized by the VM at
JPC18-13.

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Electric Brake Operation

Electric Brake Operation

Overview
This truck uses an electric brake. With the
brake coil de-energized, the brake is in a
“normally applied” state due to spring pressure.
With the brake coil energized, the brake is held
in a released state due to magnetic force.

Brake Release
When the deadman pedal is depressed, the
brake coil is energized. The current flow creates
a magnetic field that draws the armature plate
against the coil body, compressing the brake
coil springs. The carrier and pads, attached to
the Traction Motor shaft, is free to rotate.

Brake Application
If the lift truck is traveling when the deadman
pedal is released, the VM causes the lift truck to
plug to a stop. When the VM senses the lift
truck has stopped, it de-energizes the brake
coil. The magnetic field holding the brake
released now collapses. The springs in the
brake coil push the armature plate down on the
top of the carrier and pads. The brake pads
pressed between the armature plate and the
adapter plate prevent the Traction Motor shaft
from rotating.

Brake Release Screws

Two brake release screws are stored in the
brake coil body. These screws are not used
when removing the entire brake assembly from
the Traction Motor, but are used when
disassembling the brake itself. The brake
release bolts are threaded into the armature
plate. The screws pull the armature plate up,
overcoming the spring pressure.

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Pinout Matrix

Pinout Matrix • Normal Level: the approximate voltage

that you should see on that wire for the
state indicated. Unless otherwise
The pinout matrix table lists functions and indicated, voltages are Direct Current (DC)
normal voltages of terminals and harness and are measured with respect to (wrt) B–
connector pins. The matrix columns have the at TP4.
following meanings:
• Signal Source: the device or connection
• Item #: sequential number to aid in that supplies the signal directly to the
reference. wire.
• Connection: the actual wire numbers or • Signal User: the device or connection to
component abbreviations on the electrical which the wire directly delivers the signal.
schematic.
• Function Description: brief definition of
the signal carried on the wire.
• Theory of Operation:
• A detailed description of the signal
carried on the wire. If the signal is
variable, it indicates the state of a
related component that causes the
signal to vary.
• Identifies possible causes for lack of
correct signal.

Table 8-1. Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

1 JPC3-1 thru 4 USB Communications Port

+5V supply to the solid state potentiometer

Secondary
and switch in the optional Secondary
2 JPC4-1 +5VP 5±0.25V VM Control
Control Handle. Measure wrt DGND
Handle
JPC12-12.

Reference for the switches and

Secondary
potentiometer in the optional Secondary <0.5V;
3 JPC4-2 DGND VM Control
Control Handle. If this voltage is not correct, B+ wrt TP1
Handle
intermittent handle codes may appear.

S10 open: Secondary

Input to the VM from horn button (S10) in
4 JPC4-3 S_HORN >4.5V; VM Control
the optional Secondary Control Handle.
closed: <0.5V Handle

Input to the VM from the wiper of the Neutral: 1.1V; Secondary

5 JPC4-4 S_THROTTLE Secondary Control Handle potentiometer. Full TF: 1.6V; Control VM
Measure wrt DGND JPC4-2. Full FF: 0.5V Handle

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

Deadman Up:
4.6V;
CCW steer:
JPC6-1 NEUTRAL_ This input tells the VM that the steer Steer
6 4.5V; VM
(AC Lift) PULSE amplifier is connected and functioning. Amplifier
CW steer: 0.0V;
No steering:
voltage varies

At rest: 11.5V;
CCW steer:
This is a control voltage used to rotate the
11.6V;
JPC6-2 drive unit in the CW direction. The average
7 CW_PWM CW steer fast: VM SA
(AC Lift) DC value varies, depending on the amount
5V;
and speed of steering requested.
CW steer slow:
9V

Analog voltage which varies with the steer Steering CW:

motor current and is sent from the steer 1.8V;
JPC6-3 STEER_ Steer
8 amplifier to the VM. This voltage is used by At rest: 2.5V; VM
(AC Lift) CURRENT Amplifier
the VM to establish current reading for Steering CCW:
opens or shorts in the steer system. 3.2V

Reference for the control circuits in the steer

JPC6-4 <0.5V;
9 DGND amplifier. If missing, the steer amplifier does VM SA
(AC Lift) B+ wrt TP1
not power up.

Steering CW:
This is a control voltage used to rotate the 11.6V;
JPC6-5 drive unit in the CCW direction. The At rest: 11.5V;
10 CCW_PWM VM SA
(AC Lift) average DC value varies depending on the Steering CCW:
amount and speed of steering requested. 9V slow
5V fast

Operating voltage from the VM for the

JPC6-6
11 +12V control circuits in the steer amplifier. If this is 10.7 to 13V VM SA
(AC Lift)
missing, the steering is inoperable.

12 JPC9 FlashWare Connection

Input to the VM when the Aux Start Switch Switch open:

13 JPC10-2 AUX START (S23) is closed, allowing the truck to start 5V; S23 VM
when the option is enabled. closed: <0.5V

Voltage from the VM to the Thermakit

Control Card to control heaters in the ON: <0.5V;
14 JPC10-3 THERM_EN VM Heaters
Primary and Secondary Control Handles OFF: >10.5V
and heated floor pad.

<0.5V;
15 JPC10-4 DGND B– supply to S23 from the VM. VM S23
B+ wrt TP1

Encoder
+12V supply to Steer Encoder 1. Used as a
JPC10-6 connected: 9V; Steer Tiller
16 +12V_EN1 connect detect to verify the Steer Tiller VM
(AC Lift) Disconnected: Encoder
Encoder is connected to the VM.
10.7 to 13V

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

Encoder
+12V supply to Steer Encoder 2. Used as a
JPC10-7 connected: 9V; Steer Tiller
17 +12V_EN2 connect detect to verify the Steer Tiller VM
(AC Lift) Disconnected: Encoder
Encoder is connected to the VM.
10.7 to 13V

Steer
JPC10-9 <0.5V;
18 DGND B– for the Steer Motor Encoder. VM Motor
(AC Lift) B+ wrt TP1
Encoder

+5V supply to the solid state potentiometers

Primary
and switches in the Primary Control Handle.
19 JPC12-1 +5VP 4.9V VM Control
If this is <4.75V, the handle will not function
Handle
correctly. Measure wrt DGND at JPC12-12.

Input to the VM from the wiper of the Neutral: 1.0V;

20 JPC12-2 LIFT primary lift pot (VR2). Measure wrt DGND Full FF: 1.84V; VR2 VM
at JPC12-12. Full TF: 0.30V

Input to the VM from the wiper of the Neutral: 1.2V;

21 JPC12-3 P_THROTTLE primary throttle pot (VR1). Measure wrt Full FF: 1.9V; VR1 VM
DGND at JPC12-12. Full TF: 0.45V

Input to the VM from the reach switch (S4). S4 open:

Note: When other aux function switches >4.0V;
22 JPC12-4 REACH S4 VM
are activated, reading can change by as S4 closed:
much as 0.5V. <0.5V

S6 open:
>4.0V;
23 JPC12-5 TILT_UP Input to the VM from the tilt up button (S6). S6 VM
S6 closed:
<0.5V

S7 open:
Input to the VM from the tilt down button >4.0V;
24 JPC12-6 TILT_DOWN S7 VM
(S7). S7 closed:
<0.5V

OFF: <0.5V; Primary

25 JPC12-7 H_HTR DC supply to handle heater (HTR6). ON: 7.5 to VM Control
8.5V Handle

S8 open:
Input to the VM from the sideshift left button >4.0V;
26 JPC12-8 SSHIFT_LEFT S8 VM
(S8). S8 closed:
<0.5V

S9 open:
Input to the VM from the sideshift right >4.0V;
27 JPC12-9 SSHIFT_RIGHT S9 VM
button (S9). S9 closed:
<0.5V

Input to the VM from the primary control S3 open:

handle horn switch (S3). Note: When >4.0V;
28 JPC12-10 P_HORN S3 VM
other aux function switches are activated, S3 closed:
reading can change by as much as 0.5V. <0.5V

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

Input to the VM from the retract switch (S5). S5 open:

Note: When other aux function switches >4.0V;
29 JPC12-11 RETRACT S5 VM
are activated, reading can change by as S5 closed:
much as 0.5V. <0.5V

Reference for all switches and

potentiometers in the primary control Primary
<0.5V;
30 JPC12-12 DGND handle. If this voltage is not <0.5V wrt TP4 VM Control
B+ wrt TP1
on the power panel, then intermittent Handle
handle codes may appear.

This connects B–F on the VM to TP4 (B–)

31 JPC14-1 B–F <0.5V wrt TP4 FRC VM
through FU6 on the Fuse/Relay Card (FRC).

This connects DGND and AGND on the VM

to TP4 (B–) through FU6 on the Fuse/Relay
32 JPC14-2 DGND Card. This is the reference for all circuits on FRC VM
the truck that are referenced to either <0.5V;
DGND or AGND. B+ wrt TP1

Reference for the control circuits in the

33 JPC14-3 DGND VM Display
Operator Display.

Carries negative component of the digital

communications between the VM and the
TPA, LPA (AC Lift), and the Operator
Display. If missing, the LPA and Operator
TPA, LPA,
34 JPC14-4 BUS_I– Display cannot communicate with the VM. 2.24V VM
Display
Troubleshoot using resistance checks in
Test I23. No useful information can be
gained by measuring the voltage on this
wire.

Operating voltage from the VM to the

35 JPC14-5 +12VD +10.5 to 13V VM Display
Operator Display.

Control path for K1, K2, K3, and K4 on the

Fuse/Relay Card. After S1 is closed, all Relays OFF: B+; K1, K2,
RELAY_
36 JPC14-6 relays are energized simultaneously during Relays ON: VM K3, and
ENABLE
SelfTest if the voltage at Battery_Sense_In is <3.0V K4
at an acceptable level.

B+ provided to the VM when K4 is closed.

This voltage is used to power the heaters in
Cold
cold storage trucks. If the Ambient Temp K4 closed: B+;
37 JPC14-7 B+K4 K4 Storage
Sensor detects <40°F, the VM keeps this K4 open: 0.2V
heaters
circuit ON to power the heaters, even with
the Key Switch turned OFF.

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

Connects DGND and AGND on the VM to

TP4 (B–) through FU6 on the Fuse/Relay
38 JPC14-8 B–F Card. This is the reference for all circuits on FRC VM
the truck that are referenced to either
DGND or AGND.

Connects DGND and AGND on the VM to

TP4 (B–) through FU6 on the Fuse/Relay
<0.5V;
39 JPC14-9 B–F Card. This is the reference for all circuits on FRC VM
B+ wrt TP1
the truck that are referenced to either
DGND or AGND.

Connects DGND and AGND on the VM to

TP4 (B–) through FU6 on the Fuse/Relay
40 JPC14-10 DGND Card. This is the reference for all circuits on FRC VM
the truck that are referenced to either
DGND or AGND.

Carries positive component of the digital

communications between the VM and the
TPA, LPA (AC Lift), and the Operator
Display. If missing, the VM cannot TPA, LPA,
41 JPC14-11 BUS_I+ 2.8V VM
communicate. Troubleshoot using resistance Display
checks in Test I23. No useful information
can be gained by measuring the voltage on
this wire.

B+ that is switched by Key Switch (S1) and

used to power functions on the VM that are
initiated after S1 is closed, and are not S1 closed: B+;
42 JPC14-12 B+KEY S1 VM
affected by the EPO. This includes the VM S1 open: 0.3V
power supplies and the operation of the
microprocessor.

B+ provided to the VM when K2 is closed.

This voltage is used to power the hydraulic K2 closed: B+; Hydraulic
43 JPC14-13 B+K2 K2
solenoids on the tractor. They are K2 open: 0.3V Solenoids
de-energized when the EPO is open.

B+ provided to the VM when K2 is closed.

This voltage is used to power the hydraulic K2 closed: B+; Hydraulic
44 JPC14-14 B+K2 K2
solenoids on the tractor. They are K2 open: 0.3V Solenoids
de-energized when the EPO is open.

Solenoids open:
Control path for Aux Boost Solenoids (SOL6
JPC18-1 B+; SOL6,
45 AUX BOOST and SOL7) that is supplied B– by the VM to VM
(AC Lift) closed: approx. SOL7
close the solenoids.
12V

Control path for the 2nd pump solenoid

which diverts oil to the lift cylinder when it is De-energized:
JPC18-1
46 2nd_STAGE energized and to the tank when B+; K2 VM
(DC Lift)
de-energized. Operation is VM controlled, Energized: 24V
based on lift request and weight on forks.

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

JPC18-5 Reference for Channel 1 of the Steer Tiller Steer Tiller

47 DGND VM
(AC Lift) Encoder. Encoder
<0.5V;
JPC18-6 Reference for Channel 2 of the Steer Tiller Steer Tiller
48 DGND B+ wrt TP1 VM
(AC Lift) Encoder. Encoder

49 JPC18-7 DGND Reference for the Deadman Switch (DS1). VM DS1

Contactor
Control path for the Main Power Contactor
JPC18-8 MAIN_ Open: B+;
50 (MPC) that is supplied B– by the VM to VM MPC
(AC Lift) CONTACTOR Closed: approx.
close the contactor.
12V

Contactor
Control path for the Traction Power
JPC18-8 TRACTION_ Open: B+;
51 Contactor (TPC) that is supplied B– by the VM TPC
(DC Lift) CONTACTOR Closed: approx.
VM to close the contactor.
12V

Contactor
Control path for the Aux Contactor (AUX)
JPC18-9 AUX_ Open: B+;
52 that is supplied B– by the VM to close the VM AUX
(AC Lift) CONTACTOR Closed: approx.
contactor.
12V

Contactor
Control path for the Lift Power Contactor
JPC18-9 LIFT_ Open: B+;
53 (LPC) that is supplied B– by the VM to close VM LPC
(DC Lift) CONTACTOR Closed: approx.
the contactor.
12V

De-energized
Control path for the Load Holding solenoid
(K2 closed): B+;
54 JPC18-10 L/H (SOL1) that is switched to B– by the VM to VM L/H SOL1
Energized:
energize the L/H solenoid coil (lowering).
13.3V

Contactor
Control path for the Steer Contactor (STR)
STR_ Open: B+;
55 JPC18-11 that is supplied B– by the VM to close the VM STR
CONTACTOR Closed: approx.
contactor.
12V

De-energized
(K2 closed): B+; Reach
56 JPC18-12 REACH_SOL Control path for Reach solenoid coil. VM
Energized: Solenoid
13.2V

De-energized
SIDESHIFT_ (K2 closed): B+; Sideshift
57 JPC18-14 Control path for Sideshift solenoid coil. VM
SOL Energized: Solenoid
13.1V

De-energized
(K2 closed): B+; Tilt
58 JPC18-15 TILT_SOL Control path for Tilt solenoid coil. VM
Energized: Solenoid
13.1V

De-energized
Control path for the horn that is switched to (K2 closed): B+;
59 JPC18-16 HORN VM Horn
B– by the VM to energize the horn. Energized:
0.02 V

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

De-energized
Control path for the amplifier and motor
(K2 closed): B+;
60 JPC18-17 FAN compartment fans that are controlled VM Fans
Energized:
together by the VM.
0.09V

B– supply from the VM to turn ON the Alarm ON: 0V; Travel Light
61 JPC18-18 ALARM VM
optional travel light and alarm. Alarm OFF: B+ and Alarm

+12V supply for 1st Speed Limiting Switch

62 JPC20-1 +12VP VM S12
(S12).

+12V supply to the Deadman Switch 1

63 JPC20-2 +12VP VM DS1
(DS1).

+12V supply for optional High Speed

64 JPC20-3 +12VP VM S25
Travel Switch (S25).

Pressure
65 JPC20-4 +12VP +12V supply for the Pressure Transducer. VM
Transducer
10.7 to 13V
+12V supply for the optional Lift Cutout
66 JPC20-6 +12VP VM S27
Switch (S27).

Steer
67 JPC20-7 +12VP +12V supply for the Steer Motor Encoder. VM Motor
Encoder

68 JPC20-9 +12VP +12V supply to the Steer Limit Switch (S11). VM S11

+12V supply to the Right Battery Gate

69 JPC20-10 +12VP VM S58
Switch (S58).

Control path for SOL3, a combination De-energized:

proportional relief and dump valve. This is B+;
used both as a variable system relief and to When lift
JPC20-12 dump oil back to the reservoir when lift is request stops:
70 DUMP VM SOL3
(AC Lift) no longer requested and the Lift Motor/ 12V for 1 to 2
pump is slowing down. This permits seconds;
immediate lower without waiting for the Aux functions
pump to stop turning. energized: 24V

Control path for the Aux Dump Solenoid

(SOL8). This solenoid diverts steering/ De-energized:
JPC20-12 auxiliary hydraulic fluid to the reservoir B+;
71 AUXDUMP VM SOL8
(DC Lift) when de-energized (no aux function Energized:
requested) and to the aux functions when 3.7V
energized.

JPC20-13
72 B+DUMP B+ from K2 to SOL3. B+ VM SOL3
(AC Lift)

JPC20-13
73 B+AUXDUMP B+ from K2 to SOL8. B+ VM SOL8
(DC Lift)

Brake ON: B+;

Control path for the electrically released
74 JPC20-14 BRAKE Brake OFF: 0V VM Brake
brake on the Traction Motor.
at first, then 9V

75 JPC20-15 B+L/L B+ supplied to SOL2 when K2 is energized. B+ VM SOL2

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

De-energized:
B+;
Control path for the Lift/Lower Solenoid No lower:
76 JPC20-16 L/L SOL2. Voltage present during lower 37.6V varies VM SOL2
depends on the lower request from VR2. proportionally to
Full lower:
18.8V

77 JPC20-17 B+AUX1 B+ supply for SOL5T solenoid. B+ VM SOL5T

De-energized:
B+
Energized:
Sideshift Left:
Control path for one of the directional 20V;
78 JPC20-18 AUX1 solenoids (SOL5T) for the aux functions Tilt Down: VM SOL5T
sideshift left, tilt down, and retract. 17.5V;
Retract High:
20V;
Retract Low:
24V

79 JPC20-19 B+AUX2 B+ supply for SOL5B solenoid. B+ VM SOL5B

De-energized:
B+;
Energized:
Control path for one of the directional Sideshift Right:
80 JPC20-20 AUX2 solenoids (SOL5B) for the aux functions 20V; VM SOL5B
sideshift right, tilt up, and reach. Tilt Up: 18.0V;
Reach High:
20V;
Reach Low: 24V

Used by the VM to determine when the Telescopics

SPEED_LIMIT_ telescopic is unnested. Speed is reduced at nested: <0.5V;
81 JPC22-1 S12 VM
1 this point to the value set in Configure Telescopics
Mode. unnested: >4V

Used by the VM to determine when the

BATTERY GATE
82 JPC22-3 Right Battery Gate is in place (S58 is S58 VM
RT SW Open: 5V;
closed).
Closed: 0V
HS TRAVEL Used by the VM to determine when the
83 JPC22-4 S25 VM
SW carriage is above S25.

Channel_A_1 is one part of the steering

request from the Steer Tiller Encoder on
electric steer trucks when the steering tiller is >4.5V or <0.5V
moved. It is a square wave (0V and 4.5V) when tiller
JPC22-5 CHANNEL_A_ identical to Channel_B_1 but different stationary. DC Steer Tiller
84 VM
(AC Lift) 1 phase. The VM uses the phase relationship value when Encoder
of the two channels to determine the turning handle
direction and speed of the steering request. approx. 2.5V
When the tiller is stationary, the voltage can
be either high or low.

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Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

LIFT CUTOUT Used by the VM to determine when the

85 JPC22-6 S27 VM
SW carriage is above S27. Open: 5V;
BATTERY GATE Used by the VM to determine when the Left Closed: 0V
86 JPC22-7 S57 VM
LT SW Battery Gate is in place (S57 is closed).

Input to the VM from the Deadman Switch

(DS1). This is used by the VM to determine Released: >4V;
87 JPC22-8 DEADMAN DS whether to ignore or comply with other Depressed: DS1 VM
operational requests from either of the <0.5V
control handles.

ChannelA_4 is one part of the steering

position feedback from the Steer Motor
Encoder when the drive unit is rotated. It is
a square wave (0V and 4.5V) identical to
Not turning: 0V
ChannelB_4 but different phase. The VM Steer
JPC22-9 or 4.5V;
88 CHANNELA_4 uses the phase relationship of the two Motor VM
(AC Lift) Turning either
channels to determine that the direction and Encoder
direction: 1.8V
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.

ChannelB_4 is one part of the steering

position feedback from the Steer Motor
Encoder when the drive unit is rotated. It is
a square wave (0V and 4.5V) identical to
Not turning: 0V
ChannelA_4 but different phase. The VM Steer
JPC22-10 or 4.5V;
89 CHANNELB_4 uses the phase relationship of the two Motor VM
(AC Lift) Turning either
channels to determine that the direction and Encoder
direction: 1.8V
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.

JPC22-11 <0.5V;
90 DGND Reference for Steer Limit Switch (S11). VM S11
(AC Lift) B+ wrt TP1

Channel_B_1 is one part of the steering

request from the Steer Tiller Encoder on
electric steer trucks when the steering tiller is Not turning:
moved. It is a square wave (0V and 4.5V) >4.5V or
JPC22-12 CHANNEL_B_ identical to Channel_A_1 but different <0.5V; Steer Tiller
91 VM
(AC Lift) 1 phase. The VM uses the phase relationship Turning either Encoder
of the two channels to determine the direction:
direction and speed of the steering request. approx. 2.5V
When the tiller is stationary, the voltage can
be either high or low.

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Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

Channel_A_2 is one part of the steering

request from the Steer Tiller Encoder on
electric steer trucks when the steering tiller is Not turning:
moved. It is a square wave (0V and 4.5V) >4.5V or
JPC22-13 CHANNEL_A_ identical to Channel_B_2 but different <0.5V; Steer Tiller
92 VM
(AC Lift) 2 phase. The VM uses the phase relationship Turning either Encoder
of the two channels to determine the direction:
direction and speed of the steering request. approx. 2.5V
When the tiller is stationary, the voltage can
be either high or low.

Channel_B_2 is one part of the steering

request from the Steer Tiller Encoder on
electric steer trucks when the steering tiller is Not turning:
moved. It is a square wave (0V and 4.5V) >4.5V or
JPC22-14 CHANNEL_B_ identical to Channel_A_2 but different <0.5V; Steer Tiller
93 VM
(AC Lift) 2 phase. The VM uses the phase relationship Turning either Encoder
of the two channels to determine the direction:
direction and speed of the steering request. approx. 2.5V
When the tiller is stationary, the voltage can
be either high or low.

Brushes not
Brush wear indicator on the armature (A1
worn: 0V;
JPC22-15 BRUSH_WEAR brush) of the Lift Motor. The VM uses this
94 Brushes worn: Armature VM
(DC Lift) _1 voltage to stop lift and sound an alarm
Armature
when the brushes are worn.
voltage 34V

Brushes not
Brush wear indicator on the armature (A2
worn: 0V;
JPC22-16 BRUSH_WEAR brush) of the Lift Motor. The VM uses this
95 Brushes worn: Armature VM
(DC Lift) _2 voltage to stop lift and sound an alarm
Armature
when the brushes are worn.
voltage 34V

Control path for the optional Nested Switch K2 Closed

(S14) on the carriage. The VM reduces (carriage
NESTED
96 JPC22-18 travel speed to the configured value (0 to nested): B+; K2 VM
SWITCH
3.5 mph/5.76 km/h) when the switch is Open
open. (unnested): 0V

B+ when there is not an open between B+ Closed: B+;

and STR2. This voltage is used by the VM to Open: Voltage
97 JPC22-19 FU1_SENSE FU1-2 VM
determine the state of FU1 and the STR drops slowly to
contactor. 0V

B+ when there is not an open between B+

JPC22-20 LPC Closed: B+;
98 FU3_SENSE and LPC2. This voltage is used by the VM to LPC2 VM
(DC Lift) Open: 0V
determine the state of the LPC and FU3.

EPO Closed:
Sense wire used by the VM to determine
99 JPC22-21 EPO_SENSE B+; EPO VM
when the EPO is open.
Open: 0V

The Steer Limit Switch (S11) stops drive unit Open (metal): 4
JPC22-22 rotation when closed. This switch is closed to 7V;
100 STEER_LIMIT S11 VM
(AC Lift) just before the hard stops are reached for Closed (air):
both CW and CCW rotation. 0.7V

8-32 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

+12V supply to Left Battery Gate Switch

101 JPC24-1 +12VP 10.5 to 13VDC VM S57
(S57).

B– supply to Right Battery Gate Switch

102 JPC24-3 DGND VM S58
(S58) from the VM.

Pressure
103 JPC24-6 DGND Reference for pressure transducer. VM
Transducer
<0.5V;
B– supply to Left Battery Gate Switch (S57)
104 JPC24-8 DGND B+ wrt TP1 VM S57
from the VM.

JPC24-10 Reference for the Lift Motor temperature

105 DGND VM VM
(DC Lift) sensor.

106 JPC24-11 DGND Reference for the Ambient Temp Sensor. T VM

No load: 1.0V;
1000lb.
Analog DC voltage that varies directly as (454 kg) out of Pressure
107 JPC24-18 PRESSURE VM
the pressure varies. free lift: 1.8V; Transducer
2500 lb.
(1134 kg): 2.5V

Contactor
JPC24-21 MAIN_CONT_ Sense wire used by the VM to determine the
108 Open: 0V; MPC2 VM
(AC Lift) SENSE state of the Main Contactor.
Closed: B+

Contactor
JPC24-21 Sense wire used by the VM to determine the
109 TPC_SENSE Open: 0V; TPC1 VM
(DC Lift) state of the Traction Power Contactor (TPC).
Closed: B+

70°F (21°C):
Analog DC voltage that varies directly as
2.2V;
JPC24-22 LIFT_MOT_ the temperature of the Lift Motor changes.
110 Open or LMT VM
(DC Lift) TEMP The VM uses this voltage to stop lift at
disconnected:
279°F (137°C).
5V

Input to the VM from the Ambient Temp

AMBIENT_ 73°F (22.8°C):
111 JPC24-23 Sensor. This informs the VM when to turn T VM
TEMP 3V
ON the optional heaters.

Used by the VM to determine the correct

battery is connected. It accepts any voltage
BATTERY_ between 28V and 45V. If the correct
112 JPC24-24 B+ FRC VM
SENSE_IN battery is sensed, Relay_Enable is
energized during start-up. After start-up, this
voltage is used to determine BSOC.

+12V supply from the Display for the OCSS

113 JPD1-1 +12VD 10.5 to 13V
System.
Display OCSS
B– supply from the Display to the OCSS <0.5V;
114 JPD1-4 DGND
System. B+ wrt TP1

Publication: 1112860, Issued: 15 Feb 2012 8-33

Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

+12V supply from the Display to the

115 JPD3-1 +12VD 10.5 to 13V
Sounder.

Sounder OFF: Display Sounder

B– supply from the Display to turn ON the 10.5 to 13V;
116 JPD3-2 Sounder
Sounder. Sounder ON:
approx. 6V

117 JPF1-1
B– B– to FU8 on the Fuse/Relay Card (FRC). TP4 FRC
118 JPF1-2 <0.5V;
B+ wrt TP1
Aux Power,
119 JPF1-4 B–F B–F from FU8 to power the optional WMM. FU8 to B–
WMM

Optional
120 JPF1-6 B+K2 B+ to SPL-7 to power optional devices. B+ K2
Devices

Contactor
121 JPF2-1 B+K2 B+K2 to the contactor coils. K2
Coils

Horn,
122 JPF2-2 B+K2 B+K2 to power the horn and brake.
Brake
K2 energized:
123 JPF2-3 B+K2 B+K2 to power the compartment fans. B+ Fans
K2
124 JPF2-5 B+K2 B+K2 to power SOL1. L/H SOL1

B+K2 to the reach, sideshift, tilt solenoids, Carriage

125 JPF2-8 B+K2
and Nested Switch (S14). Functions

K1 energized:
126 JPF2-9 B+K1 B+ to TS1. K1 TS1
B+

127 JPF3-1
B– B– to FU6 on the FRC. TP4 FRC
128 JPF3-2 <0.5V;
B+ wrt TP1
B–F for 1st Speed Limiting Switch (S12) on
129 JPF3-8 B–F FU6 S12
mast.

130 JPF4-1
B+ to FU5 and the thermistor on the FRC.
131 JPF4-2
B+ B+ TP1 FRC
132 JPF4-3
B+ to FU7 on the FRC.
133 JPF4-4

B+ supply from EPO to K1, K2, and K3. All

functions associated with those functions
S1 and EPO
134 JPF4-5 B+EPO are inoperable when the EPO is open. This EPO K1, K2, K3
closed: B+
also supplies voltage to EPO_Sense on the
VM.

FU5 good: B+;

135 JPF4-10 B+ B+ from FU5 to Key Switch (S1). FU5 S1
FU5 open: 0V

136 JPF4-12 B+KEY B+ from Key Switch (S1) to the EPO. S1 closed: B+ S1 EPO

8-34 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

Optional
137 JPF4-15 B+ B+ for battery connected aux power. B+ FU7
Aux Power

B+ present when K3 is energized. This is

used to power the control circuits of the LPA.
JPL1-1 It is also used by the LPA to produce +12V K3 energized:
138 B+K3 K3 LPA
(AC Lift) for the L Vel Sensor+ and the internal B+
circuits of the LPA. If voltage is not present,
check K3 coil and tip circuit.

JPL1-7
139 I/O GND Return path for the LME and LMT. <0.5V VM LME, LMT
(AC Lift)

Analog voltage that varies with the lift

motor temperature. Used by the LPA to 75°F (24°C):
140 JPL1-8 L TEMP+ LMT LPA
adjust motor performance when a motor approx. 1V
overtemp condition exists.

B+ to the LPA when K3 is closed, informing

141 JPL1-11 ID1 B+ K3 LPA
the amp it is the lift amp.

Carries the positive component of the

digital communications between the LPA
and the VM. If missing, the LPA cannot
JPL1-23 communicate with the Operator Display or
142 BUS_1+ 2.94V LPA TPA
(AC Lift) VM. Troubleshoot using resistance checks in
Test I23. No useful information can be
gained by measuring the voltage on this
wire.

L VEL
143 JPL1-26 +12V supply to the Lift Motor Encoder. 10.9 to 13V LPA LME
SENSOR+

This square wave is generated whenever

there is movement of the LME. It is either
high (>8V) or low (<1V). The frequency
Motor
varies directly with the speed of the Lift
JPL1-31 Stationary: >8V
144 L VEL PHASE A Motor. Identical formation to L Vel Phase B, LME LPA
(AC Lift) or <1V;
except for the phasing between the two.
Turning: 4 to 6V
The LPA uses the quadrature phase
relationship between Phases A and B to
determine lift speed.

This square wave is generated whenever

there is movement of the LME. It is either
high (>8V) or low (<1V). The frequency
Motor
varies directly with the speed of the Lift
JPL1-32 Stationary: >8V
145 L VEL PHASE B Motor. Identical formation to L Vel Phase A, LME LPA
(AC Lift) or <1V;
except for the phasing between the two.
Turning: 4 to 6V
The LPA uses the quadrature phase
relationship between Phases A and B to
determine lift speed.

Publication: 1112860, Issued: 15 Feb 2012 8-35

Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

Carries negative component of the digital

communications between the Operator
Display, LPA, and VM. If missing, the LPA
cannot communicate with the Operator Operator
146 JPL1-35 BUS_1– 2.2V LPA
Display or VM. Troubleshoot using Display
resistance checks in Test I23. No useful
information can be gained by measuring
the voltage on this wire.

B+ present when K3 is energized. This is

used to power the control circuits of the
TPA. It is also used by the TPA to produce K3 energized:
147 JPT1-1 B+K3 K3 TPA
+12V for the T Vel Sensor+ and the internal B+
circuits of the TPA. If voltage is not present,
check K3 coil and tip circuit.

<0.5V; DGND on
148 JPT1-7 I/O GND Return path for the TME and TMT. TME, TMT
B+ wrt TP1 VM

Analog voltage that varies with the traction

motor temperature. Used by the TPA to 75°F (24°C):
149 JPT1-8 T TEMP+ TMT TPA
adjust motor performance when a motor approx. 1V
overtemp condition exists.

B+ to the TPA when K3 is closed, informing

150 JPT1-12 ID0 B+ K3 TPA
the amp it is the traction amp.

Carries positive component of the digital

communications between the TPA and VM.
If missing, the TPA cannot communicate with
Operator
151 JPT1-23 BUS_I+ the VM. Troubleshoot using resistance 2.93V TPA
Display
checks in Test I23. No useful information
can be gained by measuring the voltage on
this wire.

T VEL
152 JPT1-26 +12V supply to the TME. 10.7 to 13V TPA TME
SENSOR+

Generated when there is movement of the

TME. It is a square wave that is either high
Motor
(>8V) or low (<1V). The frequency varies
Stationary: >8
153 JPT1-31 T VEL PHASE A directly with motor speed. Identical to T VEL TME TPA
or <1V;
Phase B except for phase. The VM uses the
Turning: 4 to 6V
relationship between phases to determine
travel direction and speed.

Generated when there is movement of the

TME. It is a square wave that is either high
Motor
(>8V) or low (<1V). The frequency varies
Stationary: >8
154 JPT1-32 T VEL PHASE B directly with motor speed. Identical to T VEL TME TPA
or <1V;
Phase A except for phase. The VM uses the
Turning: 4 to 6V
relationship between phases to determine
travel direction and speed.

8-36 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

Carries the negative component of the

digital communication between the
Operator
155 JPT1-35 BUS_1– Operator Display, TPA, and VM. 2.2V TPA
Display
Troubleshoot using resistance checks in
Test I23.

B+ to the LPA used to pre-charge the

LPA B+ amplifier and produce the AC phases U, V,
156 LPA B+ B+ MPC LPA
(AC Lift) and W to the Lift Motor. Voltage increases
from 0V to B+ as the amplifier charges.

B– from TP4 on the Power Panel. Used for

LPA B– LPA power circuits. Without B–, U, V, and <0.5V;
157 LPA B– TP4 LPA
(AC Lift) W cannot be produced and the Lift Motor B+ wrt TP1
will not operate.

158 MS-A1 Steering CW:

slow - approx.
Output from the Steer Amp (SA) to the Steer
4V; fast -
Motor (MS). Can be positive or negative,
approx. 28V;
B+ or B– depending on steer direction requested. SA SM
159 MS-A2 Steering CCW:
Connect + meter lead to A1.
slow - approx.
Connect – meter lead to A2.
–4V; fast -
approx. –28V

B+ from the Steer Contactor through FU1 to

160 STR-2 B+ the Steer Amp (SA) to power the steer B+ FU1 SA
motor.

B– from TP4 to the Steer Amp to power the <0.5V;

161 TP4 B– TP4 SA
steer motor. B+ wrt TP1

B+ to the TPA used to pre-charge the

amplifier and produce the AC phases U, V,
TPA B+
162 B+ and W when the MPC is closed to power B+ MPC TPA
(AC Lift)
the Traction Motor. Voltage increases from
0V to B+ as the amplifier charges.

B+ to the TPA used to pre-charge the

amplifier and produce the AC phases U, V,
TPA +
163 B+ and W when the TPC is closed to power the B+ TPC TPA
(DC Lift)
Traction Motor. Voltage increases from 0V
to B+ as the amplifier charges.

B– from TP4 on the Power Panel. Used for

TPA power circuits. Without B–, U, V, and <0.5V;
164 TPA B– B– TP4 TPA
W cannot be produced and the Traction B+ wrt TP1
Motor will not operate.

One of three phases from the LPA to the Lift VAC between
Motor. This AC voltage is produced by the two phases:
LPA and is dependent on B+ at the + Stationary:
U on LPA LIFT MOTOR
165 terminal and B– on the LPA. This AC voltage 0VAC; LPA LM
(AC Lift) PHASE U
is measured between any two phases and Full Lift: 24VAC;
varies from 0VAC at rest to about 24VAC at Stall: approx.
full RPM. 4VAC

Publication: 1112860, Issued: 15 Feb 2012 8-37

Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks

Pinout Matrix

Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User

VAC between
One of three phases from the TPA to the
two phases:
Traction Motor. This AC voltage is produced
Stationary:
TRACTION by the TPA and is dependent on B+ at the +
0VAC;
166 U on TPA MOTOR terminal and B– on the TPA. This AC voltage TPA TM
Full Travel:
PHASE U is measured between any two phases and
24VAC;
varies from 0VAC at rest to about 24VAC at
Stall: approx.
full RPM.
4VAC

One of three phases from the LPA to the Lift VAC between
Motor. This AC voltage is produced by the two phases:
LPA and is dependent on B+ at the + Stationary:
V on LPA LIFT MOTOR
167 terminal and B– on the LPA. This AC voltage 0VAC; LPA LM
(AC Lift) PHASE V
is measured between any two phases and Full Lift: 24VAC;
varies from 0VAC at rest to about 24VAC at Stall: approx.
full RPM. 4VAC

VAC between
One of three phases from the TPA to the
two phases:
Traction Motor. This AC voltage is produced
Stationary:
TRACTION by the TPA and is dependent on B+ at the +
0VAC;
168 V on TPA MOTOR terminal and B– on the TPA. This AC voltage TPA TM
Full Travel:
PHASE V is measured between any two phases and
24VAC;
varies from 0VAC at rest to about 24VAC at
Stall: approx.
full RPM.
4VAC

One of three phases from the LPA to the Lift VAC between
Motor. This AC voltage is produced by the two phases:
LPA and is dependent on B+ at the B+ Stationary:
W on LPA LIFT MOTOR
169 terminal and B– on the LPA. This AC voltage 0VAC; LPA LM
(AC Lift) PHASE W
is measured between any two phases and Full Lift: 24VAC;
varies from 0VAC at rest to about 24VAC at Stall: approx.
full RPM. 4VAC

VAC between
One of three phases from the TPA to the
two phases:
Traction Motor. This AC voltage is produced
Stationary:
TRACTION by the TPA and is dependent on B+ at the +
0VAC;
170 W on TPA MOTOR terminal and B– on the TPA. This AC voltage TPA TM
Full Travel:
PHASE W is measured between any two phases and
24VAC;
varies from 0VAC at rest to about 24VAC at
Stall: approx.
full RPM.
4VAC

8-38 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section A. Appendix

Section A. Appendix

Publication: 1112860, Issued: 15 Feb 2012 A-1

Section A. Appendix Models 7500/7520 Reach-Fork ® Trucks

Lubrication Specification Chart

Lubrication Specification
Chart
Table A-1. Lubrication Specification Chart

Approved Raymond Lubricants

Where Used Type Specification Raymond Part Number

75W-90 Synthetic Gear

Drive Unit Gear Case Gear 990-655/001 (1 qt./0.9 liters)
Oil
(all applications) Lubricant 990-655/003 (1 gal./3.8 liters)
API Service GL-5

Hydraulic Reservoir 990-616/04 (1 qt./0.9 liter)

(Non-CS trucks) Hydraulic 990-616/01 (1 gal./3.8 liters)
ISO VG 46
+50°F to +120°F Fluid 990-616/02 (2 gal./7.6 liters)
(+10°C to +49°C) 990-616/03 (5 gal./18.9 liters)

Hydraulic Reservoir
(CS trucks - in and out of
Hydraulic 1017238
freezer) ISO VG 32
Fluid Note: Do not add any additives.
0°F to +50°F
(–18°C to +10°C)

Hydraulic Reservoir
(CS trucks - confined to
Hydraulic 990-618/TX1 (1 gal./3.8 liters)
freezer) MIL-H-5606E
Fluid 990-618/01 (1 gal./3.8 liters)
–20°F to 0°F
(–29°C to –18°C)

Mast Uprights, Bearings,

and so forth
(all-weather) Grease NLGI 2 1012992
–20°F to +120°F
(–29°C to +49°C)

Teflon 1151877/001 (Rexoil)

Lift Chains Aerosol
Grease 1151877/002 (Rocol)

A-2 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section A. Appendix

Thread Adhesives, Sealants, and Lubricants

Thread Adhesives,
Sealants, and Lubricants
Table A-2. Thread Adhesives, Sealants, and Lubricants

Loctite*
Raymond P/N Application
Number/Color

990-403 Thread-locking 1/4 in. and below 222/Purple

990-445 Cold Storage Silicone Sealing Compound

990-452 Anti-Seize Lubricant, Heavy Duty High Temperature

990-462 See P/N 1013829

990-463 Thread-locking 1 in. and under, contamination tolerant 603/Green

990-533 Thread-locking Primer T7471

990-536 See P/N 1013829

990-538 Thread-locking Cleaner 707

990-544 Thread-locking 1 in. and under 271/Red

990-552 Hydraulic Sealant 569

990-571 Thread-locking 1 in. and over 277/Red

990-638 Molybdenum Anti-Seize Compound (Molykote) /Silver

990-644 Corrosion Inhibitor Coating

990-659 RTV Silicone Sealant 5900/Black

990-666 Thread-locking Primer 7649 (19269)

990-669 Thread-locking, primerless high strength 2760

243 or 2440
1013829 Thread-locking 1/4 to 3/4 in. medium strength
7242 (Cyberbond)

Note: *Loctite is a registered trademark of the Loctite Corporation. Brand endorsement is not implied
here, but listed only as a commonly identified product.

Publication: 1112860, Issued: 15 Feb 2012 A-3

Section A. Appendix Models 7500/7520 Reach-Fork ® Trucks

Component Specific Service/Torque Chart

Component Specific
Service/Torque Chart
Table A-3. Component Specific Service/Torque Chart

Thread-Locking
Component Sub-Component(s) Torque to:
Compound P/N

Auxiliary Manifold (Std AC Lift) mounting bolts 990-536 21 ft. lb. (29 Nm)

Auxiliary Motor (DC Lift) motor mtg bolts 990-536 15 ft. lb. (21 Nm)

pressure fitting torque n/a 45 ft. lb. (61 Nm)

Auxiliary Pump (DC Lift)
mounting bolts 990-536 11 ft. lb. (15 Nm)

Baseleg baseleg mounting bolts 990-669 165 ft. lb. (223 Nm)
Apply anti-seize compound
(P/N 990-452) to locating pins. load wheel plate mtg bolts 1013829 50 ft. lb. (68 Nm)

Battery Gate Switches Adjust the gap between the switch and target to 0.16 in. (4 mm) max.

Deadman Pedal Assembly

Pedal travel:
assembly to frame n/a 15 ft. lb. (21 Nm)
Fore/Aft Stance - 3.50 in. (90 mm)
Dockstance: 3.58 in. (99 mm)

Drive Wheel mounting bolts n/a 170 ft. lb. (230 Nm)

EPO Switch n/a 990-536 6 ft. lb. (8.6 Nm)

Adjustment: Fully lower carriage and adjust gap between switch and
High Speed Travel Switch (S25)
rail from 0.10 to 0.22 in. (2.54 to 5.58 mm).

Horn bracket to frame 990-536 15 ft. lb. (21 Nm)

Hose, Over-the-Mast pulley stud 1013289 130 ft. lb. (174 Nm)

Adjustment:
1. Fully raise carriage and adjust gap between switch and rail from
Lift Cutout Switch (S27) 0.10 to 0.25 in. (2.54 to 6.35 mm).
2. Align the vertical center line of the switch just below the bottom
edge of the rail so the sensor LED is OFF.

lift pump mtg bolts 55 ft. lb. (72 Nm)

Lift Motor 990-536
Apply anti-seize compound motor mtg bolts to deck 15 ft. lb. (21 Nm)
(P/N 990-638) to pump spline and
mating surfaces. 204 to 221 in. lb.
lift motor power cables n/a
(23 to 25 Nm)

P1 fitting (AC Lift) 85 ft. lb. (115 Nm)

Lift Pump input fitting (AC Lift) 120 ft. lb. (163 Nm)
Apply anti-seize compound n/a
P1 fitting (DC Lift) 85 ft. lb. (115 Nm)
(P/N 990-638) to spline, mating
surfaces. P2 fitting (DC Lift) 60 ft. lb. (81 Nm)

lift pump mounting bolts 990-536 55 ft. lb. (72 Nm)

A-4 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section A. Appendix

Component Specific Service/Torque Chart

Thread-Locking
Component Sub-Component(s) Torque to:
Compound P/N

Manifold, Auxiliary
mounting bolts 21 ft. lb. (29 Nm)
(Reach/Tilt/Sideshift) 990-536
Manifold, Main mounting bolts 21 ft. lb. (29 Nm)

Refer to “Mating Mast to Tractor” on

Mast mast to tractor
page 7-159 or page 7-172.

Overhead Guard mounting bolts 990-536 130 ft. lb. (174 Nm)

amplifier bolts to bracket 6 ft. lb. (8.6 Nm)

Power Amplifier, Lift (AC Lift) bracket mtg bolts to deck 15 ft. lb. (21 Nm)

power cables 11 ft. lb. (15 Nm)

amplifier bolts to bracket 6 ft. lb. (8.6 Nm)

n/a
Power Amplifier, Traction bracket mtg nuts to deck 15 ft. lb. (21 Nm)

power cables 11 ft. lb. (15 Nm)

95 ft. lb. (129 Nm)

Proportional Valve n/a
Run Learn Lower

Pulleys, Over-the-Mast pulley stud 1013289 130 ft. lb. (174 Nm)

switch bracket to drive

Steer Limit Switch S11 (AC Lift) 990-536 9 ft. lb. (12 Nm)
unit

Adjustment:
1. Lower carriage and adjust gap between switch and rail from 0.10
Speed Limiting Switch, First (S12) to 0.25 in. (2.54 to 6.35 mm).
2. Align the vertical center line of the switch just above the bottom
edge of the rail so the sensor LED is ON.

pinion gear set screw 6 ft. lb. (8.6 Nm).

Steer Motor, Electric (AC Lift)
Note: Apply anti-seize compound pinion gear mtg bolt 1013829 21 ft. lb. (29 Nm)
(P/N 990-638) to pinion gear. Orient
pinion gear with shoulder toward motor mtg bolts 30 ft. lb. (42 Nm)
mounting bolt.
flange mtg bolts 95 ft. lb. (129 Nm)

spur gear 6.25 ft. lb. (8.5 Nm)

990-536
mounting bolts 55 ft. lb. (72 Nm)

Steer Motor, Hydraulic (DC Lift) flange mtg bolts 75 ft. lb. (102 Nm)

pressure fittings 60 ft. lb. (81 Nm)

n/a
drain connection 21 ft. lb. (28 Nm)

Steer Tiller cap screws

Steering Orbitrol (DC Lift) mounting bolts 990-536 15 ft. lb. (21 Nm)

Stops, Carriage n/a 35 ft. lb. (47.5 Nm)

Publication: 1112860, Issued: 15 Feb 2012 A-5

Section A. Appendix Models 7500/7520 Reach-Fork ® Trucks

Component Specific Service/Torque Chart

Thread-Locking
Component Sub-Component(s) Torque to:
Compound P/N

Temperature Sensor, DC Lift Apply heatsink compound (P/N 990-508) to sensor threads. Make sure
Motor sensor does not touch field poles when retaining nut is tightened.

pinion gear nut 45 ft. lb. (61 Nm)

Traction Motor 990-536
Note: When replacing Traction mounting bolts 13 ft. lb. (17 Nm)
Motor, thoroughly clean motor 204 to 221 in. lb.
shaft, keyway, and threads with power cables n/a
(23 to 25 Nm)
P/N 990-666.
steer limit sensing rail 9 ft. lb. (12 Nm)
990-536
Travel Light n/a 23 ft. lb. (31 Nm)

A-6 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section A. Appendix

Torque Chart - Hydraulic Fittings

Torque Chart - Hydraulic

Fittings
Table A-4. Torque Chart - Hydraulic Fittings

JIC SAE Straight Thread Steel Plugs

SAE
Thread (37° Flare Thread)
Dash Hollow Hex Head Plug HP50N Hex Head Plug P50N
Size
Size
ft. lb. Nm ft. lb. Nm ft. lb. Nm

-2 5/16-24 3 ±1 4 ±1 3 ±0.5 4 ±0.6 7.5 ±0.5 10 ±0.6

-3 3/8-24 6 ±1 8 ±1 5 ±0.5 7 ±0.6 14 ±1 19 ±1

-4 7/16-20 12 ±1 16 ±1 11 ±1 15 ±1 18 ±1 24 ±1

-5 1/2-20 15 ±1 20 ±1 15 ±1 20 ±1 22 ±1 30 ±1

-6 9/16-18 21 ±1 28 ±1 18 ±1 24 ±1 27 ±2 37 ±3

-8 3/4-16 45 ±2 61 ±3 46 ±2 62 ±3 48 ±2 65 ±3

-10 7/8-14 60 ±5 81 ±7 75 ±5 102 ±7 90 ±5 122 ±7

-12 1 1/16-12 85 ±5 115 ±7 85 ±5 115 ±7 110 ±5 149 ±7

-14 1 3/16-12 105 ±5 142 ±7 130 ±6 176 ±8 145 ±6 197 ±8

-16 1 5/16-12 120 ±5 163 ±7 135 ±6 183 ±8 160 ±6 217 ±8

-20 1 5/8-12 170 ±10 230 ±14 225 ±12 305 ±16 225 ±12 305 ±16

-24 1 7/8-12 200 ±15 271 ±20 250 ±12 339 ±16 250 ±12 339 ±16

-32 2 1/2-12 270 ±20 366 ±27 325 ±15 441 ±20 325 ±15 441 ±20

Publication: 1112860, Issued: 15 Feb 2012 A-7

Section A. Appendix Models 7500/7520 Reach-Fork ® Trucks

Torque Chart - Straight Thread Face Seal O-Rings

Torque Chart - Straight

Thread Face Seal
O-Rings
Table A-5. Torque Chart - Straight Thread Face Seal O-Rings

SAE Dash Tube Size

ft. lb. Nm
Size Thread Size

-4 9/16-18 18 ±1 24 ±1

-6 11/16-18 27 ±2 37 ±3

-8 13/16-16 40 ±2 54 ±3

-10 1-14 63 ±3 85 ±4

-12 1 3/16-12 90 ±4 122 ±5

-14 1 5/16-32 95 ±6 129 ±8

-16 1 7/16-12 120 ±8 163 ±11

-20 1 11/16-12 140 ±8 190 ±11

-24 2-12 165 ±8 224 ±11

-32 2 1/2-12 360 ±10 488 ±14

A-8 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section A. Appendix

Torque Chart - Standard (Ferrous)

Torque Chart - Standard

(Ferrous)
Table A-6. 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

6-40 12 9 18 13 25 19

8-32 19 14 29 22 41 31

8-36 20 15 31 23 44 33

10-24 27 21 42 32 60 45

10-32 31 24 48 36 68 51

1/4-20 66 49 100 76 143 107

1/4-28 75 56 120 87 164 123

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 32 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 85 65 120 90

9/16-12 70 50 110 80 150 110

9/16-18 80 60 120 90 170 130

5/8-11 95 70 150 110 210 160

5/8-18 110 85 170 130 240 180

Publication: 1112860, Issued: 15 Feb 2012 A-9

Section A. Appendix Models 7500/7520 Reach-Fork ® Trucks

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.

3/4-10 170 130 260 200 380 280

3/4-16 190 140 300 220 420 320

7/8-9 170 125 430 320 600 460

7/8-14 185 140 470 350 660 500

1-8 250 190 650 480 900 680

1-12 275 205 700 520 1000 740

1 1/8-7 350 270 800 600 1280 960

1 1/8-12 400 300 880 660 1440 1080

1 1/4-7 500 375 1120 840 1820 1360

1 1/4-12 550 420 1240 920 2000 1500

1 3/8-6 650 490 1460 1100 2380 1780

1 3/8-12 750 560 1680 1260 2720 2040

1 1/2-6 870 650 1940 1460 3160 2360

1 1/2-12 980 730 2200 1640 3560 2660

Note: Use “oiled” values for bolts with thread-locking compound.

A-10 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section A. Appendix

Torque Chart - Metric (Ferrous)

Torque Chart - Metric

(Ferrous)
Table A-7. Torque Chart - Ferrous Metric

Ferrous Metric Bolts, Coarse Thread

(Grade rating stamped on head of bolt)

Grade 8.8 Grade 10.9

Diameter
Torque (bolts oiled) Torque (bolts oiled)
(in millimeters)
ft. lb. Nm ft. lb. Nm

6 6 8.2 8 11.3

8 15 20 20 27

10 30 41 42 57

12 55 75 75 102

16 130 177 185 252

20 270 367 375 510

24 460 626 640 870

Publication: 1112860, Issued: 15 Feb 2012 A-11

Section A. Appendix Models 7500/7520 Reach-Fork ® Trucks

Torque Chart - Standard (Brass)

Torque Chart - Standard

(Brass)
Table A-8. Torque Chart - Standard Brass

Brass MS63 Standard Bolts, Coarse Thread

Torque (bolts oiled)

Size
in. lb. Nm

4-40 3.3 0.37

4-48 3.6 0.40

6-32 6.1 0.69

6-40 6.8 0.77

8-32 11 1.24

8-36 11 1.24

10-24 14 1.58

10-32 17 1.92

1/4-20 35 3.96

1/4-28 40 4.52

5/16-18 73 8.25

5/16-24 81 9.15

3/8-16 130 14.69

3/8-24 147 16.61

Note: Use “oiled” values for bolts with

thread-locking compound.

A-12 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section A. Appendix

Torque Chart - Metric (Brass)

Torque Chart - Metric

(Brass)
Table A-9. Torque Chart - Brass Metric

Brass MS63 Metric Bolts, Coarse Thread

Diameter Torque (bolts oiled)

(in millimeters) in. lb. Nm

3 4.4 0.5

3.5 7.0 0.79

4 10 1.1

5 19 2.1

6 34 3.8

8 79 9

10 150 17

Note: Use “oiled” values for bolts with

thread-locking compound.

Publication: 1112860, Issued: 15 Feb 2012 A-13

Section A. Appendix Models 7500/7520 Reach-Fork ® Trucks

Decimal Equivalent Chart

Decimal Equivalent Chart

Table A-10. Decimal Equivalent Chart
To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 .397
1/32 .031 .03 .794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081

A-14 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section A. Appendix

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400

Publication: 1112860, Issued: 15 Feb 2012 A-15

Section A. Appendix Models 7500/7520 Reach-Fork ® Trucks

Standard/Metric Conversions

Standard/Metric Conversions
To Convert... Multiply, Add, or Subtract...
Area
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Distance
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Mass
Ounces to Grams Ounces x 28.35
Grams to Ounces Ounces x 0.035
Ounces to Kilograms Ounces x 0.028
Kilograms to Ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to Pounds Kilograms x 2.2
Pressure
Pounds per Square Inch (PSI) to kiloPascals PSI x 6.894
kiloPascals to Pounds per Square Inch (PSI) kiloPascals x 0.145
Speed
Miles per hour to Kilometers per hour Miles per hour x 1.609
Kilometers per hour to Miles per hour Kilometers per hour x 0.6214
Temperature
Fahrenheit to Celsius (°F minus 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) plus 32
Torque
Inch Pounds (in. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lb.) Newton Meters x 0.737
Volume
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26

A-16 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section I. Index

Section I. Index
Numerics Battery
Charging . . . . . . . . . . . . . . . . . . . . 7-69
2d Pump Valve SOL4 . . . . . . . . . . . . .7-105 Cleaning Exterior . . . . . . . . . . . . . 7-69
Connector/Cables . . . . . . . . . . . . . 7-68
Maintenance . . . . . . . . . . . . . . . . . 7-69
A Safety . . . . . . . . . . . . . . . . . . . . . . . 2-5
State-of-Charge (BSOC) . . . . . 5-5, 7-70
Abbreviations, List of . . . . . . . . . . . . . . 1-4 Configuring . . . . . . . . . . . . . . . 3-18
AC Lift Motor Testing . . . . . . . . . . . . . . . . . . . . . 7-69
Temperature Sensor . . . . . . . . . . 7-83 Battery Gate Switches . . . . . . . . . . . . . A-4
AC Motors . . . . . . . . . . . . . . . . . . . . . 5-14 Bearings
Acceleration Mast, Shimming . . . . . . . . . . . . . 7-129
Lift, Configuring . . . . . . . . . . . . . 3-18 Carriage to Inner Tele
Lower, Configuring . . . . . . . . . . . . 3-18 Model 7500 . . . . . . . . . . . 7-156
Travel, Configuring . . . . . . . . . . . 3-17 Model 7520 . . . . . . . . . . . 7-169
Acronyms, List of . . . . . . . . . . . . . . . . 1-4 Inner Tele to Outer Tele
Active Service Mode . . . . . . . . . . 3-22, 3-24 Model 7500 . . . . . . . . . . . 7-155
Adjustment Model 7520 . . . . . . . . . . . 7-168
Auxiliary Pressure . . . . . . . . . . . . 7-95 Outer Tele to Main Frame
Proportional Valve . . . . . . . . . . . . 7-94 Model 7500 . . . . . . . . . . . 7-154
Reach Cylinder . . . . . . . . . . . . . .7-120 Model 7520 . . . . . . . . . . . 7-167
Alarm, Travel, Configuring . . . . . . . . 3-17 Reach Carriage . . . . . . . . . . . . . . 7-128
AMP Connectors . . . . . . . . . . . . . . . . 7-73 Bleeding Hydraulic System . . . . . . . . . 7-88
Analog Tests . . . . . . . . . . . . . 6-27 to 6-54 Bow Pads . . . . . . . . . . . . . . . . . . . . . 7-131
Summary List . . . . . . . . . . . . . . . 6-25 Brake
See Tests, Analog for Individual Tests Application, Theory . . . . . . . . . . . . 8-22
Anchors, Chain . . . . . . . . . . . . . . . . .7-134 Floating Disk . . . . . . . . . . . . . . . . 7-61
Auto Power Off ™Device . . . . . . . . . . . 3-20 Coil Replacement . . . . . . . . . . 7-62
Aux Manifold . . . . . . . . . . . . . . . . . . . . A-5 Installation . . . . . . . . . . . . . . . 7-62
AC Lift w/Regen Lower . . . . . . . . 7-98 Pad Replacement . . . . . . . . . . . 7-61
Mounting . . . . . . . . . . . . . . . . . . . . A-4 Removal . . . . . . . . . . . . . . . . . 7-61
Aux Manifold - Standard Reach . . . . .7-100 Overview . . . . . . . . . . . . . . . . . . . . 8-22
Auxiliary Dump Valve SOL8 . . . . . . .7-105 Release Screws, Use of . . . . . . . . . 8-22
Auxiliary Functions, Troubleshooting 5-16 Release, Theory . . . . . . . . . . . . . . . 8-22
Auxiliary Motor (DC lift) . . . . . . . . . . . . A-4 Theory of Operation . . . . . . . . . . . 8-22
Auxiliary Pressure Adjustment . . . . . 7-95 BSOC (Battery State-of-Charge) . 5-5, 7-70
Auxiliary Pump (DC lift) . . . . . . . . . . . . A-4 Configuring . . . . . . . . . . . . . . . . . . 3-18
Auxiliary Valve SOL5B/5T . . . 7-104, 7-105 Setting BSOC Cutout . . . . . . . . . . . 5-5

B C

Backlash, Drive Unit . . . . . . . . . . . . . 7-58 Cable Installation, Mast

Baseleg . . . . . . . . . . . . . . . . . . . . 7-22, A-4 Model 7500 . . . . . . . . . . . . . . . . . 7-157
Model 7520 . . . . . . . . . . . . . . . . . 7-169
Cable Removal, Mast
Model 7500 . . . . . . . . . . . . . . . . . 7-150
Model 7520 . . . . . . . . . . . . . . . . . 7-162

Publication: 1112860, Issued: 15 Feb 2012 I-1

Section I. Index Models 7500/7520 Reach-Fork ® Trucks

Cable, Over-the-Mast . . . . . . . . . . . . 7-140 Configure Mode . . . . . . . . . . . . .3-11, 3-13

Cable Only Replacement . . . . . . . 7-146 Factory Defaults, Restoring .3-15, 3-17
Cable, Terminology . . . . . . . . . . . . . . . .5-7 Menu Settings . . . . . . . . . 3-17 to 3-21
Cables, Power . . . . . . . . . . . . . . . . . . . 7-79 See also Individual Parameter Name
Card Connectors
Fuse/Relay . . . . . . . . . . . . . . . . . . .5-9 AMP . . . . . . . . . . . . . . . . . . .7-73, 7-76
Tilt/Sideshift Switch Circuit Card . . . . . . . . . . . . . . . . . . 5-8
Fore/Aft Stance . . . . . . . . . . . . 7-39 Fuse/Relay Card . . . . . . . . . . . . . . 5-9
Vehicle Manager . . . . . . . . . . . . . . .5-8 Molex . . . . . . . . . . . . . . . . . . . . . . 7-72
Carriage . . . . . . . . . . . . . . . . . . . . . . 7-133 Vehicle Manager . . . . . . . . . . . . . . . 5-8
Bearings . . . . . . . . . . . . . . . . . . . 7-128 Contactors . . . . . . . . . . . . . . . . . . . . . 4-11
Configuring Reach/Retract . . . . . . 3-19 Control Handle
Installation into Mast Dockstance . . . . . . . . . . . 7-37 to 7-40
Model 7500 . . . . . . . . . . . . . . 7-157 Pot Heaters . . . . . . . . . . .7-37, 7-40
Model 7520 . . . . . . . . . . . . . . 7-169 Fore/Aft Stance
Manual Lowering . . . . . . . . . . . . . . 7-93 Primary . . . . . . . . . . . . 7-32 to 7-36
Removal from Mast Flex Circuit Assembly . . . . 7-32
Model 7500 . . . . . . . . . . . . . . 7-150 Pot Heaters 7-32, 7-33, 7-34, 7-37,
Model 7520 . . . . . . . . . . . . . . 7-162 7-38, 7-39
Stops . . . . . . . . . . . . . . . . . . . . . . .A-5 ThermaKit Heater 7-34, 7-35, 7-39
Caster Assembly . . . . . . . . . . . . . . . . . 7-28 Fore-Aft Stance
Height Adjustment . . . . . . . . . . . . 7-29 Primary
Caster, Steerable . . . . . . . . . . . . . . . . . 7-28 Pot Heaters . . . . . . . .7-33, 7-38
Height Adjustment . . . . . . . . . . . . 7-29 Shell Disassembly . . .7-32, 7-37
Caution, Definition . . . . . . . . . . . . . . . .2-2 ThermaKit Heater . . .7-34, 7-39
CB1 & CB2 Counterbalance Valve . . . 7-105 Secondary . . . . . . . . . . 7-41 to 7-42
CE1 Compensating Element Valve . . . 7-105 ThermaKit Heater . . . . . . . 7-41
Chains Tilt/Sideshift Switch . . . . . . . . . . . 7-40
Anchors . . . . . . . . . . . . . . . . . . . 7-134 Dockstance . . . . . . . . . . . . . . . 7-39
Condition-Cause Chart . . . . . . . . . 4-12 Fore/Aft Stance . . . . . . . . . . . 7-35
Free Lift . . . . . . . . . . . . . . . . . . . 7-137 Controls, Learn . . . . . . . . . . . . . . . . . 3-22
Main Lift, 7500 . . . . . . . . . . . . . . 7-137 Conversion
Maintenance . . . . . . . . . . . . . . . . . 4-12 Decimal to Fraction . . . . . . . . . . . A-14
Changing Password or SuperWrd . . . . 3-13 Fraction to Decimal . . . . . . . . . . . A-14
Check Valve Conversions, Standard/Metric . . . . . . A-16
CV-1 . . . . . . . . . . . . . . . . 7-104, 7-105 Corrosion Inhibitor, Cold Storage . . . . 7-85
CV-2 . . . . . . . . . . . . . . . . . . . . . . 7-105 Counterbalance Valve CB1 & CB2 . . 7-105
CV-3 . . . . . . . . . . . . . . . . . . . . . . 7-105 Cushion, Lift Cylinder Lowering
Circuit Card Connectors . . . . . . . . . . . .5-8 Free Lift . . . . . . . . . . . . 7-117 to 7-118
Fuse/Relay Card . . . . . . . . . . . . . . .5-9 Main Lift . . . . . . . . . . . . . . . . . . . 7-117
Vehicle Manager . . . . . . . . . . . . . . .5-8 Cutout Switch, Lift (S27) . . . . . . . . . . . A-4
Cleaning Cutout, Lift, Configuring . . . . . . . . . . 3-18
Battery . . . . . . . . . . . . . . . . . . . . . 7-69 CV-1 Check Valve . . . . . . . . . .7-104, 7-105
Lift Truck . . . . . . . . . . . . . . . . . . . .2-4 CV-2 Check Valve . . . . . . . . . . . . . . . 7-105
Clock, Setting . . . . . . . . . . . . . . . . . . . 3-20 CV-3 Check Valve . . . . . . . . . . . . . . . 7-105
Coast Distance, Configuring . . . . . . . . 3-17
Codes
Power Amplifier . . . . . . . . . . . . . . . .6-2
Summary List . . . . . . . . . . . . . . . . .6-3
Cold Storage Conditioning . . . . . . . . . . 7-85
Cold Storage, Theory of Operation . . . . .8-6
Compensating Element Valve CE1 . . . 7-105

I-2 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section I. Index

Cylinder Drive Unit . . . . . . . . . . . . . . . . 7-44 to 7-60

Free Lift . . . . . . . . . . . . .7-108 to 7-109 Assembly . . . . . . . . . . . . . 7-53 to 7-59
Lowering Cushion . .7-117 to 7-118 Helical Gear . . . . . . . . . . . . . . 7-55
Model 7500 . . . . . . . . 7-150, 7-157 Output Shaft . . . . . . . . . . . . . . 7-53
Model 7520 . . . . . . . . 7-162, 7-169 Pivot Ring . . . . . . . . . . . . . . . . 7-58
Seal Repacking . . . .7-110 to 7-112 Spiral Pinion . . . . . . . . . . . . . . 7-53
Main Lift . . . . . . . . . . . .7-113 to 7-115 Backlash Measurement . . . . . . . . . 7-58
Lowering Cushion . . . . . . . . .7-117 Disassembly . . . . . . . . . . . 7-49 to 7-53
Seal Repacking . . . . . . . . . . .7-116 Output Shaft . . . . . . . . . . . . . . 7-50
Reach . . . . . . . . . . . . . . . . . . . . .7-119 Pivot Ring . . . . . . . . . . . . . . . . 7-49
Adjustment . . . . . . . . . . . . . .7-120 Spiral Pinion . . . . . . . . . . . . . . 7-52
Tilt . . . . . . . . . . . . . . . . . . . . . . .7-122 Exploded Parts Diagram . . . . . . . . 7-44
CYL-P Pressure Transducer . . 7-104, 7-105 Helical Gear Assembly . . . . . . . . . 7-55
Installation . . . . . . . . . . . . . . . . . . 7-59
D Output Shaft
Assembly . . . . . . . . . . . . . . . . 7-53
Disassembly . . . . . . . . . . . . . . 7-50
DC Motor
Pivot Ring
Troubleshooting . . . . . . . . . . . . . 5-10
Assembly . . . . . . . . . . . . . . . . 7-58
DC Motor Test . . . . . . . . . . . . . . . . . . 5-12
Disassembly . . . . . . . . . . . . . . 7-49
Deadman
Removal . . . . . . . . . . . . . . . . . . . . 7-48
Pedal Assembly . . . . . . . . . . . . . . . A-4
Shim Formulas . . . . . . . . . . . . . . . 7-56
Deadman Pedal Adjustment . . . . . . . 7-63
Shim Installation . . . . . . . . . . . . . 7-56
Decals and Plates . . . . . . . . . 7-17 to 7-21
Spiral Pinion
Deceleration
Assembly . . . . . . . . . . . . . . . . 7-53
Lift, Configuring . . . . . . . . . . . . . 3-18
Disassembly . . . . . . . . . . . . . . 7-52
Lower, Configuring . . . . . . . . . . . . 3-18
Troubleshooting . . . . . . . . . . . . . . 7-47
Decimal to Fraction Conversion . . . . . A-14
Drive Wheel and Tire . . . . . . . . . . . . . . A-4
Deep-Reach
Manifold . . . . . . . . . . . . . . . . . . .7-102
Tilt/Sideshift Manifold . . . . . . . . .7-103 E
Deep-Reach Manifold . . . . . . . . . . . .7-102
Diagnostic Mode Electric Steer Motor (AC Lift) . . . . . . . . . A-5
See Service Mode Electrical Symptoms . . . . . . . . 5-26 to 5-27
Digital Input Tests . . . . . . . . .6-63 to 6-102 Electrical Tests
Summary List . . . . . . . . . . . . . . . 6-25 Summary List . . . . . . . . . . . . . . . . 6-25
See Tests, Input for Individual Tests Electrical Troubleshooting
Digital Output Tests . . . . . .6-103 to 6-124 Symptoms . . . . . . . . . . . . 5-26 to 5-27
Summary List . . . . . . . . . . . . . . . 6-25 Electronic Operator Key . . . . . . 3-12, 3-20
See Tests, Output for Individual Tests Electrostatic Discharge
Display, Operator . . . . . . . . . . . . . . . 3-10 See Static Precautions
Troubleshooting . . . . . . . . . . . . . 5-26 Encoder
AC Traction Motor Speed . . . . . . . 7-83
Steering (AC Lift) . . . . . . . . . . . . . . 7-26
English Units, Configuring Display for 3-18
Entering a Password or SuperWrd . . . 3-13
EPO Switch . . . . . . . . . . . . . . . . . . . . . A-4
Error Log . . . . . . . . . . . . . . . . . 3-22, 3-24
Error Messages
Power Amplifier . . . . . . . . . . . . . . . . 6-2
Summary List . . . . . . . . . . . . . . . . . 6-3
ESD Ground Jack . . . . . . . . . . . . . . . . 2-7

Publication: 1112860, Issued: 15 Feb 2012 I-3

Section I. Index Models 7500/7520 Reach-Fork ® Trucks

F Heater
Control Handle
Factory Default Configure Settings 3-15, 3-17 Dockstance
Fault Codes Potentiometers . . . . . . . . . 7-37
Power Amplifier . . . . . . . . . . . . . . . .6-2 Fore/Aft Stance
Summary List . . . . . . . . . . . . . . . . .6-3 Potentiometers 7-32, 7-33, 7-34,
Filter 7-37, 7-38, 7-39
Hydraulic ThermaKit . . . . 7-34, 7-35, 7-39
AC Lift . . . . . . . . . . . . . . . . . . . 7-89 Fore-Aft Stance
DC Lift . . . . . . . . . . . . . . . . . . . 7-89 Potentiometers . . . . .7-33, 7-38
Torque (DC Lift) . . . . . . . . . . . 7-105 ThermaKit . . . . 7-34, 7-39, 7-41
FlashWare Helical Gear Assembly, Drive Unit . . . 7-55
Connecting to Truck . . . . . . . . . . . .3-8 High Speed Travel Switch (S25) . . . . . . A-4
PC Installation . . . . . . . . . . . . . . . .3-8 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Starting . . . . . . . . . . . . . . . . . . . . . .3-8 Horn Switch
FlashWare Program . . . . . . . . . . . . . . . .3-8 Test 018 . . . . . . . . . . . . . . . . . . . 6-116
Flex Circuit Assembly Test I15 . . . . . . . . . . . . . . . . . . . . 6-74
Fore/Aft Stance . . . . . . . . . . . . . . . 7-32 Hose
Flow Limiter Free Lift . . . . . . . . . . . . . . . . . . . 7-149
Free Lift . . . . . . . . . . . . . . . . . . . 7-125 Installation, Mast
Main Lift . . . . . . . . . . . . . . . . . . . 7-124 Model 7500 . . . . . . . . . . . . . . 7-157
Forks Model 7520 . . . . . . . . . . . . . . 7-169
Angle . . . . . . . . . . . . . . . . . . . . . . . 4-13 Main Lift . . . . . . . . . . . . . . . . . . . 7-139
Hooks . . . . . . . . . . . . . . . . . . . . . . 4-15 Over-the-Mast . . . . . . . . . . 7-140, A-4
Inspection . . . . . . . . . . . . . . . . . . . 4-13 Removal, Mast
Markings . . . . . . . . . . . . . . . . . . . . 4-16 Model 7500 . . . . . . . . . . . . . . 7-150
Positioning Locks . . . . . . . . . . . . . 4-14 Model 7520 . . . . . . . . . . . . . . 7-162
Straightness . . . . . . . . . . . . . . . . . 4-13 Hour Meters . . . . . . . . . . . . . . . .3-11, 3-16
Tip Height . . . . . . . . . . . . . . . . . . . 4-14 HTI
Wear . . . . . . . . . . . . . . . . . . . . . . . 4-14 Codes and Tests
Fraction to Decimal Conversion . . . . .A-14 Test I26 . . . . . . . . . . . . . . . . . 6-82
Free Lift Cylinder . . . . . . . . 7-108 to 7-109 Test I86 . . . . . . . . . . . . . . . . . 6-98
Model 7500 . . . . . . . . . . . 7-150, 7-157 Pressure Switch
Model 7520 . . . . . . . . . . . 7-162, 7-169 Torque . . . . . . . . . . . .7-104, 7-105
Seal Repacking . . . . . . . 7-110 to 7-112 Hung-Up Carriage, Lowering . . . . . . . 7-93
Fuse/Relay Card Connectors . . . . . . . .5-9 Hydraulic
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Filter
AC Lift . . . . . . . . . . . . . . . . . . 7-89
DC Lift . . . . . . . . . . . . . . . . . . 7-89
G Torque (DC Lift) . . . . . . . . . . 7-105
Manifold
Ground Jack, ESD . . . . . . . . . . . . . . . .2-7 See Manifold
Steer Motor (DC Lift) . . . . . . . . . . . . A-5
H System
Bleeding . . . . . . . . . . . . . . . . . 7-88
Harness Troubleshooting
Inspection . . . . . . . . . . . . . . . . . . . 7-71 Guidelines . . . . . . . . . . . . . 5-15
Repair . . . . . . . . . . . . . . . . . . . . . . 7-71 Symptoms . . . . . . . 5-16 to 5-24
Soldering Procedures . . . . . . . . . . . 7-71
Terminology . . . . . . . . . . . . . . . . . .5-7 I

IETM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

I-4 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section I. Index

Inertial Dampener . . . . . . . . . . . . . . . 7-64 Lift/Lower

Input Tests . . . . . . . . . . . . . .6-63 to 6-102 Manifold
Summary List . . . . . . . . . . . . . . . 6-25 AC Lift w/Regen Lower . . . . . . 7-97
See Tests, Input for Individual Tests System
Inspection Theory of Operation . . . 8-17 to 8-21
Contactors . . . . . . . . . . . . . . . . . . 4-11 Troubleshooting . . . . . . . . . . . 5-21
Installation Valve SOL2 . . . . . . . . . . . 7-104, 7-105
FlashWare . . . . . . . . . . . . . . . . . . . 3-8 Limit Switch, Speed, First (S12) . . . . . . A-5
Truck . . . . . . . . . . . . . . . . . . . . . . 3-6 Limit Switch, Steer S11 (AC Lift) . 7-27, A-5
Warranty . . . . . . . . . . . . . . . . . . . . 3-7 Linkage, Steering . . . . . . . . . . . . . . . . 7-31
Interactive Electronic Load
Technical Manuals . . . . . . . . . . . . 1-3 Holding Valve SOL1 . . . . 7-104, 7-105
Shuttle LS-1 . . . . . . . . . . 7-104, 7-105
J Load Holding Valve SOL1 . . . . . . . . . 7-104
Locator
Photos, Components . . . . . . 7-5 to 7-13
Jacking Safety . . . . . . . . . . . . . . . . . . . 2-8
Loctite®
See Thread Adhesives
L Lower
Acceleration, Configuring . . . . . . . 3-18
Learn Function . . . . . . . . . . . . . 3-11, 3-22 Deceleration, Configuring . . . . . . . 3-18
Controls . . . . . . . . . . . . . . . . . . . 3-22 Function
Weight . . . . . . . . . . . . . . . . . . . . . 3-22 Theory of Operation . . . . . . . . . . 8-9
Lift Troubleshooting . . . . . . . . . . . 5-23
Acceleration, Configuring . . . . . . . 3-18 Lowering Carriage Manually . . . . . . . . 7-93
Chain Inspection . . . . . . . . . . . . . 4-12 LS-1 Load Shuttle . . . . . . . . . 7-104, 7-105
Cutout Switch (S27) . . . . . . . . . . . . A-4 Lubrication Points . . . . . . . . . . . . . . . 4-10
Cutout, Configuring . . . . . . . . . . . 3-18 Lubrication Specification Chart . . . . . . A-2
Cylinder
Free Lift . . . . . . . . . .7-108 to 7-109 M
Model 7500 . . . . . 7-150, 7-157
Model 7520 . . . . . 7-162, 7-169
Main Lift Cylinder . . . . . . . . 7-113 to 7-115
Main Lift . . . . . . . . .7-113 to 7-115
Seal Repacking . . . . . . . . . . . . . . 7-116
Deceleration, Configuring . . . . . . 3-18
Main Manifold . . . . . . . . . . . . . . . . . . . A-5
Function
AC Lift, Standard . . . . . . . . . . . . . 7-96
Theory
DC Lift . . . . . . . . . . . . . . . . . . . . . 7-99
AC Lift . . . . . . . 8-8, 8-11, 8-14
Maintenance Minder ™ Tool . . . . . 3-20, 4-3
DC Lift . . . . . . . . . . . . . . . 8-18
Maintenance Mode
Troubleshooting . . . . . . . . . . . 5-21
See Service Mode
Hose, Main . . . . . . . . . . . . . . . . .7-139
Manifold
Limit Cutout, Configuring . . . . . . 3-18
Aux . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Motor
AC Lift w/Regen Lower . . . . . . 7-98
DC Lift Motor
Component Torque . . . . . 7-104
Temperature Sensor . . . . . . A-6
Mounting Bolt Torque . . . . . . . . A-4
Speed Sensor . . . . . . . . . . . . . 7-83
Standard Reach . . . . . . . . . . 7-100
Torque Specs . . . . . . . . . . . . . . A-4
Component Torque . . . . . 7-105
Power Amplifier (AC Lift) . . . . . . . . A-5
Deep-Reach . . . . . . . . . . . . . . . . 7-102
Pressure Adjustment . . . . . . . . . . 7-91
Component Torque . . . . . . . . 7-105
Pump . . . . . . . . . . . . . . . . . . . . . . A-4
Lift Cutout, Configuring . . . . . . . . . . 3-18

Publication: 1112860, Issued: 15 Feb 2012 I-5

Section I. Index Models 7500/7520 Reach-Fork ® Trucks

Lift/Lower Modes of Operation . . . . . . . . 3-11 to 3-24

AC Lift w/Regen Lower . . . . . . 7-97 Overview . . . . . . . . . . . . . . . . . . . 3-11
Component Torque . . . . . 7-104 Program . . . . . . . . . . . . . . . .3-11, 3-12
Main . . . . . . . . . . . . . . . . . . . . . . . .A-5 Configure . 3-11, 3-13, 3-17 to 3-21
AC Lift Standard Restoring Factory Defaults 3-15,
Component Torque . . . . . 7-104 3-17
AC Lift, Standard . . . . . . . . . . . 7-96 Hour Meters . . . . . . . . . .3-11, 3-16
DC Lift . . . . . . . . . . . . . . . . . . . 7-99 Serial Number . . . . . . . . .3-11, 3-16
Component Torque . . . . . 7-105 Service . . . . . . . . . 3-11, 3-22, 3-23
Tilt/Sideshift Active . . . . . . . . . . . .3-22, 3-24
Deep-Reach . . . . . . . . . . . . . . 7-103 Error Log . . . . . . . . . .3-22, 3-24
Component Torque . . . . . 7-105 Learn . . . . . . . . . . . .3-11, 3-22
Manifold Torque Specs . . . . 7-104 to 7-105 Controls . . . . . . . . . . . 3-22
Manual Lowering of Carriage . . . . . . . . 7-93 Weight . . . . . . . . . . . . . 3-22
Mast Static . . . . . . . . . . . . . . . . 3-23
Model 7500 Version . . . . . . . . . . . . . .3-11, 3-16
Assembly . . . . . . . . . 7-154 to 7-161 Run . . . . . . . . . . . . . . . . . . . . . . . 3-11
Disassembly . . . . . . 7-150 to 7-153 Tones . . . . . . . . . . . . . . . . . . . 3-12
Main Lift Chain Installation . . 7-155 Molex Connectors . . . . . . . . . . . . . . . . 7-72
Main Lift Chain Removal . . . . 7-151 Motors
Mating Tractor to Mast . . . . . 7-159 AC . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Separation of Telescopics . . . . 7-151 Lift Temp Sensor . . . . . . . . . . . 7-83
Separation of Tractor Open Winding . . . . . . . . . . . . . 5-14
and Mast . . . . . . . . . . . . . 7-150 Shorted Winding . . . . . . . . . . . 5-14
Model 7520 Traction Temp Sensor . . . . . . . 7-83
Assembly . . . . . . . . . 7-167 to 7-173 Armature . . . . . . . . . . . . . . . . . . . 5-13
Disassembly . . . . . . 7-162 to 7-166 Auxiliary (DC Lift) . . . . . . . . . . . . . . A-4
Main Lift Chain Installation . . 7-168 DC . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Main Lift Chain Removal . . . . 7-164 Field Winding Test . . . . . . . . . 5-13
Mating Tractor to Mast . . . . . 7-172 Grounded Motor Test . . . . . . . 5-12
Separation of Telescopics . . . . 7-165 Open Circuit Test . . . . . . . . . . 5-12
Separation of Tractor Short Circuited Armature . . . . 5-13
and Mast . . . . . . . . . . . . . 7-162 Lift - Torque Specs . . . . . . . . . . . . . A-4
Shimming . . . . . . . . . . . . . . . . . . 7-129 Power Cable Terminals . . . . . . . . . 7-81
Types . . . . . . . . . . . . . . . . . . . . . . .3-4 Steering (AC Lift) - Torque Specs . . A-5
Mast Bearing Shimming Temperature Sensor . . . . . . . . . . . . A-6
Carriage to Inner Tele Traction - Torque Specs . . . . . . . . . A-6
Model 7500 . . . . . . . . . . . . . . 7-156 Troubleshooting . . . . . . . . . . . . . . 5-26
Model 7520 . . . . . . . . . . . . . . 7-169 AC . . . . . . . . . . . . . . . . . . . . . 5-14
Inner Tele to Outer Tele DC . . . . . . . . . . . . . . . . . . . . . 5-10
Model 7500 . . . . . . . . . . . . . . 7-155
Model 7520 . . . . . . . . . . . . . . 7-168 O
Outer Tele to Main Frame
Model 7500 . . . . . . . . . . . . . . 7-154
OCSS
Model 7520 . . . . . . . . . . . . . . 7-167
Test I80 – Upper Beam . . . . . . . . . 6-91
Messages and Codes
Test I81 – Lower Beam . . . . . . . . . 6-93
Power Amplifier . . . . . . . . . . . . . . . .6-2
Open Circuit DC Motor Test . . . . . . . . 5-12
Meters, Hour . . . . . . . . . . . . . . . 3-11, 3-16
Open Winding AC Motor . . . . . . . . . . . 5-14
Metric Units, Configuring Display for . 3-18
Operator Compartment Sensor System
Test I80 – Upper Beam . . . . . . . . . 6-91
Test I81 – Lower Beam . . . . . . . . . 6-93

I-6 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section I. Index

Operator Display . . . . . . . . . . . . . . . . 3-10 Program Mode . . . . . . . . . . . . . 3-11, 3-12

Troubleshooting . . . . . . . . . . . . . 5-26 Menu Settings . . . . . . . . . . 3-16 to 3-22
Operator Key, Electronic . . . . . . 3-12, 3-20 See also Individual Parameter Name
Orbitrol, Steering (DC Lift) . . . . . . . . . . A-5 Proportional Valve Adjustment . . . . . . 7-94
Output Tests . . . . . . . . . . . .6-103 to 6-124 Pulleys, Over-the-Mast . . . . . . . . . . . . . A-5
Summary List . . . . . . . . . . . . . . . 6-25 Pump
See Tests, Output for Individual Tests Auxiliary (DC Lift) . . . . . . . . . . . . . . A-4
Outrigger Lift . . . . . . . . . . . . . . . . . . . . . . . . . A-4
See Baseleg
Overhead Guard Installation . . . . . . . . A-5 R
Over-the-Mast Hose . . . . . . . . . . . . . . A-4
Over-the-Mast Hose/Cable . . . . . . . .7-140
Reach Carriage
Cable Only Replacement . . . . . . .7-146
See Carriage
Reach Cylinder . . . . . . . . . . . . . . . . . 7-119
P Adjustment . . . . . . . . . . . . . . . . . 7-120
Reach Function
Passwords Configuring Speed . . . . . . . . . . . . 3-19
Changing Password or SuperWrd . 3-13 Theory of Operation
Electronic Operator Key . . . . 3-12, 3-20 AC Lift . . . . . . . . . . . . . . 8-10, 8-15
Entering Password or SuperWrd . 3-13 DC Lift . . . . . . . . . . . . . . . . . . 8-19
Password . . . . . . . . . . . . . . . 3-12, 3-20 Reach Speed, Configuring . . . . . . . . . . 3-19
SuperWrd . . . . . . . . . . . . . . 3-12, 3-20 Reach Valve
Pin Extraction Deep-Reach . . . . . . . . . . . . . . . . 7-102
AMP Connectors . . . . . . . . . . . . . 7-73 Std Reach . . . . . . . . . . . . . . . . . . 7-100
Molex Connectors . . . . . . . . . . . . 7-72 REL-1 Relief Valve (DC Lift) . . . . . . . . 7-105
Pin Insertion REL-2 Relief Valve (AC Lift) . . . . . . . . 7-104
AMP Connectors . . . . . . . . . . . . . 7-74 REL-3 Relief Valve (DR) . . . . . . . . . . . 7-105
Molex Connectors . . . . . . . . . . . . 7-72 Relief Valve REL-1 (DC lift) . . . . . . . . 7-105
Pinout Matrix . . . . . . . . . . . . 8-23 to 8-38 Relief Valve REL-2 (AC lift) . . . . . . . . 7-104
Pivot Ring, Drive Unit Relief Valve REL-3 (DR) . . . . . . . . . . . 7-105
Assembly . . . . . . . . . . . . . . . . . . . 7-58 Retract Function
Disassembly . . . . . . . . . . . . . . . . 7-49 Configuring Speed . . . . . . . . . . . . 3-19
POD-1 Valve . . . . . . . . . . . . . . . . . . .7-104 Troubleshooting . . . . . . . . . . . . . . 5-20
Power Amplifier Retract Speed, Configuring . . . . . . . . . 3-19
Connector . . . . . . . . . . . . . . . . . . 7-76 Run Mode . . . . . . . . . . . . . . . . . . . . . . 3-11
Discharging Internal Capacitor . . . 5-2 Tones . . . . . . . . . . . . . . . . . . . . . . 3-12
LED Diagnostics . . . . . . . . . . . . . . 6-2
Lift (AC Lift) . . . . . . . . . . . . . . . . . . A-5 S
Traction . . . . . . . . . . . . . . . . . . . . . A-5
Power Cables . . . . . . . . . . . . . . . . . . . 7-79
Safety
Power Cables, Motor . . . . . . . . . . . . . 7-81
Battery . . . . . . . . . . . . . . . . . . . . . . 2-5
Preset Lift Heights, Configuring . . . . . 3-21
Decals . . . . . . . . . . . . . . . 7-17 to 7-21
Pressure Adjustment
Definitions . . . . . . . . . . . . . . . . . . . 2-2
Auxiliary . . . . . . . . . . . . . . . . . . . 7-95
ESD . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Pressure Switch, HTI
General . . . . . . . . . . . . . . . . . . . . . . 2-3
Torque . . . . . . . . . . . . . . . 7-104, 7-105
Jacking . . . . . . . . . . . . . . . . . . . . . . 2-8
Pressure Transducer CYL-P . . . . . . . .7-104
Static Precautions . . . . . . . . . . . . . . 2-7
Torque . . . . . . . . . . . . . . . 7-104, 7-105
Tie-Down for Transport . . . . . . . . . 2-10
Primary Control Handle . . . . . 7-32 to 7-36
Welding . . . . . . . . . . . . . . . . . . . . . 2-11
Priority-on-Demand Valve POD-1 . . . .7-104

Publication: 1112860, Issued: 15 Feb 2012 I-7

Section I. Index Models 7500/7520 Reach-Fork ® Trucks

Scheduled Maintenance Sideshift Function

180 Days . . . . . . . . . . . . . . . . . . . . .4-6 Theory of Operation . . . . . . .8-10, 8-15
2000 Deadman Hours . . . . . . . . . . .4-9 DC Lift . . . . . . . . . . . . . . . . . . 8-20
360 Days . . . . . . . . . . . . . . . . . . . . .4-9 Troubleshooting . . . . . . . . . . . . . . 5-18
500 Deadman Hours . . . . . . . . . . . .4-6 Sideshift Valve
Chains . . . . . . . . . . . . . . . . . . . . . 4-12 Deep-Reach . . . . . . . . . . . . . . . . 7-103
Charts . . . . . . . . . . . . . . . . . .4-2 to 4-9 Std Reach . . . . . . . . . . . . . . . . . . 7-100
Guidelines . . . . . . . . . . . . . . . . . . . .4-2 Software
Lubrication Points . . . . . . . . . . . . . 4-10 Displaying Version . . . . . . . .3-11, 3-16
Maintenance Minder ™ Tool . . . . . . .4-3 SOL1 Load Holding Valve . . . .7-104, 7-105
Seal Repacking SOL2 Lift/Lower Valve . . . . . .7-104, 7-105
Free Lift Cylinder . . . . . 7-110 to 7-112 SOL3 Proportional Main Relief/
Main Lift Cylinder . . . . . . . . . . . . 7-116 Dump Valve . . . . . . . . . . . . . . . . 7-104
Sealants, Specifications . . . . . . . . . . . .A-3 SOL4 2d Pump Valve . . . . . . . . . . . . 7-105
Secondary Control Handle . . . 7-41 to 7-42 SOL5B/5T Auxiliary Valve . . .7-104, 7-105
SelfTest . . . . . . . . . . . . . . . . . . . . . . . . .8-2 SOL8 Auxiliary Dump Valve . . . . . . . 7-105
Sensor Soldering Procedures . . . . . . . . . . . . . 7-71
AC Lift Motor Temperature . . . . . . 7-83 Special Tools . . . . . . . . . . . . . . . . . . . 7-16
AC Traction Motor Speed . . . . . . . . 7-83 Specification Plate . . . . . . . . . . . . . . . . 3-3
DC Lift Motor Temperature . . . . . . .A-6 Speed
OCSS Limit Switch 1, Configuring . . . . . 3-17
Lower Beam Test I81 . . . . . . . . 6-93 Limit Switch 2, Configuring . . . . . 3-17
Upper Beam Test I80 . . . . . . . . 6-91 Limiting Switch, First (S12) . . . . . . A-5
Serial Number Reach, Configuring . . . . . . . . . . . . 3-19
Displaying from Program Retract, Configuring . . . . . . . . . . . 3-19
Mode . . . . . . . . . . . . . . . 3-11, 3-16 Travel, Configuring . . . . . . . . . . . . 3-17
Location on Specification Plate . . . .3-3 Spiral Pinion, Drive Unit
Service Information Documents . . . . . . . iv Assembly . . . . . . . . . . . . . . . . . . . 7-53
Service Intervals Disassembly . . . . . . . . . . . . . . . . . 7-52
See Scheduled Maintenance Charts Standard/Metric Conversions . . . . . . A-16
Service Mode . . . . . . . . . . .3-11, 3-22, 3-23 Static
Active Service Mode . . . . . . . . . . . . 3-24 Precautions . . . . . . . . . . . . . . . . . . 2-7
Static Service Mode . . . . . . . . . . . . 3-23 Service Mode . . . . . . . . . . . . . . . . 3-23
Service/Torque Chart, Steer
Component Specific . . . . . . . . . . . . .A-4 Limit Switch S11 (AC lift) . . . 7-27, A-5
Shimming Motor, Electric (AC lift) . . . . . . . . . . A-5
Drive Unit . . . . . . . . . . . . . . . . . . . 7-56 Motor, Hydraulic (DC Lift) . . . . . . . . A-5
Mast Bearings . . . . . . . . . . . . . . . 7-129 Steerable Caster . . . . . . . . . . . . . . . . . 7-28
Carriage to Inner Tele Height Adjustment . . . . . . . . . . . . 7-29
Model 7500 . . . . . . . . . . . 7-156 Steering
Model 7520 . . . . . . . . . . . 7-169 Encoder (AC lift) . . . . . . . . . . . . . . 7-26
Inner Tele to Outer Tele Limit Switch S11 (AC Lift) . . . 7-27, A-5
Model 7500 . . . . . . . . . . . 7-155 Linkage . . . . . . . . . . . . . . . . . . . . 7-31
Model 7520 . . . . . . . . . . . 7-168 Orbitrol (DC Lift) . . . . . . . . . . . . . . A-5
Outer Tele to Main Frame Steerable Caster . . . . . . . . . . . . . . 7-28
Model 7500 . . . . . . . . . . . 7-154 Height Adjustment . . . . . . . . . 7-29
Model 7520 . . . . . . . . . . . 7-167 Theory of Operation . . . . . . . . . . . . 8-4
Shorted Winding on AC Motor . . . . . . . 5-14 DC Lift . . . . . . . . . . . . . . . . . . 8-17
Shorts to Frame Test . . . . . . . . . . . . . .5-2 Troubleshooting . . . . . . . . . . . . . . 5-20
Stops, Carriage . . . . . . . . . . . . . . . . . . A-5

I-8 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section I. Index

SuperWrd . . . . . . . . . . . . . . . . . 3-12, 3-20 Test A14 – Power Supply

Changing . . . . . . . . . . . . . . . . . . . 3-13 +12VDC . . . . . . . . . . . . . . . 6-36
Entering . . . . . . . . . . . . . . . . . . . 3-13 Test A15 – Battery Voltage . . . . 6-37
Switch Test A20 – Lift Motor Current . 6-39
First Speed Limit, Configuring . . . 3-17 Test A22 – Primary Traction
High Speed Travel (S25) . . . . . . . . . A-4 Throttle (VR1) Request . . . . 6-40
HTI Pressure S18 Test A23 – Lift Throttle
Torque . . . . . . . . . . . . 7-104, 7-105 (VR2) Request . . . . . . . . . . 6-41
Lift Cutout (S27) . . . . . . . . . . . . . . A-4 Test A26 – Travel and Lift/
Second Speed Limiting, Lower +5V DC Power
Configuring . . . . . . . . . . . . . . 3-17 Supply . . . . . . . . . . . . . . . . 6-42
Speed Limiting, First (S12) . . . . . . . A-5 Test A29 – Secondary Throttle
Steer Limit (AC Lift) S11 . . . . 7-27, A-5 Potentiometer (VR3) Voltage 6-43
Tilt/Sideshift . . . . . . . . . . . . 7-39, 7-40 Test A30 – Secondary Traction
Fore/Aft Stance . . . . . . . 7-35, 7-39 Throttle (VR3) Request . . . . 6-44
UnNested, Configuring . . . . . . . . . 3-17 Test A31 – Solenoid 5T (AUX1)
Switch Adjustment . . . . . . . . . . . . . . . A-4 Current . . . . . . . . . . . . . . . 6-45
Switch Gap . . . . . . . . . . . . . . . . . . . . . A-4 Test A32 – Solenoid 5B (AUX2)
Switches Current . . . . . . . . . . . . . . . 6-46
Battery Gate . . . . . . . . . . . . . . . . . A-4 Test A33 – Aux Dump (SOL3)/
EPO . . . . . . . . . . . . . . . . . . . . . . . . A-4 Main Relief Dump (SOL8)
Symbols, List of . . . . . . . . . . . . . . . . . . 1-4 Current . . . . . . . . . . . . . . . 6-47
Symptom Tables Test A34 – Solenoid 2 (Lift/Lower)
Electrical Symptoms . . . . 5-26 to 5-27 Current . . . . . . . . . . . . . . . 6-48
Hydraulic Functions . . . . 5-16 to 5-24 Test A35 – Brake Current . . . . 6-49
Travel Functions . . . . . . . . . . . . . 5-25 Test A36 – Ambient Temperature
Sensor . . . . . . . . . . . . . . . . 6-50
T Test A37 – Steer Power Amplifier
Current . . . . . . . . . . . . . . . 6-51
Test A41 – Emergency Power Off
Temperature Sensor
(EPO) Switch . . . . . . . . . . . 6-54
DC Lift Motor . . . . . . . . . . . . . . . . . A-6
Test A42 – Primary Travel Pot
Temperature Sensor, AC Lift Motor . . 7-83
Learn Value . . . . . . . . . . . . 6-55
Temperature Sensor,
Test A43 – Lift Pot Learn Value 6-56
AC Traction Motor . . . . . . . . . . . . 7-83
Test A96 – BSM Curr . . . . . . . . 6-57
Terminals, Motor Power Cable . . . . . . 7-81
Test A97 – BSM Volt . . . . . . . . 6-58
Tests
Test A98 – BSM Temp . . . . . . . 6-59
Analog . . . . . . . . . . . . . . . 6-27 to 6-54
Test A99 – H20 Snse . . . . . . . . 6-60
Test A04 – Primary Throttle
Input
Potentiometer (VR1) Voltage 6-28
Test I00 – Deadman Switch (S2) 6-64
Test A05 – Lift/Lower Potentiometer
Test I01 – Nested Switch (S14) . 6-65
Voltage . . . . . . . . . . . . . . . 6-29
Test I02 – First Speed Limiting
Test A08 – Traction Motor
Switch (S12) . . . . . . . . . . . 6-66
Temperature . . . . . . . . . . 6-30
Test I06 – Reach Switch (S4) . . 6-67
Test A09 – Lift Motor
Test I07 – Retract Switch (S5) . 6-68
Temperature . . . . . . . . . . 6-31
Test I08 – Tilt Up Switch (S6) . 6-69
Test A10 – TPA Temperature . 6-33
Test I09 – Tilt Down
Test A100 – BSM Comm . . . . . 6-61
Switch (S7) . . . . . . . . . . . . 6-70
Test A11 – Traction Motor
Test I10 – Sideshift Right
Current . . . . . . . . . . . . . . 6-34
Switch (S9) . . . . . . . . . . . . 6-71
Test A13 – Pressure Sensor
Voltage . . . . . . . . . . . . . . . 6-34

Publication: 1112860, Issued: 15 Feb 2012 I-9

Section I. Index Models 7500/7520 Reach-Fork ® Trucks

Test I11 – Sideshift Left Test O03 – Toggle AUX

Switch (S8) . . . . . . . . . . . . . 6-72 Contactor . . . . . . . . . . . . 6-107
Test I14 – Steering Fuse (FU1) . 6-73 Test O04 – Toggle Aux1 Directional
Test I15 – Horn Switch (S3) . . . 6-74 (SOL5T) Solenoid . . . . . . . 6-108
Test I19 – Drive Motor Speed Test O05 – Toggle Aux2 Directional
Sensor . . . . . . . . . . . . . . . . 6-75 (SOL5B) Solenoid . . . . . . 6-109
Test I20 – Lift Motor Speed Test O06 – Toggle Reach
Sensor . . . . . . . . . . . . . . . . 6-76 Solenoid . . . . . . . . . . . . . 6-110
Test I22 – Lift Cutout Test O07 – Toggle Tilt
Switch (S27) . . . . . . . . . . . . 6-77 Solenoid . . . . . . . . . . . . . 6-111
Test I23 – CAN Bus Test . . . . . 6-78 Test O08 – Toggle the Sideshift
Test I24 – Steer Feedback Solenoid . . . . . . . . . . . . . 6-112
Proximity Sensor . . . . . . . . 6-80 Test O09 – Aux Dump (SOL3)/
Test I25 – Steer Motor Encoder 6-81 Main Relief Dump (SOL8)
Test I26 – Height Indicator Current . . . . . . . . . . . . . . 6-113
Encoder . . . . . . . . . . . . . . . 6-82 Test O11 – Toggle the Load Hold
Test I27 – Secondary Horn (SOL1) Solenoid . . . . . . . . 6-114
Switch (S10) . . . . . . . . . . . . 6-83 Test O12 – Ramp the Proportional
Test I33 – Steer Tiller Encoder 1 Lower (SOL2) Solenoid . . . 6-115
Connect Detect . . . . . . . . . 6-84 Test O18 – Toggle Horn . . . . . 6-116
Test I34 – Steer Tiller Encoder 2 Test O19 – Audible Alarm . . . 6-117
Connect Detect . . . . . . . . . 6-85 Test O20 – Travel Alarm . . . . 6-118
Test I35 – Steer Tiller Encoder 1 Test O23 – Toggle Fans . . . . . 6-119
(Channel A & B) . . . . . . . . . 6-86 Test O25 – Toggle the 2d Pump
Test I36 – Steer Tiller Encoder 2 (SOL4) Solenoid . . . . . . . . 6-120
(Channel A & B) . . . . . . . . . 6-87 Test O28 – Ramp Lift Motor
Test I39 – Neutral Pulses . . . . . 6-88 (AC Lift) . . . . . . . . . . . . . . 6-121
Test I60 – Security Start Switch Test O29 – Ramp Traction
(optional) . . . . . . . . . . . . . . 6-89 Motor . . . . . . . . . . . . . . . 6-122
Test I63 – High Speed Travel Switch Test O30 – Toggle the Brake
(S25) . . . . . . . . . . . . . . . . . 6-90 Coil . . . . . . . . . . . . . . . . . 6-123
Test I80 – OCSS Upper Beam Test O32 – Toggle Relays K1,
Test . . . . . . . . . . . . . . . . . . 6-91 K2, K3, and K4 . . . . . . . . 6-124
Test I81 – OCSS Lower Beam Shorts to Frame . . . . . . . . . . . . . . . 5-2
Test . . . . . . . . . . . . . . . . . . 6-93 Summary List . . . . . . . . . . . . . . . . 6-25
Test I82 – OCSS Cnt . . . . . . . . 6-95 Theory of Operation
Test I83 – BatGateL . . . . . . . . . 6-96 BSOC . . . . . . . . . . . . . . . . . . . . . . . 5-5
Test I84 – BatGateR . . . . . . . . . 6-97 Cold Storage . . . . . . . . . . . . . . . . . . 8-6
Test I86 – Lift Height . . . . . . . . 6-98 Electric Brake . . . . . . . . . . . . . . . . 8-22
Test I90 – Degrees Turned Lift/Aux System . . . . . . . . 8-17 to 8-21
Past Steer Flag . . . . . . . . . . 6-99 AC Lift
Test I91 – iPort Communication Lift with Aux . . . . . . . . . . . 8-11
Test . . . . . . . . . . . . . . . . . 6-100 Lift without Aux . . . . .8-8, 8-14
Test I92 – iPort Error Bitmap . 6-102 Reach . . . . . . . . . . . .8-10, 8-15
Output DC Lift . . . . . . . . . . . . 8-17 to 8-21
Test O00 – Toggle the TPC Lift . . . . . . . . . . . . . . . . . . 8-18
Contactor . . . . . . . . . . . . . 6-104 Reach . . . . . . . . . . . . . . . . 8-19
Test O01 – Toggle the STR Sideshift . . . . . . . . . . . . . . 8-20
Contactor . . . . . . . . . . . . . 6-105 System Components .8-17, 8-19
Test O02 – Toggle the LPC Tilt . . . . . . . . . . . . . . . . . . 8-20
Contactor . . . . . . . . . . . . . 6-106 Lower . . . . . . . . . . . . . . . . . . . . 8-9

I-10 Publication: 1112860, Issued: 15 Feb 2012

Models 7500/7520 Reach-Fork ® Trucks Section I. Index

Sideshift . . . . . . . . . . . . 8-10, 8-15 Torque Specs

System Components . . . . . . . . 8-7 Aux Manifold
Tilt . . . . . . . . . . . . . . . . . . 8-9, 8-15 Regen Lower . . . . . . . . . . . . . 7-104
Lift/Lower System Standard Reach . . . . . . . . . . 7-105
Aux Pump . . . . . . . . . . . . . . . 8-12 Deep-Reach Manifold . . . . . . . . . 7-105
Lift/Lower Pump . . . . . . . . . . 8-12 Lift/Lower Manifold
Pinout Matrix . . . . . . . . . 8-23 to 8-38 Regen Lower . . . . . . . . . . . . . 7-104
SelfTest . . . . . . . . . . . . . . . . . . . . . 8-2 Main Manifold
Steering System . . . . . . . . . . . . . . . 8-4 DC Lift . . . . . . . . . . . . . . . . . 7-105
DC Lift . . . . . . . . . . . . . . . . . . 8-17 Non-Regen . . . . . . . . . . . . . . 7-104
Traction System . . . . . . . . . 8-2 to 8-6 Tilt/Sideshift Manifold
Battery Connected . . . . . . . . . . 8-2 Deep-Reach . . . . . . . . . . . . . . 7-105
Deadman Pedal Depressed . . . . 8-3 Traction Motor
Key Switch Turned On . . . . . . . 8-2 Power Cable Terminal Nuts . . . . . . 7-81
Requesting Travel . . . . . . . . . . 8-4 Traction Motor Torque Specs . . . . . . . . A-6
ThermaKit Traction Power Amplifier . . . . . . . . . . . A-5
Dockstance . . . . . . . . . . . . . 7-37, 7-40 LED Diagnostics . . . . . . . . . . . . . . . 6-2
Fore-Aft Stance Traction System Functional Operation
Primary . . . . . . . . . . . . . 7-34, 7-39 See Theory of Operation, Traction
Fore/Aft Stance System
Primary . . . . 7-32, 7-34, 7-35, 7-39 Transducer, Pressure CYL-P . . . . . . . 7-104
Thread Adhesives, Specifications . . . . . A-3 Torque . . . . . . . . . . . . . . 7-104, 7-105
Tie-Down for Transport . . . . . . . . . . . 2-10 Transmission
Tilt See Drive Unit
Cylinder . . . . . . . . . . . . . . . . . . .7-122 Transport, Tie-Down for . . . . . . . . . . . 2-10
Function Travel Acceleration, Configuring . . . . . 3-17
Theory Travel Alarm, Configuring . . . . . . . . . . 3-17
AC Lift w/o Regen . . . . . . . 8-9 Travel Functions, Troubleshooting . . . 5-25
AC Lift w/Regen . . . . . . . . 8-15 Travel Light . . . . . . . . . . . . . . . . . . . . . A-6
DC Lift . . . . . . . . . . . . . . . 8-20 Travel Speed Limit
Troubleshooting . . . . . . . . . . . 5-18 Switch 1, Configuring . . . . . . . . . . 3-17
Valve Switch 2, Configuring . . . . . . . . . . 3-17
Deep-Reach . . . . . . . . . . . . . .7-103 Travel Speed, Configuring . . . . . . . . . . 3-17
Std Reach . . . . . . . . . . . . . . .7-100 Travel Switch, High Speed (S25) . . . . . . A-4
Tilt/Sideshift
Manifold (Deep-Reach) . . . . . . . . .7-103
Switch
Dockstance . . . . . . . . . . . . . . 7-40
Fore/Aft Stance . . . . . . . . . . . 7-35
Tire, Drive . . . . . . . . . . . . . . . . . . . . . . A-4
Tones, Run Mode . . . . . . . . . . . . . . . 3-12
Tools, Special . . . . . . . . . . . . . . . . . . 7-16
Torque Chart
Face Seal O-Rings . . . . . . . . . . . . . A-8
Hydraulic Fittings . . . . . . . . . . . . . A-7
Metric (Brass) . . . . . . . . . . . . . . . A-13
Metric (Ferrous) . . . . . . . . . . . . . . A-11
Standard (Brass) . . . . . . . . . . . . . A-12
Standard (Ferrous) . . . . . . . . . . . . A-9

Publication: 1112860, Issued: 15 Feb 2012 I-11

Section I. Index Models 7500/7520 Reach-Fork ® Trucks

Troubleshooting CV-1 Check Valve . . . . . . .7-104, 7-105

Auxiliary Functions . . . . . . . . . . . . 5-16 CV-2 Check Valve . . . . . . . . . . . . 7-105
Chains . . . . . . . . . . . . . . . . . . . . . 4-12 CV-3 Check Valve . . . . . . . . . . . . 7-105
Dead Lift Truck . . . . . . . . . . . . . . . 5-27 LS-1 Load Shuttle . . . . . . .7-104, 7-105
Drive Unit . . . . . . . . . . . . . . . . . . . 7-47 Manifold Torque Specs . 7-104 to 7-105
Electrical . . . . . . . . . . . . . . . . . . . . .5-2 POD-1 . . . . . . . . . . . . . . . . . . . . 7-104
Symptoms . . . . . . . . . . 5-26 to 5-27 Proportional, Adjustment . . . . . . . 7-94
Fuses . . . . . . . . . . . . . . . . . . . . . . .5-6 Reach
Hydraulic Deep-Reach . . . . . . . . . . . . . 7-102
Guidelines . . . . . . . . . . . . . . . . 5-15 Std Reach . . . . . . . . . . . . . . . 7-100
Symptoms . . . . . . . . . . 5-16 to 5-24 REL-1 Relief (DC Lift) . . . . . . . . . 7-105
Lift Function . . . . . . . . . . . . . . . . . 5-21 REL-2 Relief (AC Lift) . . . . . . . . . 7-104
Lift/Lower Functions . . . . . . . . . . . 5-21 REL-3 Relief (DR) . . . . . . . . . . . . 7-105
Lower Function . . . . . . . . . . . . . . . 5-23 Sideshift
Motors . . . . . . . . . . 5-10 to 5-14, 5-26 Deep-Reach . . . . . . . . . . . . . 7-103
AC . . . . . . . . . . . . . . . . . . . . . . 5-14 Std Reach . . . . . . . . . . . . . . . 7-100
DC . . . . . . . . . . . . . . . . . . . . . . 5-10 SOL1 Load Holding . . . . . .7-104, 7-105
Operator Display . . . . . . . . . . . . . . 5-26 SOL2 Lift/Lower . . . . . . . .7-104, 7-105
Pinout Matrix . . . . . . . . . . 8-23 to 8-38 SOL3 Proportional Main Relief/Dump . .
Retract Function . . . . . . . . . . . . . . 5-20 7-104
Shorts to Frame Test . . . . . . . . . . . .5-2 SOL4 2d Pump . . . . . . . . . . . . . . 7-105
Sideshift Function . . . . . . . . . . . . . 5-18 SOL5B/5T Auxiliary . . . . .7-104, 7-105
Steering Function . . . . . . . . . . . . . 5-20 SOL8 Auxiliary Dump . . . . . . . . . 7-105
Symptom Tables . . . . . . . . 5-16 to 5-27 Steering Orbitrol (DC Lift) . . . . . . . . A-5
Tilt Function . . . . . . . . . . . . . . . . . 5-18 Tilt
Travel Functions . . . . . . . . . . . . . . 5-25 Deep-Reach . . . . . . . . . . . . . 7-103
Std Reach . . . . . . . . . . . . . . . 7-100
U Vehicle Manager
Circuit Card Connectors . . . . . . . . . 5-8
Vehicle Operation . . . . . . . . . . . . . . . . . 3-7
Units, Configuring Display . . . . . . . . . 3-18
Version, Displaying Software . . .3-11, 3-16
UnNested Switch, Configuring . . . . . . . 3-17
Vertical Hold, Configuring . . . . . . . . . 3-21
Uprighting Truck, How To . . . . . . . . . . .3-6

W
V
Warning, Definition . . . . . . . . . . . . . . . 2-2
Valve
Warranty . . . . . . . . . . . . . . . . . . . . . . . 3-7
CB1 & CB2 Counterbalance . . . . 7-105
Weight, Learn . . . . . . . . . . . . . . . . . . . 3-22
CE1 Compensating Element
Welding Safety . . . . . . . . . . . . . . . . . . 2-11
(DC lift) . . . . . . . . . . . . . . . . . 7-105
WHLD
Display Format, Configuring . . . . . 3-21
Weight-Height Configuration Table 3-16
Wiring
General . . . . . . . . . . . . . . . . . . . . 7-71
Harness Terminology . . . . . . . . . . . 5-7
Inspection . . . . . . . . . . . . . . . . . . 7-71
Repair . . . . . . . . . . . . . . . . . . . . . 7-71
Soldering Procedures . . . . . . . . . . 7-71
Wrist strap, ESD . . . . . . . . . . . . . . . . . 2-7

I-12 Publication: 1112860, Issued: 15 Feb 2012

 !1112860A!
1112860A

Printed by the Digital Print Center,

The Raymond Corporation, Greene, NY
 Schematics

Models Serial Numbers

7500/7520 31,001 and Up This publication applies to the all subsequent releases of this product until
otherwise indicated in new editions or bulletins. Changes occur periodically to
7700/7720 the information in this publication.

If you need assistance with your lift truck, or to order additional copies of this
document, contact your local authorized Raymond Dealer. To locate your local
authorized Raymond Dealer, go to www.raymondcorp.com.

Publication: 1138412A Issued: 15 Feb 2012 Use with Maintenance Manuals 1112860A and 1137893A

©2012 The Raymond Corporation.

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-1. Power Distribution Diagram - Standard AC Lift

Publication: 1138412A, Issued: 15 Feb 2012 2

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-2. Power Distribution Diagram - DC Lift

Publication: 1138412A, Issued: 15 Feb 2012 3

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-3. Power Distribution Diagram - AC Lift with Regen Lower

Publication: 1138412A, Issued: 15 Feb 2012 4

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-4. Electrical Schematic - Standard AC Lift (Sheet 1 of 6)

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Publication: 1138412A, Issued: 15 Feb 2012 5

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-5. Electrical Schematic - DC Lift (Sheet 2 of 6)

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Publication: 1138412A, Issued: 15 Feb 2012 6

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-6. Electrical Schematic - AC Lift with Regen Lower (Sheet 3 of 6)

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Publication: 1138412A, Issued: 15 Feb 2012 7

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-7. Electrical Schematic - Options (Sheet 4 of 6)

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Publication: 1138412A, Issued: 15 Feb 2012 8

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-8. Electrical Schematic - Options (con’t) (Sheet 5 of 6)

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Publication: 1138412A, Issued: 15 Feb 2012 9

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-9. Electrical Schematic - Legend (Sheet 6 of 6)
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Publication: 1138412A, Issued: 15 Feb 2012 10

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-10. Hydraulic Schematic - Standard AC Lift (Sheet 1 of 2)

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Standard AC Lift

Publication: 1138412A, Issued: 15 Feb 2012 11

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-11. Hydraulic Schematic - Standard AC Lift (Sheet 2 of 2)

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Standard AC Lift - Options

Publication: 1138412A, Issued: 15 Feb 2012 12

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-12. Hydraulic Schematic - AC Lift with Regen Lower (Sheet 1 of 2)

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AC Lift with Regen Lower

Publication: 1138412A, Issued: 15 Feb 2012 13

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-13. Hydraulic Schematic - AC Lift with Regen Lower (Sheet 2 of 2)

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AC Lift with Regen Lower - Options

Publication: 1138412A, Issued: 15 Feb 2012 14

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-14. Hydraulic Schematic - DC Lift - Standard Reach (Sheet 1 of 3)

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DC Lift - Standard Reach

Publication: 1138412A, Issued: 15 Feb 2012 15

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-15. Hydraulic Schematic - DC Lift - Deep-Reach (Sheet 2 of 2)

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DC Lift - Deep Reach
Publication: 1138412A, Issued: 15 Feb 2012 16
Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-16. Hydraulic Schematic - DC Lift - Aux Functions (Sheet 3 of 3)

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42 DC Lift - Aux Functions
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Publication: 1138412A, Issued: 15 Feb 2012 17