Maintenance Manual

4150/4250
Stand-Up Counterbalanced Lift Trucks

Models Serial Numbers

4150 42,000 and Up
4250 42,067 and Up

Publication: 1193671C Revised: 15 Aug 2022

This publication, 1193671C, applies to the Stand-Up Counterbalanced Lift Truck Models 4150
(S/N 42,000 and up) and 4250 (S/N 42,067 and up), and to all subsequent releases of this
product until otherwise indicated in new editions or bulletins.

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 Solutions and Support Center, found at www.raymondcorp.com.

©2022 The Raymond Corporation.

All rights reserved.

All brands and product names are trademarks or registered trademarks of their respective
companies.

This Raymond product is covered by one or more United States Patents. For more information
go to www.raymondcorp.com/patents.
Models 4150/4250 Maintenance Manual 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
Safety Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Towing Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Lift Truck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
FlashWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Minder™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Contactor Tip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Chain Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hydraulic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . 5-23
Symptom Tables: Drive Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . 5-30
Messages, Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Summary List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Analog Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Output Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97

Publication: 1193671C, Revised: 15 Aug 2022 i

Table of Contents Models 4150/4250 Maintenance Manual

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Special Tools and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Steering and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Traction System Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Steering System Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Lift/Lower System Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Component Specific Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Torque Chart - Straight Thread Face Seal O-Rings . . . . . . . . . . . . . . A-7
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Torque Chart - Metric (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Torque Chart - Thread-Forming Screws . . . . . . . . . . . . . . . . . . . . . . A-12
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

ii Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Document Revision History

Document Revision History

Revision Date Description of Changes

A 15 May 2014 Initial Release

B 13 Jun 2016 Incorporated outstanding RSIs and add new mast content.

C 15 Aug 2022 Incorporated outstanding RSIs

Publication: 1193671C, Revised: 15 Aug 2022 iii

Service Information List Models 4150/4250 Maintenance Manual

Service Information List

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

RSI Number Subject Issue Date

CTB-14-006 Quad Mast Flow Control Valve Removal and Installation August 19, 2014

CTB-14-008A Lift Chain Adjustment November 4, 2014

MUL-15-003 Fuse/Relay Card Troubleshooting April 7, 2015

MUL-15-004 Aux Motor Brush Inspection and Installation May 25, 2015

CTB-15-004 Drive Unit Updates July 27, 2015

MUL-15-007 Electrical Troubleshooting September 10, 2015

MUL-15-008 New Pump Spline Lubricant October 1, 2015

CTB-15-008 New Brake Assembly Available October 29, 2015

CTB-15-007 New Software Release October 30, 2015

CTB-17-003 New Software Release March 8, 2017

MUL-17-001 Scheduled Maintenance Changes August 15, 2017

CTB-17-008 TT Mast Roller Bearing (Puck) Adjustment September 13, 2017

MUL-17-003 New Fuse Relay Card Available September 14, 2017

MUL-17-004 Control Handle Set Screw September 14, 2017

MUL-18-001 Cold Storage Hydraulic Fluid Part Number Change March 12, 2018

CTB-18-004 Jacking and Blocking Procedures July 11, 2018

CTB-18-006 New Brake Assembly October 22, 2018

CTB-19-002A ComfortStance Control Rod Replacement January 8, 2020

CTB-19-003A Test A36 – Ambient Temperature January 8, 2020

CTB-20-001A New Fault Codes February 10, 2020

CTB-20-002A Manual Correction Static Strap Inspection February 17, 2020

MUL-20-001A Scheduled Maintenance Information Update April 27, 2020

CTB-21-001A New Software Available April 29, 2021

MUL-21-001A Energy Power System Public Standard Interface Option May 19, 2021

MUL-21-002A Energy Power System Power Source Limiting Option June 17, 2021

iv Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section 1. How to Use This Manual

Section 1. How to Use This Manual

Publication: 1193671C, Revised: 15 Aug 2022 1-1

Section 1. How to Use This Manual Models 4150/4250 Maintenance Manual

Manual Design

Manual Design • 7. Component Procedures contains

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

1-2 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section 1. How to Use This Manual

Interactive Electronic Technical Manuals

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

Blue text in the Maintenance Manual is linked

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

Publication: 1193671C, Revised: 15 Aug 2022 1-3

Section 1. How to Use This Manual Models 4150/4250 Maintenance Manual

Abbreviations and Symbols

Abbreviations and
Symbols
The following abbreviations, acronyms, and symbols are used in this manual.
Term/Symbol Definition Term/Symbol Definition
A Ampere ESDS Electrostatic Discharge
Sensitive
Agnd analog ground
amp Ampere or amplifier
FF Forks-first
APM Auxiliary Processing
Module fpm feet per minute
approx approximately FRC Fuse/Relay Card
Assy assembly ft. foot or feet
Aux auxiliary
AWG American Wire Gauge gal. gallon or gallons
Gnd ground
BDI Battery Discharge Indicator
BSM Battery Sensor Module HD hours on deadman
BSOC Battery State-of-Charge Ht height
Hgt/Wgt Height/Weight
CAN Controller Area Network
cc cubic centimeter IETM Interactive Electronic
Technical Manual
CCW counterclockwise
in. inch or inches
cm centimeter
ISS Integral Side Shifter
COP Computer Operating
Program
CW clockwise kg kilogram(s)
CS cold storage kHz kilohertz
km/h kilometers per hour
dim. dimension kPa kilo Pascal
Dgnd/D-GND digital ground
DMLL Deadman Lift/Lower lb. pound or pounds
DMM Digital MultiMeter L/H Load Holding
DSOC Displayed State-of-Charge L/L Lift/Lower
DVM Digital Voltmeter LPA Lift Power Amplifier
LPC Lift Power Contactor
EE UL Electric Lift Truck Type lpm liters per minute
Certification Rating where LTPA Left Traction Power Amp
electrical equipment is
completely enclosed
mA milliampere
EMF ElectroMotive Force
max maximum
EPO Emergency Power Off
min minute or minimum
EPS Energy Power Source/
Electric Power Source ml milliliter

ESD Electrostatic Discharge mm millimeter

MM Maintenance Minder™

1-4 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section 1. How to Use This Manual

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

mph miles per hour SWM Supplier Wireless Module
MS MicroSoft S/W Software
mS millisecond or milliseconds
mV millivolt or millivolts temp Temperature
mVAC millivolts - alternating TF Tractor-first or Two-stage
current mast with full free lift
TML Traction Motor Left
NMT Network Management TMR Traction Motor Right
No. number TPA Traction Power Amplifier
NV non-volatile TPC Traction Power Contactor
NVM Non-Volatile Memory TS Traction Speed
Nm newton meter T/S troubleshoot
TT Three-stage mast
OACH Overall Collapsed Height
OD Operator Display UL Underwriters Laboratories,
OI Operator Interface Inc.
OSHA Occupational Safety and USB Universal Serial Bus
Health Association
oz ounce V Version, Volt, or Volts
VDC Volts Direct Current
PC Personal Computer VM Vehicle Manager
prox proximity
pot potentiometer wrt with respect to
psi pounds per square inch Wt Weight
PSI Public Standard Interface w/ with
PSL Power Source Limiting w/o without
PTC Positive Temperature
Coefficient (Thermistors) @ at
PWM Pulse Width Modulation ™ trademark
P/N Part Number © copyright
® registered trademark
rpm revolutions per minute + plus or positive
R/R repair/replace – minus or negative
RTPA Right Traction Power Amp ± plus or minus
° degrees
SAE Society of Automotive °F degrees Fahrenheit
Engineers
°C degrees Celsius/
sec second Centigrade
SG specific gravity < less than
SOC State-of-Charge > greater than
SOH State-of-Health % percent
SOL Solenoid = equals
spec specification
SW Switch

Publication: 1193671C, Revised: 15 Aug 2022 1-5

Section 1. How to Use This Manual Models 4150/4250 Maintenance Manual

Abbreviations and Symbols

1-6 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section 2. Safety

Section 2. Safety

Publication: 1193671C, Revised: 15 Aug 2022 2-1

Section 2. Safety Models 4150/4250 Maintenance Manual

Safety Definitions

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

Indicates a potentially hazardous

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

Indicates a potentially hazardous

situation which, if not avoided, may
result in minor or moderate injury. It can
also be used to alert against unsafe
practices.

2-2 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section 2. Safety

General Safety

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

Do not operate or work on this lift truck unless

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

Before working on this lift truck, always turn

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

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

Do not wear watches, rings, or jewelry when

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

Follow the scheduled lubrication, maintenance,

and inspection steps.

Publication: 1193671C, Revised: 15 Aug 2022 2-3

Section 2. Safety Models 4150/4250 Maintenance Manual

General Safety

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

Do not wash this lift truck with a hose.

Do not use an open flame near the lift truck,
except when welding. See “Welding Safety.”

Do not park this lift truck in a cold storage area

overnight unless the lift truck is conditioned for
Do not use gasoline for cleaning parts. When cold storage.
using cleaning fluids, obey the manufacturer’s
Safety Data Sheets.

Do not add to or modify this lift truck until you

Clean up any spills, including hydraulic fluid, contact your local Raymond Solutions and
oil, or grease that has leaked or spilled on the Support Center to receive written manufacturer
floor. approval.

2-4 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section 2. Safety

Battery Safety

Battery Safety (with or without arm shields), and a rubber

apron.

As a battery is being charged, an

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

Battery electrolyte is a solution of

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

Keep the charging area well-ventilated to avoid

explosive gas concentration.

Wear personal protective equipment to protect

eyes, face, and skin when authorized to check,
handle, or fill batteries. This equipment
includes goggles or face shield, rubber gloves

Publication: 1193671C, Revised: 15 Aug 2022 2-5

Section 2. Safety Models 4150/4250 Maintenance Manual

Battery Safety

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

Do not lay tools or metal objects on top of the

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

Make sure the vent holes in the filler plugs are

open to allow the gas to escape from the cells.

Vent Hole

Keep batteries clean. Corrosion causes shorts

to the frame and the possibility of sparks.

Do not allow cleaning solution, dirt, or any

foreign matter to enter the cells.

2-6 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section 2. Safety

Battery Safety

Make sure you install the correct size battery. A

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

Never plug a battery charger into the lift truck’s

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

Publication: 1193671C, Revised: 15 Aug 2022 2-7

Section 2. Safety Models 4150/4250 Maintenance Manual

Static Precautions

Static Precautions • To transport static sensitive components,

including failed components being
returned, put the components in an
Electronic circuit boards can contain anti-static bag or box (available from your
Electrostatic Discharge Sensitive (ESDS) local authorized Raymond Solutions and
devices. Support Center).

Static charges can accumulate from normal The wrist strap and associated accessories
operation of the lift truck as well as movement should be tested monthly to verify they are
or contact between non-conductive materials working correctly. The wrist strap contains a
(plastic bags, synthetic clothing, synthetic soles one megohm resistor in the strap cord that acts
on shoes, styrofoam coffee cups, and so forth.) as a fuse for personal protection. If this resistor
is open, the strap becomes ineffective.
Static electricity can be discharged to a circuit
board or component by touching the parts. An Anti-Static Field Service Kit (P/N 1-187-059)
Electrostatic Discharge (ESD) is also possible is available. The kit includes a wrist strap,
through the air when a charged object is put ground cord, and static-dissipative work
close to another surface at a different electrical surface (mat). Follow the instructions packaged
potential. ESD can occur without seeing or with the kit.
feeling it.
Figure 2-2. Anti-Static Kit with Wrist Strap and Mat
Whenever working on or near ESDS devices,
follow these precautions:
• Put a static discharge wrist strap around
your wrist. Connect the ground cord to the
wrist strap connector.
• Connect the wrist strap plug to a ground
jack on the lift truck. See Figure 2-1. If
you cannot use a ground jack, connect the
ground clip to an unpainted, grounded
surface on the lift truck frame.

Figure 2-1. ESD Ground Jack Location

ESD Ground Jack

Replacement wrist straps (P/N 1-187-058/001)

are also available. Contact your local Raymond
Solutions and Support Center for information.

• Handle circuit boards by the edges only.

Avoid touching the edge connectors.
• If you are removing or installing static
sensitive components, put them on a
correctly grounded static mat.

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Models 4150/4250 Maintenance Manual Section 2. Safety

Jacking Safety

Jacking Safety Jacking the Lift Truck

When performing jacking procedures: When the lift truck is jacked up for any reason,
take the necessary precautions listed here to
• Use a 5-ton jack that meets ANSI/ASME make sure that the lift truck does not tip over.
B30.1 or equivalent Safety Standards.
1. Park the lift truck on a level surface.
• Hoists must meet the following standards:
2. Lower the forks completely.
• ASME B30.2 (Overhead and Gantry
Cranes) 3. Remove any load.
• ASME B30.16 (Overhead Underhung 4. Put all controls in neutral.
and Stationary Hoists 5. Turn the key switch OFF and disconnect
To determine the needed capacity of the the battery connector.
hoist, refer to the lift truck with maximum 6. Block the wheels to prevent movement of
battery weight as set forth on the the lift truck.
specification tag.
7. Attach an appropriately rated rigging
• When required, use a support stand with a device to the top of the mast, and an
2-ton capacity that meets ASME PALD overhead hoist to stabilize the mast if
2009. jacking higher than described in this
• Jack the lift truck high enough to section.
complete the task, but do not exceed the 8. Put the jack under the designated jacking
values referenced in the following points. See Figure 2-3 and Figure 2-4.
paragraphs. Figure 2-3. Jacking the Drive Wheel

Use extreme care when the lift truck is

jacked up, elevated, or placed on blocks
or jack stands. Never block the lift truck
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an
overhead hoist to stabilize the mast, if
jacking the lift truck higher than
described in this maintenance manual.
Keep hands and feet clear while jacking
the lift truck. After the lift truck is
elevated to the required height, place Figure 2-4. Jacking the Tractor
blocks of a solid material that will
support the weight of the lift truck, or
jack stands that will support the weight
of the lift truck, beneath the specified
locations shown in this maintenance
manual, for support. Lower the lift truck
onto the blocks or jack stands. Never
rely on the jack or jack stand alone to
support the lift truck.

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Section 2. Safety Models 4150/4250 Maintenance Manual

Jacking the Lift Truck

NOTE: Always use solid blocks to support the

lift truck. Never rely on jacks or chains
to hold the lift truck.
9. After working on the lift truck, test all
controls and functions to make sure
operation is correct.

Jacking the Drive Wheel

To jack the drive wheel:

1. Place the jack in the designated jacking
position. See Figure 2-3.
2. Jack the lift truck so that the drive wheel
is off the floor no more than 1 in. (25.4
mm).
3. Place a block under the frame as shown in
Figure 2-3.
NOTE: Always use solid blocks to support the
lift truck. Never rely on jacks or chains
to hold the lift truck.
4. After working on the lift truck, test all
controls and functions to verify correct
operation.

Jacking the Tractor

To jack the tractor:

1. Place the jack in the designated jacking
position near the steerable wheel. See
Figure 2-4.
2. Jack the lift truck so that the steerable
wheel is off the floor no more than 6 in.
(152 mm).
3. Block under the frame as shown in
Figure 2-4.
NOTE: Always use solid blocks to support the
lift truck. Never rely on jacks or chains
to hold the lift truck.
4. After working on the lift truck, test all
controls and functions to verify correct
operation.

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Models 4150/4250 Maintenance Manual Section 2. Safety

Towing Safety

Towing Safety
To safely tow this lift truck: When towing is complete, remove the
1. Lower the carriage and remove any load brake release bolts and return them to
from the forks. their stow location on the tractor frame.
2. Turn the key switch OFF and disconnect Failure to do so can cause serious injury.
the battery connector.
3. Install the brake release bolts.
NOTE: The brake release bolts are stowed on
the tractor frame above the left traction
motor.

Figure 2-5. Brake Release Bolt Installation

4. Using a suitable towing vehicle, lift the lift

truck until the steer tire is no more than
1 in. (25 mm) off the floor.
5. Tow the lift truck slowly in the tractor-first
direction.

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Section 2. Safety Models 4150/4250 Maintenance Manual

Welding Safety

Welding Safety
Disconnect the battery before you
attempt to inspect, service, or repair the
lift truck. Discharge all power amplifier’s
Flame cutting or welding on painted internal capacitor by jumpering the +
surfaces may produce potentially and – terminals with a 100 ohm 25W
harmful fumes, smoke, and vapors. resistor.
Before you do any flame cutting or
welding, remove the coating in the area
where the operation will occur.

Coating removal can occur by

mechanical and/or chemical methods.
Perform flame cutting and/or welding
only in well ventilated areas.

Before working on this lift truck, make sure

that:
• Test for shorts to frame (refer to
• Fire protection equipment is nearby. Troubleshooting). Correct any shorts
• You know where the nearest eyewash before you weld.
station is. • Clean the area to be welded.
• Protect all lift truck components from
heat, weld spatter, and debris.
• Attach the ground cable as close to the
weld area as possible. Do not attach the
ground cable to fasteners or other
removable components.
• 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.

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Models 4150/4250 Maintenance Manual Section 3. Systems Overview

Section 3. Systems Overview

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Section 3. Systems Overview Models 4150/4250 Maintenance Manual

Introduction

Introduction
This manual provides information for
maintenance and repair of Model 4150/4250
Stand-Up Counterbalanced lift trucks by
Raymond.

This manual contains the most current and

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

For the latest information on your Raymond lift

truck, contact your local authorized Raymond
Solutions and Support Center.

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Models 4150/4250 Maintenance Manual Section 3. Systems Overview

Lift Truck Specifications

Lift Truck Specifications

Specification Tag
This lift truck is rated for performance by load
center and load weight. Review the specification
tag for detailed load capacity and load center
information. See Figure 3-1.

Due to continuous product improvement,

specifications are subject to change without
notice or obligation.

Figure 3-1. Lift Truck Specification Tag

Approx. weight of lift
Serial number truck with battery
installed, minus load
Raymond Model # and operator

Nominal battery Approx. weight of

voltage lift truck minus
battery, load, and
operator
*Max battery weight
for this lift truck

*Min battery weight

Max load capacity for this lift truck
of this lift truck

Max Battery
Rated Capacity

*Battery weight must be

between the min and
max weight.

NOTE: The lift truck serial number can also be Load Capacity
found:
• on the mast specification tag on the Always refer to the specification tag on your lift
lower left mast upright truck for the correct ratings for your lift truck.

• stamped on the tractor frame below

the top console cover in the operator
compartment

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Section 3. Systems Overview Models 4150/4250 Maintenance Manual

General Information

General Information Fluid Capacities

Drive Units (each) Hydraulic Reservoir
Model and Mast Designations 1.275 gal. Metal - 6 gal. (22.7 liters)
(4.82 liters) Plastic - 6.5 gal. (24.6 liters)
The model number includes the model and the
mast series designation.
Refer to “Lubrication Specification Chart” on
Max Load
Model Mast page A-2.
Forks Lowered
C30TF
3000 lb. (1360 kg)
C30TT
C35TF
4150 3500 lb. (1588 kg)
C35TT
C40TF
4000 lb. (1815 kg)
C40TT
C30TF
C30TT 3000 lb. (1360 kg)
C30QM
C35TF
C35TT 3500 lb. (1588 kg)
C35QM
4250
C40TF
C40TT 4000 lb. (1815 kg)
C40QM
C50TF
C50TT 5000 lb. (2268 kg)
C50QM

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

13.75 1700 (771) 2050 (929) 800

16.5 1980 (898) 2250 (1022) 930

18.5 2300 (1043) 2600 (1180) 1085

21.25 2593 (1176) 2900 (1315) 1240

23.75 2700 (1226) 3250 (1474) 1395

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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Models 4150/4250 Maintenance Manual Section 3. Systems Overview

Lift Truck Installation

Lift Truck Installation

Installation must be performed by a Raymond
Certified Solutions and Support Center
Technician to make sure of warranty coverage.

During installation, a visual and functional

inspection must be performed. Refer to
Stand-Up Counterbalanced Lift Truck
Installation Guide.

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Section 3. Systems Overview Models 4150/4250 Maintenance Manual

FlashWare

FlashWare • USB to USB - this method requires the

correct drivers to be installed on the
device. Typically, this type of connection is
Overview much faster than a serial connection. With
the key switch OFF, connect cable
FlashWare allows you to update software, view P/N 1120332/XXX to a USB port on the
options, and configure options on the lift truck device and the P3 connector on the
through the following features: manager. See Figure 3-2.

• Update Vehicle Manager software • Serial to Serial - this method requires a

surge protector (P/N 154-010-801) to be
• Clear Primary Memory connected in series with the cable to
• Clear Vehicle Manager protect the device. With the key switch
• Reset factory default settings OFF, connect cable P/N 610-809/201 to a
serial port on the device and the J9
• Update Power Amplifier Software connector on the manager. See Figure 3-2.

For more detailed FlashWare information, click Figure 3-2. Lift Truck FlashWare Connections
on Help and select Help Topics from the
FlashWare menu bar. Serial connector (J9) USB connector (P3)

FlashWare can be installed on any Microsoft

(MS) compatible device. The device
communicates with the lift truck software via a
serial (9 pin) or USB port.

Installing FlashWare on a
Windows Compatible Device
If you are a customer service technician, obtain
FlashWare from your Raymond Solutions and
Support Center. Starting FlashWare
1. With the key switch ON, double-click the
If you are a Raymond Solutions and Support
FlashWare icon on the main desktop
Center technician, obtain FlashWare from the
screen or navigate via Start > Programs >
Raymond Portal software download site.
FlashWare. The lift truck opening screen is
shown. See Figure 3-3.
To install FlashWare on the device, double-click
the installation file and follow the instructions
Figure 3-3. Truck Opening Screen
on 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 FlashWare to Lift

Truck
There are two methods available to connect the
device to a manager:
NOTE: When you use or enter FlashWare, it is
normal for a 50 Series Code to show.

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Models 4150/4250 Maintenance Manual Section 3. Systems Overview

Starting FlashWare

2. From the menu bar, click

Communications, then select the
applicable connection type:
• COMx (9-pin Serial)
• COMx (USB)
NOTE: “x” numbers varies depending on the
computer configuration.
3. From the menu bar, select Connect to
Truck > All Other Trucks. If the device is
connected to a correctly functioning
Vehicle Manager, the Truck Setup screen
is shown.
NOTE: Refer to FlashWare Help for specific
FlashWare related topics.

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Section 3. Systems Overview Models 4150/4250 Maintenance Manual

Operator Display

Operator Display
The Operator Display (OD) shows alphanumeric
data received from the Vehicle Manager (VM).

The data shown includes:

• Time and date
• Battery Discharge Indicator (BDI)
• Weight of load (option)
• VM Software version
• Attachment Selection function
• Hour meters (key hours [KH]), deadman
hours [HD], lift/aux hours [HL], and total
miles [TM]
• Ambient temperature
• OCSS beam trip count
• Lift truck serial number
• Status/Fault messages
• Service required indicator
• Overtemperature indicator
• Lift-limit indicator (optional)

Figure 3-4. Operator Display

Up Button Down Button Key Switch

Display

Overtemperature
Indicator
Battery Discharge Service Required Enter Button Emergency
Indicator Indicator Power Off

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Models 4150/4250 Maintenance Manual Section 3. Systems Overview

Passwords

Passwords 2. Enter the password as follows:

NOTE: The default Maintenance Password is
Two levels of passwords are used on this lift _ 2 _ _ _ _ _ _. The default Configuration
truck: Configuration and Maintenance. Password is 1 _ _ _ _ _ _ _.
To illustrate this procedure, assume you
Configuration Mode Password are entering the default Maintenance
Password (_ 2 _ _ _ _ _ _). Look at the OD.
The Configuration Mode Password allows you to The flashing underscore is the active
enter Configure Mode (refer to “Configure Mode” character position. To move the active
on page 3-11). Configure Mode is intended for character position to the right, press
customer use in setting performance Enter.
parameters within those features purchased To move the active character position to
with the lift truck. the left, hold down the Enter button and
press the Down button. When the
character position you want to change is
Maintenance Mode Password active, release the buttons.
The Maintenance Mode Password allows you to 3. Press the Up button to scroll up through
enter Maintenance Mode. Maintenance Mode is the numbers (0,1,2,3—7,8,9) and letters
intended to be used by qualified and trained (a,b,c—x,y,z).
service technicians only. Press the Down button to scroll down
through the letters (z,y,x—c,b,a) and
It is strongly recommended that the numbers (9,8,7—2,1,0).
Maintenance Mode Password be changed
during installation from the factory. This is to NOTE: Push and hold the button to scroll very
make sure that access to Maintenance Mode is quickly.
restricted to qualified personnel only. If the Release the button when the letter or
password is lost, changed, or forgotten, a reset number you want is shown in the
to the original factory password can be character position.
performed in FlashWare. In doing so, all
4. Move to the next character position you
settings are reset to the original factory default
want to change.
parameters. Consequently, all variable settings
must be reconfigured. Document all lift truck • Press the Enter button to move the
configuration settings before a reset is active character position to the right.
performed. • Hold down the Enter button and press
NOTE: Password recovery can be performed via the Down button to move the active
the Raymond Portal if FlashWare is not character position to the left.
available. Within the Raymond Portal, 5. Repeat Step 3 to change the letter or
select Service > Software > Superword number in this character position.
Recovery Passkey Program and follow 6. Repeat Steps 3 and 4 to enter the
the procedure in the Superword_readme remaining characters of the password.
file.
7. When the OD shows the correct password,
press Enter. If the password is correct,
Entering a Password you are now in Maintenance Mode.
NOTE: Press the Enter button to access 8. If you make a mistake while entering a
Maintenance or Configure Mode after an character, repeat Steps 3 through 7.
error code is shown.
1. Press Enter. The OD shows an eight
character field of underscores.

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Section 3. Systems Overview Models 4150/4250 Maintenance Manual

Electronic Key

Electronic Key
Electronic Key is a configurable software
feature that allows the customer to establish an
operator password.

When the key switch is turned ON, the operator

is prompted to enter the electronic key
(password).

The lift truck does not enter Run Mode unless

the correct password (electronic key) is entered.

Changing a Password
NOTE: When entering the default value
Configuration password, you must enter
the password in the beginning space.
For the Maintenance password, you
leave the beginning space blank. The
default Electronic Key is 3 _ _ _ _ _ _ _.
1. After entering either the Configuration or
Maintenance password, the screen scrolls
and asks if you want to change the
password.
• Example: Enter New Maint Password
• Press Enter. The screen stops scrolling.
Enter a new password.
2. Press Enter to cursor all the way to the
right until you are asked to enter a new
password again.
3. Scroll Up or Down, selecting Quit until
you get to a Save prompt. Select Yes.

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Models 4150/4250 Maintenance Manual Section 3. Systems Overview

Modes of Operation

Modes of Operation Run Mode, the default mode of operation. Run

Mode is also entered when the lift truck exits
Configure or Maintenance Mode.
There are three modes of operation for this lift
truck:
Configure Mode
• Run Mode - the standard working mode
for the lift truck. Configure Mode is used to change individual lift
• Configure Mode - used to change the lift truck performance parameters for specific
truck operating parameters. customer requirements. Refer to Table 3-1.
• Maintenance Mode - used to access
Learn Mode, perform different tests To enter Configure Mode, you must enter the
needed for troubleshooting, enable Active Configuration Mode password. See “Entering a
Maintenance Mode, view logged errors and Password” on page 3-9.
the OCSS trip counter, and set sideshift
and tilt speeds. When Configure Mode is entered, the current
value selected is shown first, followed by a
description of the setting being modified.
Run Mode
When the lift truck is powered ON and SelfTest
is completed, the lift truck automatically enters

Table 3-1. Configure Mode Menu

Configure Mode Menu
Shaded rows are options that must be enabled in FlashWare

Menu Message Shown and Parameter

Description
Item Selections Available

Quit “Exit Configuration Mode” Allows exit of Config Mode. Select Yes to save
Save?Yes changes. Select No to abandon changes before
Save? No leaving Configure Mode. If no changes were
made, the session exits at the “Quit” prompt.

Default “Restore Factory Defaults” Restores all initial lift truck values established at
Restor?No the factory except travel speeds and passwords.
Restor?Yes Document current configuration settings before
restore is performed.

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Section 3. Systems Overview Models 4150/4250 Maintenance Manual

Configure Mode

Configure Mode Menu

Shaded rows are options that must be enabled in FlashWare

Menu Message Shown and Parameter

Description
Item Selections Available

Travel “Set Forward Max Speed” Set maximum forward (forks-first) speed. Can be
1.0 to 7.2 mph (1.6 to 11.5 km/h) set as low as 1 mph (1.6 km/h), in increments of
(Model 4150 - Default is 7.2 mph) 0.1 mph (0.16 km/h).
1.0 to 8.0 mph (1.6 to 12.8 km/h)
(Model 4250 - Default is 8.0 mph)

“Set Reverse Max Speed” Set maximum reverse (tractor-first) speed. Can
1.0 to 7.2 mph (1.6 to 11.5 km/h) be set as low as 1 mph (1.6 km/h), in increments
(Model 4150 - Default is 7.2 mph) of 0.1 mph (0.16 km/h).
1.0 to 8.0 mph (1.6 to 12.8 km/h)
(Model 4250 - Default is 8.0 mph)

“Set Travel Accel” Set travel acceleration rate. Useful when the lift
Soft truck operates in high or very low traffic
Medium (Default) environments.
Hard

“Set Corner Decel” Set the time (in seconds) it takes for the lift truck
OFF (Default) to decelerate to a target speed (configured
1.5 maximum speed minus 1.8 mph [2.9 km/h])
2.0 during a turn.
2.5
3.0
3.5

“Set Coast Distance” Set distance the lift truck travels when the
Long (Default) control handle is released and returns to the
Medium neutral position.
Short

Lift “Set Lift Accel” Set lift acceleration rate. Useful for limiting new
Soft operators, or when large loads are expected.
Medium
Hard (Default)

BSOC “Set Lift Cutout Point” Set the lowest state-of-charge the battery can
0 - 40% (Default is 20%) have and still lift. It is adjusted to keep from
over-discharging the battery. Value is a
percentage of BSOC and can be set in 5%
increments.

“Set Alternate Lift Cutout Point” Set the lift cutout setting on a Battery Sensor
0 - 40% (Factory Set at 20%) Module (BSM) equipped battery without
FlashWare. Note: The preferred method to
change the BSM BSOC Cut-Out setting is via the
APM00 FlashWare screen.

“Set BSOC Display” Set which BSOC information is shown on the

Truck (Default) Operator Display when a BSM equipped battery
iBattery is installed in the lift truck.

Password “Enter New Configuration Password” Set password used to enter Configure Mode.
(Default is 1 _ _ _ _ _ _ _) Refer to “Passwords” on page 3-9.

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Models 4150/4250 Maintenance Manual Section 3. Systems Overview

Configure Mode

Configure Mode Menu

Shaded rows are options that must be enabled in FlashWare

Menu Message Shown and Parameter

Description
Item Selections Available

Units “Set Units for Messages” Specify the unit of measure shown on the
English (Default) Operator Display.
Metric

Mnt Mind “Setup Maintenance Minder” Enable/disable, configure, and reset

Quit MM “Exit MM” Maintenance Minder (MM).
Enable “Turn on MM”
*Setup
50 to 500FS (Factory Suggested)-> Set MM interval in 50 hr. increments.
Msg. Only----------------------------> Shows message when due.
L Cutout------------------------------> Shows message and disables lift when due.
*Reset
*Disable Note: Refer to page 4-3 for detailed information
*Shown only when Maintenance Minder is enabled. on Maintenance Minder.

APOFF “Enter the Auto Power-Off Time” Enable (set time) or disable Auto Power-Off (sleep
Disabled (Default) mode). Disables lift truck power after the preset
01Min time of inactivity.
02Min
03Min
04Min
05Min
10Min

Clock “Set Time and Date” Set lift truck’s internal clock.
Quit Clk
24Hour "Enable/Disable 24 Hour Time
Display"
Y
N
Time
01:00PM or 1300
Date
mm/dd/yy

VM XX.X “Vehicle Manager Software Version”

VMB X.X “VM Boot Software Version”

LTAXX.X “Left Traction Amp Software Version”

LTABX.XX “Left Traction Amp Boot Version”

Read only.
TAXX.X “Right Traction Amp Software Version”

RTABX.XX “Right Traction Amp Boot Version”

LA_XX.X “Lift Amp Software Version”

LPABX.XX “Lift Amp Boot Version”

Electronic “Enter New Electronic Key Password” Enter/change Electronic Key password. Requires
Key (Default is 3 _ _ _ _ _ _ _) entry of unique password before the lift truck is
operational. Refer to “Passwords” on page 3-9.

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Section 3. Systems Overview Models 4150/4250 Maintenance Manual

Configure Mode

Configure Mode Menu

Shaded rows are options that must be enabled in FlashWare

Menu Message Shown and Parameter

Description
Item Selections Available

Travel “Set Travel Alarm” Set desired action when the alarm sounds;
Alarm Forks during forks-first travel, tractor-first travel, both
Tractor directions, or not at all.
Both (Default)
None

Cust Out “Enter Customer Output Option Time” Enable (set time) or disable Customer Output
Disabled (Default) option. Disables output to JPC18-2.
0 to 120 seconds

HydOpt “Select Optional Hydraulic Attachment” Refer to “Attachment Control” on page 3-16.

Item Message Shown Selections Available Description

QuitAtt “Exit Attachment Selection”

Attach 1 “Attachment 1 Setup”

None (Default) Select flow rate in
2-7 GPM (4150) 1 GPM increments.
2-11 GPM (4250)
Clamp
N = No (Default)
Y = Yes
QuitPsi
“Set Low Clamp Pressure(psi)” Low 750 (Default) Refer to Table 3-2,
“Set Med Clamp Pressure(psi)” Med 1000 (Default) “Attachment Setup,”
“Set High Clamp Pressure(psi)” Hi 1250 (Default) on page 3-16.
“Set Max Clamp Pressure(psi)” Max 2300 (Default)
“Set Clamp Open Opn 2300 (Default) Lower psi = slower
Pressure(psi)” unclamp speed.

Attach 2 “Attachment 2 Setup”

None (Default)
2-7 GPM (4150) Select flow rate in
2-11 GPM (4250) 1 GPM increments.

Spd Limit “Set the Speed Limit Switch Speed” Set speed when speed limit switch is activated.
1.0 to 6.0 mph (1.6 to 9.6 km/h) Can be set as low as 1 mph (1.6 km/h), in
(Default is 6.0 mph) increments of 0.1 mph (0.16 km/h).

LftLimit “Set the Lift Limit W/Bypass Type” Configure lift limit bypass option: No Bypass,
No Byp (Default) Standard Bypass, or Alternate Bypass.
Alt Byp
Std Byp

Bat Gate “Set the Battery Gate Action” Configure lift truck response when the battery
ON gate switch is activated (battery gate not correctly
OFF (Default) installed).

Weight “Select the Weight Sensor” Turn ON/OFF the weight sensor. When ON,
ON weight on forks is shown on the Operator
OFF (Default) Display.

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Configure Mode

Configure Mode Menu

Shaded rows are options that must be enabled in FlashWare

Menu Message Shown and Parameter

Description
Item Selections Available

Sideshft “Enable Sideshift” Enable/disable sideshift function.

On (Default)
Off

TiltCntr “Enable tilt center” Enable/disable tilt centering function.

On
Off (Default)

BSOC “Set BSOC reset %” Set level at which the Battery Discharge Indicator
55 to 95% (Default is 75%) resets. Can be set in 5% increments.

iP “iP Forward Max Speed” Read only. Sent from iWAREHOUSE® device.
Represents max.
Forks-First speed allowed, based on operator
experience level.

“iP Reverse Max Speed” Read only. Sent from iWAREHOUSE® device.
Represents max.
Tractor-First speed allowed, based on operator
experience level.

“iP Lift Max Speed” Read only. Sent from iWAREHOUSE® device.
Represents max. lift speed allowed, based on
operator experience level.

“iP Lower Max Speed” Read only. Sent from iWAREHOUSE® device.
Represents max. lower speed allowed, based on
operator experience level.

“iP Travel Accel” Read only. Sent from iWAREHOUSE® device.

Represents max. travel acceleration speed
allowed, based on operator experience level.

“iP Lift Accel” Read only. Sent from iWAREHOUSE® device.

Represents max. lift acceleration speed allowed,
based on operator experience level.

“iP Init Spd” Set maximum travel speed after key switch is
1.0 to 7.2 mph (1.6 to 11.5 km/h) turned ON and before iWAREHOUSE® device
(Model 4150 - Default is 7.2 mph) sends a speed request. Set in 0.1 mph
1.0 to 8.0 mph (1.6 to 12.9 km/h) (0.16 km/h) increments.
(Model 4250 - Default is 8.0 mph)

“iP Err Spd” Set maximum travel speed after communications

1.0 to 7.2 mph (1.6 to 11.5 km/h) is lost with iWAREHOUSE® device. Set in 0.1
(Model 4150 - Default is 7.2 mph) mph (0.16 km/h) increments.
1.0 to 8.0 mph (1.6 to 12.9 km/h)
(Model 4250 - Default is 8.0 mph)

iPORT Limit Mode Menu items - refer to iPORT Kit Installation and Maintenance Instructions, iWAREHOUSE
Essential Installation and Maintenance Instructions and User Guide, or iWAREHOUSE Evolution Installation
and Maintenance Instructions and User Guide.

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Section 3. Systems Overview Models 4150/4250 Maintenance Manual

Attachment Control

Attachment Control SSL on the manifold. Sideshift must be disabled

in the Configure Mode Menu. The flow rates
associated with this connection are
Attachment 1 configurable under Attach 2 in the HydOpt
menu. Lift trucks with this configuration
If an attachment is added to the lift truck that cannot be equipped with sideshift.
requires only one set of hoses, the hydraulic
lines are connected to ports AC and AR on the
hydraulic manifold. Flow rates associated with Setup and Operation
this connection are configurable under Attach 1
in the HydOpt menu. Refer to Table 3-2 for specific attachment setup
information. Refer to Table 3-3, “Attachment
Operation,” on page 3-17 for specific
Attachment 2 attachment operation information.
If the attachment requires two sets of hoses, the
second set of hoses are connected to SSR and

Table 3-2. Attachment Setup

Operator Display: Hydraulic Hose Adjustment Range
Function
Config or Maintenance Mode Menu Action Ports for Flow Rate

Sideshift Sideshift speed configurable via SSR (Sideshift Right) Set SS Speed - 60% to
“Maintenance Mode” menu item SS. See SSL (Sideshift Left) 90%
Table 3-4 on page 3-20.

Push/Pull Config Menu: Navigate to HydOpt and press AC (Aux Cap) Begin with 7 GPM and
Enter. AR (Aux Rod) adjust as needed or
_Select Attach 1 specified by
___Select flow rate manufacturer*.
_____Set clamp = N

Fork Config Menu: Navigate to HydOpt and press AC (Aux Cap) Begin with 2 GPM and
Positioner Enter. AR (Aux Rod) adjust as needed or
_Select Attach 1 specified by
___Select flow rate manufacturer*.
_____Set clamp = N

Clamp Config Menu: Navigate to HydOpt and press AC (Aux Cap) Begin with 7 GPM and
Enter. AR (Aux Rod) adjust as needed or
_Select Attach 1 specified by
__Select flow rate manufacturer*.
___Set clamp = Y (see Note 1)
____Set PSI (see Note 2)

Clamp with Config Menu: Navigate to HydOpt and press SSR (Sideshift Right) Begin with 3 GPM and
roll (see Enter. SSL (Sideshift Left) adjust as needed or
Note 3) _Select Attach 2 specified by
__Select flow rate manufacturer*.

*Flow rate can be adjusted in Configure Mode in 1 GPM increments; 2 to 7 (4150), 2 to 11 (4250).
Note 1: All clamp functions must be connected to AC and AR, never to SSR and SSL.
Note 2: Default values are Max = 2300, High = 1250, Med = 1000, Low = 750. Overall Range is 250 to 2300
psi, but values cannot overlap. Example, the highest setting for Low depends on what medium is set to. The
highest value for medium depends on what High is set to and so on.
Note 3: Use SSR and SSL for the roll function on the clamp with roll attachment.

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Models 4150/4250 Maintenance Manual Section 3. Systems Overview

Attachment Control
Table 3-3. Attachment Operation
Control Handle Switch
Function Description
Input

Tilt Tilt Down and Tilt Up On taller Quad masts, the tilt rate depends on the
status of the mast proximity switch.

Sideshift Sideshift Left and Sideshift Sideshift flow rate (function speed) depends on the
Right Set SS Speed value in the Maintenance Mode
menu.

Attachment added Attachment Switches If Clamp is used, momentary tilt activation is

(Push/Pull, Clamp) required to release the load.

Attachment Function Attachment Switches, The input for the second function of the
added to the lift truck Sideshift Left and Sideshift attachment requires the use of the sideshift input.
that requires 2 Right
functions (Barrel
Clamp with Roll, Fork
Positioner with
Sideshift)

Additional Auxiliary Functions High-Flow Attachment (One-Speed

Operation)
The design of this lift truck allows for the
addition of up to two auxiliary functions. See To activate a one-speed high-flow attachment:
Figure 3-5.
1. Press the top attachment button to
operate the attachment. See Figure 3-6.
Refer to the Owner Manual to configure
additional auxiliary functions. Figure 3-6. Top Attachment Button

Figure 3-5. Location of Additional Aux Functions

2. Press the lower attachment button to

operate the reverse action of the
Location of up to attachment.
two additional
auxiliary functions.

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Section 3. Systems Overview Models 4150/4250 Maintenance Manual

Attachment Control

Clamp Attachment button to activate unclamp. See

Figure 3-9.
Press the top attachment button to activate the
clamp. See Figure 3-7. Figure 3-9. Tilt Back Button

Figure 3-7. Top Attachment Button

3. Continue to press the bottom attachment

button to unclamp the load. See
Figure 3-10.

Figure 3-10. Bottom Attachment Button

Unclamp Attachment
1. Press and hold the bottom attachment
button to select unclamp. See Figure 3-8.
NOTE: It is not necessary to press the tilt back
Figure 3-8. Bottom Attachment Button
button each time to activate unclamp.
However, the tilt back button must be
momentarily pressed to unclamp
whenever the previous activation was for
clamp,

Clamp Attachment (With Variable

Pressure)
1. Press and release the top attachment
button momentarily to activate the clamp.
See Figure 3-11.

2. While holding the bottom attachment

button in, momentarily press the tilt back

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Models 4150/4250 Maintenance Manual Section 3. Systems Overview

Attachment Control
Figure 3-11. Top Attachment Button

2. The clamp pressure is shown on the

Operator Display.
3. To select another pressure, use the
UP/DOWN buttons on the Operator
Display. See Figure 3-12. The clamp
pressure you select remains active until
another pressure is selected; even if the lift
truck is turned OFF.

Figure 3-12. UP/DOWN Buttons on Operator Display

NOTE: Four clamp pressure settings are

available: Low, Med, High, and Max.
These pressures are set in the Config
Menu.
4. Press the top attachment button to
activate the clamp.

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Section 3. Systems Overview Models 4150/4250 Maintenance Manual

Maintenance Mode

Maintenance Mode
Maintenance Mode is used to test, cycle, and
troubleshoot functions on the lift truck. (Refer
to Table 3-4.)

To enter Maintenance Mode, you must enter the

maintenance password. See “Entering a
Password” on page 3-9.

Table 3-4. Maintenance Mode Menu

Menu Message Shown
Description
Item and Parameter Selections Available

Quit “Exit Maintenance Mode” Allows exit of Maintenance Mode. Select

Save?Yes Yes to save changes. Select No to
Save? No abandon changes before leaving
Maintenance Mode. If no changes were
made, the session exits at the “Quit”
prompt.

Default “Restore Factory Defaults” Restores all initial lift truck values
Restor?N established at the factory (including
Restor?Y travel speeds and passwords). Document
current configuration settings before
restore is performed.

Learn “Enter the Learn Mode” Perform Learn after replacing the VM,
Enter control handle, control handle pots, tilt
Quit “Exit Learn Mode” center pot, or optional weight transducer.
Weight “Learn Weight” (optional)
“Lower Carriage to Floor, then Lift 4 Inches.
Press Enter When Done”
Travel “Learn Travel”
“Return Control to Neutral, then Press Enter”
Lift “Learn Lift”
“Return Control to Neutral, then Press Enter”
Tilt “Learn Tilt”
“Return Control to Neutral, then Press Enter”
Sideshft “Learn Sideshift”
“Return Control to Neutral, then Press Enter”
Reach “Learn Reach”
“Return Control to Neutral, then Press Enter”
Retract “Learn Retract”
“Return Control to Neutral, then Press Enter”
AutoTilt “Learn Auto-tilt”
“Return Control to Neutral, then Press Enter”

Current “Enter New Maintenance Password” Set password used to enter Maintenance
Setting (Default is _ 2 _ _ _ _ _ _) Mode. Refer to “Passwords” on page 3-9.

D Inputs “Digital Inputs”

Quit “Exit Digital Inputs”
Refer to “Input Tests” beginning on Shows the Input Test sub-menu to allow
page 6-77.----> an individual Input test to be run.

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Models 4150/4250 Maintenance Manual Section 3. Systems Overview

Maintenance Mode

Menu Message Shown

Description
Item and Parameter Selections Available

A Inputs “Analog Inputs”

Quit “Exit Analog Inputs”
Refer to “Analog Tests” beginning on Shows the Analog Test sub-menu to allow
page 6-33.--> an individual Analog test to be run.

Before performing an Output Test:

• Jack the lift truck so that the drive wheels are off the floor.
• Make sure the controls are in neutral.
• Make sure the lift truck is blocked to keep it from moving.
• Lower the forks all the way to the floor.

Outputs “Digital Outputs”

“Jack up drive wheels Ready?”-------------------> Press Enter.
Quit “Exit Digital Outputs”
Refer to “Output Tests” beginning on Shows the Output Test sub-menu to
page 6-97.-> allow an individual Output test to be run.

ActM Off “Active Maintenance Select” Allows the menu to show on the Operator
ActM Off (Default) Display to toggle between Analog and
ActM On Input tests while the lift truck is in Run
Mode.

Erlog*## “Number of Errors Logged” *## = total number of error codes logged.
Quit “Exit Error Log Menu”
20 _ _-------------------------------------------------> Error code log number and associated
Clear “Press Enter to Clear Errors From the Log” code. Up to 20 error codes can be logged.

BTrip # “OCSS Beam Trip Count” Shows the number of times the OCSS
Clear? “Press Enter to Clear Count” beam was blocked since it was last
cleared.

Current “Adjust Two Speed Tilt” Allows adjustment of tilt speed (based on
Setting 5 "Set Tilt Speed" percentage) when the
(4250 only) 4 carriage is above S12. The lower the
3 (Default) number, the faster the tilt speed. The
2 higher the number, the slower the tilt
1 speed. Default is 3 and represents no
speed adjustment.

Current “Set Tilt Speed” Set tilt speed. Value is a percentage and
Setting 60 - 90% (Default is 75%) can be set in 1% increments. The higher
the percentage, the faster the tilt speed.

Current “Set SS Speed” Select sideshift speed. Adjust sideshift

Setting 60 - 90% (Default is 75%) speed between 2 and 3.5 seconds (the
higher the percentage, the faster the
sideshift speed).

Current “Max Lowering Speed” Set max lowering speed. Value is a

Setting 50 - 100% percentage and can be set in 1%
(Default is 72% 4250; 75% 4150) increments. The higher the percentage,
the faster the lowering speed.

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Section 3. Systems Overview Models 4150/4250 Maintenance Manual

Storage

Storage While in storage, periodically rotate the DC

motor shafts to coat the bearings with
lubricant, reducing the possibility of oxidation
When storing the lift truck for any length of and corrosion.
time, cover the lift truck with canvas or plastic.

If storing the lift truck for more than 30 days, Hydraulic System
jack and block the lift truck up off the floor.
The hydraulic system absorbs moisture when
left standing for a long time.

Make sure the reservoir is full before storing.

Use extreme care when the lift truck is
jacked up, elevated, or placed on blocks Before returning the lift truck to service, drain
or jack stands. Never block the lift truck the reservoir and change the filter. Fill the
between the telescopic and the floor. reservoir with new hydraulic fluid.
Attach an appropriately rated rigging
device to the top of the mast, and an Operate the hydraulic systems slowly at first to
overhead hoist to stabilize the mast, if allow lubrication of internal components.
jacking higher than described in
“Jacking Safety” on page 2-9. Keep NOTE: If the lift truck is to be stored for more
hands and feet clear while jacking the than six months, spray hydraulic
lift truck. After the lift truck is elevated components with a silicone protectant.
to the required height, place blocks of a Do not let the silicone protectant spray
solid material that will support the get on the circuit cards.
weight of the lift truck, or jack stands
that will support the weight of the lift Hydraulic Cylinders
truck, beneath the specified locations
shown in this maintenance manual, for Store the lift truck with the cylinder pistons
support. Lower the lift truck onto the retracted. Coat all exposed chrome surfaces of
blocks or jack stands. Never rely on the the piston with hydraulic fluid.
jack or jack stand alone to support the
lift truck.
Lift Chains
Warranty Liberally lubricate all chains to prevent rust
and corrosion. Refer to “Lubrication
The Raymond Corporation must be contacted Specification Chart” on page A-2.
by an authorized Raymond Solutions and
Support Center for the correct warranty
procedures. Electronics
Make sure that all the electronics stay dry.
DC Motors
The brushes in DC motors must be lifted away
from the commutator surface. When preparing
the lift truck for service, the surface must be
inspected and polished, if necessary, use a
rubber abrasive polish. Polishers are
specifically made for polishing commutators.
See “Polishing the Commutator” on page 7-58.

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Models 4150/4250 Maintenance Manual Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance

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Section 4. Scheduled Maintenance Models 4150/4250 Maintenance Manual

Maintenance Guidelines

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

Scheduled maintenance includes:

• Lubrication
• Cleaning
• Inspection
• Service

Perform all of the scheduled inspections and

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

When operating under severe or extreme

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

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Models 4150/4250 Maintenance Manual Section 4. Scheduled Maintenance

Maintenance Minder™

Maintenance Minder™ Setting Time Interval and Action

Option
Maintenance Minder is a feature that alerts the
The first time you enter the time interval menu,
operator when the lift truck is due for
the Factory Suggested setting, followed by the
scheduled maintenance.
letters FS, is shown. Subsequently, when you
enter the time interval menu, the last used
Maintenance Minder, when enabled, monitors
setting is shown. Values from 50 to 500 hours,
deadman hours. When the time interval
in increments of 50, are available. Scroll to the
between scheduled maintenance is exceeded,
desired time interval and press ENTER.
the operator is informed as follows:
• One of two messages is shown on the Scroll to the desired action option and press
display following the Daily Checklist ENTER.
message:
• MSG ONLY causes the Operator Display to
• Scheduled Maintenance Due show SCHEDULED MAINTENANCE DUE
• Lift Cutout, Scheduled Maintenance when the scheduled maintenance time
Due interval is exceeded.
• The wrench icon on the display flashes • L CUTOUT causes the Operator Display to
show LIFT CUT OUT, SCHEDULED
• The audible alarm sounds the high-low
MAINTENANCE DUE when the scheduled
tone for approx. 5 seconds.
maintenance time interval is exceeded. Lift
is disabled the next time the power circuits
Lift Cutout, when active, does not disable the
are cycled.
lift function until power to the control circuits is
cycled (key switch OFF or battery
Scroll to QUIT MM from the sub-menu. Press
disconnected).
ENTER.
When the control circuit power is cycled, lift is
Select QUIT CFG from the Config Menu. Save
disabled until Maintenance Minder is reset or
changes as prompted.
disabled, or the lift cutout option is turned OFF.

Changing Time Interval or Action

Enabling Option
MAINTENANCE MINDER is enabled and
When Maintenance Minder is active and you
configured in the Configure Mode menu. The
want to change the time interval or action
default factory setting is DISABLE. To enable
option, enter Configure Mode.
the feature, enter Configure Mode.
NOTE: For instructions on selecting Modes of With Configure Mode selected, scroll to MNT
Operation, see “Modes of Operation” on MIND and press ENTER. When entered from an
page 3-11. enabled state, Maintenance Minder offers a
sub-menu with the options QUIT MM, RESET,
With Configuration Mode selected, scroll to DISABLE, and SETUP. Scroll to SETUP, then
MAINTENANCE MINDER and press ENTER. press ENTER. The current time interval is
When entered from a disabled state, shown (hours). Proceed as described under
Maintenance Minder offers a sub-menu with the Setting Time Interval and Action Option.
options QUIT MM and ENABLE. Scroll to
ENABLE and press ENTER.

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Section 4. Scheduled Maintenance Models 4150/4250 Maintenance Manual

Disabling

Resetting Maintenance Minder

When Maintenance Minder is active and, after

you have performed scheduled maintenance,
you want to reset the reminder prompt, enter
Configure Mode.

With Configure Mode selected, scroll to MNT

MIND and press ENTER. Scroll to RESET, then
press ENTER. Select QUIT MM and press
ENTER again. Save changes, as prompted.

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

With Configure Mode selected, scroll to MNT

MIND and press ENTER. Scroll to DISABLE,
then press ENTER. Select QUIT MM and press
ENTER again. Save changes, as prompted.

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Models 4150/4250 Maintenance Manual Section 4. Scheduled Maintenance

Initial 90 Day/250 Deadman Hours (HD) Maintenance

Initial 90 Day/250 Deadman Hours (HD)

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

Component What To Do

Check/adjust roller bearings on lift trucks with TT masts (S/N 50501 up). Refer
Mast
to “Roller Bearing (Puck) Adjustment - TT Mast - S/N 50501 Up” on page 7-106.

Power Amplifiers Torque power cable terminal bolts to 95 to 105 in. lb. (10.7 to 11.8 Nm).

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Section 4. Scheduled Maintenance Models 4150/4250 Maintenance Manual

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
Battery allowable weight. 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 an open area, measure stopping distance. Traveling 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 lift truck
lengths. Stopping distance depends on the load, floor, and tire condition.
Examine for signs of oil on the friction disc. If oil is present, disassemble the
Brakes
brake, clean rotor, and replace the pads.
Measure for correct gap: Check the gap between the armature disc and the brake
coil. The gap should measure between 0.008 and 0.016 in. (0.2 and 0.4 mm). If
the gap exceeds 0.016 in. (0.4 mm), remove and disassemble the brake assembly
to check the components. Failure to keep the brakes adjusted causes premature
disc and rotor wear and excessive motor heat. Refer to “Brakes” on page 7-46.

Inspect the contactor tips for burnt or pitted surfaces. See “Contactor Tip
Inspection” on page 4-10. Failure to replace the tips may prevent the contactor
from opening or closing, causing unscheduled downtime. With the key switch
Contactors
OFF and the battery disconnected, check the plunger for smooth operation with
no binding. If binding occurs, the lift truck could malfunction or show
intermittent fault codes.

Verify that the lift/lower function is smooth and controllable. Verify that the
travel function is smooth and responsive through full range of motion. Check for
Control Handle play in the center position of the lift or travel control; repair/replace the control
handle if necessary. Verify the function of all switches. Make sure that the nylon
insert is in the lift knob set screw hole.

The deadman pedal must operate smoothly with no binding. Check for correct
Deadman Pedal
activation and deactivation of the deadman switch.

Make sure that the drain holes beneath the deadman pedal and in the battery
Drain Holes
compartment are free of any debris.

Check the oil level. See “Adding Oil” on page 7-35. Inspect for leaks. Check the
Drive Units
drive axle for play.

Inspect all power cables for nicks or cuts. Replace any cable that is damaged or
shows signs of excessive heat. Failure to do so causes intermittent system
Electrical Cables shutdowns and/or electronic failures. Check the tension of the over-the-mast
pulley cables. Set the tension so the cables just stay on the pulleys. Higher
tension causes premature failure.

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Models 4150/4250 Maintenance Manual 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

Check the fork mounting surfaces for wear. Make sure the fork positioning lock
works correctly. Examine for excessive wear, bends, cracks, welding arcs,
excessive heat, or unauthorized modifications. Replace if found. Measure the fork
Forks
thickness (Tool P/N 922-369). Visually inspect the fork markings. Inspect the
straightness of the blade and shank, fork height, and fork angle. See “Fork
Inspection” on page 4-12.

Perform a general visual inspection of the structural members for cracks,

Frame Checks
including, but not limited to, main frame and tractor.

Check the bolt torque of major components (motors, pumps, brake, drive units,
manifolds, mast-to-tractor mounting bolts, overhead guard mounting bolts). On
Hardware lift trucks equipped with the ComfortStance™ floor, check the torque of the pivot
block, and strut mounting hardware. Tighten any loose hardware. Replace any
broken or missing hardware. Refer to “Appendix” for torque values.

Check that the horn operates when you press the horn button. Check the
Horn
mounting bracket insulators.

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

Check the fluid level. See “Lubrication Specification Chart” on page A-2. Add fluid
Hydraulic Reservoir
if necessary.

Check the adjustment. Inspect for excessive stretch or wear (Tool

Lift Chains
P/N 939-10606). Lubricate. See “Chain Maintenance” on page 4-11.

Lubricate the steer wheel assembly, steer wheel axle, steer chain, sideshift
Lubrication
carriage, and fork position pins.

Wipe old grease off the mast uprights and apply new grease. Examine the mast
bearings. Inspect the rails for abnormal wear, metal flakes, or shavings. Each
pair of load rollers should be shimmed so that the total side to side clearance is
Mast
no greater than 1/16 in. (1.5 mm) at the tightest point throughout the travel of
the member. Pry between the upright and load roller so that the opposite load
roller is tight against the upright. Measure the clearance for the pair of rollers.

AC - Check the cable lugs to make sure they are tight to the terminal studs.
Torque the inside and outside nut to the values listed on page 7-56. Replace any
cable that shows signs of excessive heat. Check the sensor wires for sound
connection and condition. Blow out the inside of the motor with compressed air.

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

excessive heat is evident, inspect the armature circuit for loose connections.
Check the condition of the commutator per photos starting on page 5-15. Find
Motors the shortest brush in the holder. Remove the brush and check the overall
dimension per Table 7-6 on page 7-58. Inspect the brush for even wear over the
full surface of the brush. If the brush is not contacting the complete surface,
replace the brushes. Inspect the brush rigging for damage or loose brush holders.
Make sure the connections on the brush leads are tight. Check the brush spring
tension. Blow out the inside of the motor with compressed air. Blow out the
impeller and cooling fins. Check the cable lugs to make sure they are tight to the
terminal studs. Torque the inside and outside nut to the values listed on
page 7-56. Replace any cable that shows signs of excessive heat.

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Section 4. Scheduled Maintenance Models 4150/4250 Maintenance Manual

Every 180 Days or 500 HD

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

Component Task

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

Power Amplifiers Check the torque on the power amplifier connections.

Check for electrical shorts to the frame. Refer to “Shorts to Frame Test” on
Shorts to Frame
page 5-3. Wipe the compartments clean.

Lift-Tek ® Carriage - Check for loose or missing hardware, worn or damaged hoses
and hydraulic leaks. Inspect the rollers and wear pads. If any wear pad surface is
worn to less than 0.1 in. (2.5 mm), replace all wear pads. Lubricate the rollers.
Sideshift/Fork Refer to “ISS Inspection” on page 7-85.
Positioner Cascade™ Carriage - Check for loose or missing hardware, worn or damaged
hoses, and hydraulic leaks. Tighten the lower mounting hook cap screws to 165
ft. lb. (225 Nm). Grease the fork bearings, fork cylinder rod anchors, upper
bearings, and lower flat bearings. Refer to “Inspection” on page 7-91.

Make sure that the static straps are not worn or broken. Clean debris from the
Static Straps
straps.

Check that the steering system function is smooth and responsive. Inspect the
pivot points and bearings in the steering assembly. Inspect the teeth on the
steering gear for wear. Inspect the steer chain for correct adjustment. The chain
Steering should flex approximately 1/8 to 1/4 in. (1.6 to 3.2 mm). Inspect the wheel axle
and bearings for excessive wear. Check the gap on the steering prox switch
[should be 0.060 +0.04/ –0.03 in. (1.5 +1.0/–0.7 mm)]. Inspect the hoses and
hydraulic motor for leaks.

Switches Check all switches for correct operation. Adjust as needed.

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

Warning Decals Replace any unreadable or damaged decals.

Warning Lights Check for correct operation.

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

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Models 4150/4250 Maintenance Manual Section 4. Scheduled Maintenance

Every 360 Days or 2000 HD

Every 360 Days or 2000 HD

Perform all 180 day/500 HD maintenance tasks plus the following every 360 Days or 2000 HD

Component What To Do

Drive Units Change the fluid.

Hydraulic Reservoir Change the fluid and filter.

Separate the pump and motor. Apply lubricant (P/N 1223184) to the splines. Refer
Pump Couplings
to “Lift Motor” on page 7-64.

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Section 4. Scheduled Maintenance Models 4150/4250 Maintenance Manual

Contactor Tip Inspection

Contactor Tip Inspection

Contactor tips have special textured tips that
provide mechanical self-cleaning when the
contactor opens and closes.

When repairing contactors, use only

Raymond authorized contactor kits.

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.

Figure 4-1. Severely Pitted Contactor

• 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.

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Models 4150/4250 Maintenance Manual Section 4. Scheduled Maintenance

Chain Maintenance

Chain Maintenance
Lift Chain Inspection
Make sure chains are not damaged. Use a
Chain Gauge (P/N 939-10606) to check the
chain for wear. Replace chains when necessary
with genuine Raymond spare parts.

Condition-Cause Chart

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 lift truck chains

Infrequent Oiling

Rust
Cracked plates Replace the chain.
Corrosion

Chain Fatigue

Bent pins or plates Replace the chain.

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

Chain side wear Chain misalignment Replace the chain.

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Section 4. Scheduled Maintenance Models 4150/4250 Maintenance Manual

Fork Inspection

Fork Inspection 2. Multiply these numbers by 0.005 for

maximum allowable deviation.
• Length of blade _____ x 0.005 = ______
The following tools are required to perform fork
inspection: • Height of shank _____ x 0.005 = ______
• Fork Wear Caliper (P/N 922-369) 3. Place a straight edge on the blade of the
fork, 2 in. (51 mm) away from the heel of
• Tape Measure or Ruler
the fork. Measure any deviation and
• 24 in. Framing Square compare to the number calculated in
• 4 ft. Level Step 2 for length of blade.
4. Place a straight edge on the shank of the
Do the following when performing Scheduled fork, 2 in. (51 mm) away from the heel of
Maintenance. the fork. Measure any deviation and
compare to the number calculated in
Surface Inspection Step 2 for height of shank.
5. If either maximum deviation is exceeded,
Remove the forks from the carriage. Visually remove the fork from service.
inspect all fork surfaces for signs of damage,
including, but not limited to:
Fork Angle
• cracks
NOTE: This measurement can be done with the
• excessive wear
forks on or removed from the carriage.
• excessive heat
1. Place the fork caliper on the blade. Make
• deformation sure that the two extruded points are
• unauthorized modifications touching the blade of the fork. See
Figure 4-3.
Pay special attention to the heel and welds 2. Now open and move the caliper so the two
attaching mounting components. If any damage extruded points are touching the shank.
is found, remove the fork from service. See Figure 4-3.

Straightness of Blade and Figure 4-3. Fork Angle

Shank
Shank
NOTE: This measurement can be done with the
forks on or removed from the carriage.
1. Measure the length of the blade and the
height of the shank. See Figure 4-2.
Figure 4-2. Measuring Fork Blade and Shank

Indicator
Lines

Shank Blade

Blade

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Models 4150/4250 Maintenance Manual Section 4. Scheduled Maintenance

Fork Tip Height

3. When all four extruded points are in 6. Compare this measurement to the
contact with the fork, gently remove the maximum deviation.
caliper and note the reading on the 7. If the maximum deviation number is
indicator line, located above the hinge pin. exceeded, remove the fork from service.
See Figure 4-3.
4. If the deviation is greater than 3° of the Wear
original angle, remove the fork from
service. Fork Blade and Shank
NOTE: Most forks are manufactured with a 90° 1. Remove the forks from the carriage.
angle; therefore, a reading greater than
2. Set the front teeth of the jaws of the caliper
93° or less than 87° is unacceptable.
on the shank approximately half way up
However, there are some forks that are the shank. Make sure that the caliper is
purposely manufactured to angles held square across the shank to get an
greater than or less than 90°. accurate reading. The caliper is now set to
measure fork blade wear. Carefully remove
Fork Tip Height the caliper from the shank. See Figure 4-5.
1. With the lift truck parked on a level Figure 4-5. Measuring Fork Shank
surface and the forks on the carriage,
measure the length of the blade. See
Figure 4-2.
Multiply the length of the blade by 0.03.
Blade length _____in. x 0.03 = _____in.
This is the maximum deviation.
2. Elevate the forks approx. 4 ft. (1.2 m) off
the floor.
3. Place a 4 ft. level across the tips of the
forks. See Figure 4-4.
4. Raise one end of the level to make it level.
See Figure 4-4.
5. Measure the distance from the tip of the 3. Measure 2 in. (50 mm) out from the heel of
fork. See Figure 4-4. the fork.
4. Place the caliper over the fork arm blade at
Figure 4-4. Measuring Fork Tip Height this 2 in. (50 mm) point. See Figure 4-6.
Forks Figure 4-6. Measuring Fork Blade Wear

Distance
from tip
Level of fork

Tips

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Section 4. Scheduled Maintenance Models 4150/4250 Maintenance Manual

Wear

5. If the inside teeth of the caliper hit the

Fork Distance Carriage
fork, there is less than 10% wear. If the Mounting Between Hooks Height
inside teeth pass freely over the fork arm, Class in. (mm) in. (mm)
there is greater than 10% wear and the
fork must be removed from service. 3 18.78 (477) 20 (508)

3. Locate the correct extruded edge on the

If there is greater than 10% wear of the caliper for the fork mounting class. See
fork arm, the fork has at least a 20% Figure 4-8.
reduction in capacity. 4. Slide the extruded edge up into the hook
pocket. See Figure 4-8.
NOTE: The caliper is designed to measure forks 5. If the caliper’s extruded edge completely
up to 4 in. (102 mm). It is not to be used slides up into the fork pocket, remove the
on full or lumber tapered forks. For fork from service. See Figure 4-8.
these forks, you must know the original
fork blade thickness and take a Figure 4-8. Fork Hook Inspection
measurement of the fork arm thickness.
If the difference in the measurement
exceeds 10% of the original thickness,
the fork must be removed from service.
Fork Pocket
Fork Hooks
1. Remove the forks from the carriage.
2. Determine the fork mounting class.
a. Measure the height of the carriage or
the distance between the hooks. See
Figure 4-7.

Figure 4-7. Determining Fork Mounting Class

Fork Mounting Class

Distance between hooks 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
Carriage Height fork from service.
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)

2 15.04 (382) 16 (407)

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Section 5. Troubleshooting

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Electrical Troubleshooting

Electrical Many problems can be caused by a dirty

battery. Make sure the battery is clean. See
Troubleshooting “Battery Exterior Cleaning” on page 7-53.

Save time and trouble by looking for simple

General causes first.

Visually inspect all wiring and electrical

components for:
• Loose connections or connectors
Block the lift truck so that the drive tire
is off the floor whenever a • Loose or broken terminals
troubleshooting procedure requires • Damaged terminals, blocks, or strips
turning the key switch ON. This prevents • Broken wiring and shorted conditions
accidents caused by unexpected lift (especially those that are close to metal
truck travel. edges or surfaces)
Use extreme care when the lift truck is Use a Digital MultiMeter (DMM) such as a Fluke
jacked up, elevated, or placed on blocks meter for all measurements. Analog meters can
or jack stands. Never block the lift truck give inaccurate readings and load down
between the telescopic and the floor. sensitive electronic circuits enough to cause
Attach an appropriately rated rigging failure. Make sure that the meter cables are
device to the top of the mast, and an connected to the correct meter jacks and that
overhead hoist to stabilize the mast, if the correct function and scale are selected.
jacking higher than described in
“Jacking Safety” on page 2-9. Keep Printed circuit boards are conformal coated.
hands and feet clear while jacking the Make sure that the meter leads make a good
lift truck. After the lift truck is elevated electrical connection with the test points.
to the required height, place blocks of a
solid material that will support the When measuring voltage, connect the positive
weight of the lift truck, or jack stands meter lead to the connector or probe point
that will support the weight of the lift marked (+) in the test. Connect the negative
truck, beneath the specified locations meter lead to the connector or probe point
shown in this maintenance manual, for marked (–).
support. Lower the lift truck onto the
blocks or jack stands. Never rely on the Whenever measuring resistance, turn the key
jack or jack stand alone to support the switch OFF and disconnect the battery
lift truck. connector. Battery current can damage an
ohmmeter. Isolate the component from the
circuit.

Unless otherwise directed, disconnect Before replacing an electrical component,

the battery connector when you check disconnect and clean all jack/pin connectors on
electrical circuits or components with an the component(s) with contact cleaner (P/N
ohmmeter. Electrical current can damage 996-600/CC2). Reconnect and retest the lift
an ohmmeter. truck.

Before removing a power amplifier, Shorts to Frame

discharge the amplifier’s internal
capacitor by jumpering the + and – Shorts to frame is an industry term for
terminals with a 100 ohm 25W resistor. unintentional current leakage paths between

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Shorts to Frame

normally isolated electrical circuits and their case from battery B–. If the light
metal enclosures. illuminates at all, even momentarily, there
is a serious problem with the battery,
Shorts to frame may be metallic connections, either external contamination or internal
such as a wire conductor contacting metal damage. Do not continue until this
through worn insulation. More often, shorts to condition is corrected. The meter may be
frame are resistive “leakage” paths caused by damaged if you proceed before correcting
contamination and/or moisture. this condition.

These leakage paths can result in unwanted Install another battery in the lift truck and
electrical noise on the metallic lift truck repeat this procedure from Step 1.
structure and can cause incorrect operation.
If the test light does not illuminate,
Shorts to frame are caused by: continue to the next step.
• Accumulation of dirt 3. Use a DMM set on the ampere function to
• Battery electrolyte leakage measure the current leakage from the
battery case to battery B+ and from the
• Motor brush dust battery case to battery B– (not lift truck B+
• Motor brush leads touching the housing and B–). Begin measuring at the highest
• Breakdown in insulation ampere scale and work toward the lowest.
A reading of more than 0.001A (1mA)
• Bare wires indicates a serious short. Do not continue
• Pinched wiring harness until this condition is corrected. The meter
• Incorrect mounting of circuit cards may be damaged if you proceed before
correcting this condition.
Shorts to frame can occur at numerous
locations on a lift truck, including: Install another battery in the lift truck and
repeat this procedure from Step 1.
• Batteries
• Motors If the current is less than 0.0002A
• Cables, wiring, and harnesses (0.2mA), go to Step 4. If the current is
greater than 0.0002A (0.2mA) and less
• Heatsinks than 0.001A (1mA), remove the battery
• Bus bars from the lift truck, then continue with
• Solenoids Step 4. Make sure the battery case does
not touch the lift truck frame during the
• Contactors remaining tests.
• Terminal strips 4. With the battery disconnected (or removed
• Switches and disconnected) from the lift truck, use
• Power panel insulation a DMM to measure the resistance from lift
truck frame to lift truck B+, to lift truck B–
• Circuit card mounts (not battery B+ and B–), and to all fuses
and motors. A reading of less than 1000
Shorts to Frame Test ohms indicates a serious short. Do not
continue until this condition is corrected.
To test for shorts to frame: The meter may be damaged if you proceed
1. Turn the key switch OFF and disconnect before correcting this condition. To correct
the battery connector. the condition, perform Steps a. through e.

2. To test the battery for shorts to case, a. To identify the cause of the short to
connect a 12V test light to the battery case frame, disconnect circuit components
from battery B+, and then to the battery until the low resistance condition

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Battery State-of-Charge

disappears. Do not reconnect until the leakage current reads less

components one at a time, but leave than 0.001A (1mA). Do not reconnect
them disconnected until the low components one at a time, but leave
resistance reading disappears. Prevent them disconnected until the leakage
disconnected terminals or connectors current reads less than 0.001A (1mA).
from touching the lift truck frame or Prevent disconnected terminals or
other conductive surfaces. connectors from touching the lift truck
frame or other conductive surfaces.
b. The most likely areas to check are:
b. The most likely areas to check are:
• Motors
• Heatsinks • Motors

• Power cables • Heatsinks

• Power circuit components • Power cables

• Control circuit components • Power circuit components

c. Repair or replace the component • Control circuit components

causing the low resistance condition. c. Repair or replace the component(s)
Repeat Step 4. causing the leakage current.
Repeat Step 6.
d. Reconnect all other components
previously disconnected, one at a time, d. Reconnect all other components
measuring resistance between steps. If previously disconnected, measuring
a reading is less than 1000 ohms when current between steps. If a reading is
reconnecting a component, that more than 0.001A (1mA) when
component or its wiring is faulty; repair reconnecting a component, that
or replace as appropriate. component or its wiring is bad. Repair
or replace as appropriate.
e. When, after all components are
reconnected, the readings are greater 7. When, after all components are
than 1000 ohms, continue with the reconnected, you get a reading less than
next step. 0.001A (1mA), there is no short to frame
condition with the lift truck or the battery.
5. Reconnect the battery connector and turn
If you previously removed the battery from
the key switch ON. If the battery was
the lift truck, reinstall the battery.
previously removed, make sure the battery
case does not touch the lift truck frame.
NOTE: The functions being checked must be
Battery State-of-Charge
energized. Example: to check for shorts
to frame in the travel circuit, travel must Battery State-of-Charge (BSOC) is a feature that
be requested. monitors and remembers the charge level of the
battery connected to the lift truck and helps to
6. Use a DMM set to the current function to prevent excessive discharging of that battery.
measure current leakage to the lift truck Operating a lift truck with a discharged battery
frame from lift truck B+, lift truck B– (not can damage both the battery and the electrical
battery B+ and B–), and all fuses and DC components of the lift truck.
motor terminals. Begin measuring at the
highest ampere scale and work toward the At power-up, BSOC tests the battery voltage to
lowest. If the current is less than 0.001A determine if it is the same as it was at
(1mA), go to Step 7. If the current is more power-down. If the voltage is the same, BSOC
than 0.001A (1mA), continue with the assumes it is the same battery and continues to
following steps. monitor the battery for discharge and updates
a. To identify the cause of the short to the Operator Display as required.
frame, disconnect circuit components

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Battery State-of-Charge

If a different battery voltage is detected, BSOC Lift Cutout Adjustment

assumes a different battery is installed and
tests to determine the state-of-charge of the 1. Fill, charge, and install a battery that is
replacement battery. The replacement battery typical of the batteries normally used in
must meet one of the following criteria before this application.
the Operator Display resets and lift is restored. 2. Have a customer operator use the lift
• The replacement battery must have a truck in the normal application until
charge level at least 50% different from the cutout occurs.
previously installed battery, 3. Allow the battery to cool and stabilize for
• The charge value of the replacement at least two hours.
battery must be greater than the 4. Before filling the battery, either take
configured BSOC setting. specific gravity readings or measure open
circuit voltage of the battery cells.
The criteria are determined in this way:
5. Compare the measurements with the
• BSOC compares the charge of the battery battery manufacturer’s recommendations
that was connected to the lift truck with for maximum discharge.
the replacement battery’s charge. A charge
6. Adjust the cutout value as needed and
difference of at least 50% between the two
repeat the previous steps until battery
batteries resets BSOC to show the
cutout occurs at the desired discharge
state-of-charge of the replacement battery
level.
(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
with the Superword. The replacement
battery must be greater than the
configured percent of charge before BSOC
changes. Example - BSOC configured at
95%. Plugging in a battery at anything
below 95% charge does not change the
Operator Display. Older batteries or
applications providing inadequate
charging time could require a lower
configured value for BSOC since older
batteries might be unable to reach a
higher percent charge. Therefore, some
batteries could require BSOC configured
as low as 55% before lift cutout resets and
the Operator Display shows the charge of
the replacement battery.

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Fuses

Fuses
Test/Inspection

Examine the fuse for signs of overheating,

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

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

resistance should be less than 1 ohm.

Table 5-1 lists the fuses for a lift truck with all
available options. Not all lift trucks have all of
the fuses listed.

Table 5-1. Fuse Chart

Fuse Function Location Amps
FU1 Power Fuse for Steer Motor 100
FU2 Power Fuse for Traction Power Amplifiers Contactor Panel 750
FU3 Power Fuse for Lift Pump Motor 500
FU5 Control Fuse for Vehicle Manager B+ 15
FU6 Control Fuse for Vehicle Manager B– Fuse/Relay Card 15
FU7 Control Fuse for Aux Power B+ (See page 5-11.) 15/5
FU8 Control Fuse for Aux Power B– 15/5
FU12 Control Fuse for Strobe and Warning Light (Optional) In-line Wiring 2
FU17 Control Fuse for OCSS (Optional) Photo-Eye Heater In-line Wiring 2
FU20 Fuse for Clipboard Spotlight (Optional) In-line Wiring 2
FU35 iPORT Supplier Wireless Module In-line Wiring 2
FU50 Control Fuse for Blue Spotlight (Optional) In-line Wiring 2
FU51 Control Fuse for Blue Spotlight (Optional) In-line Wiring 2

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Electrical Connections

Electrical Connections 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
Terminology 1, 2, and 3 raised ridges at pin numbers 1, 2,
and 3. See Figure 5-1.
The term “connector JPx” means a mated
connector having two connector halves. One Figure 5-1. Molex Jack and Pin Connector
half has male connectors, or pins (P); the other
half has female connectors, or jacks (J). Pin Identifier Lines
(black lines added for clarity)
When you disconnect a mated JP connector,
you have two connector halves. The individual
connector halves are designated Jx and Px. If
you cannot find a connector designated Jx or
Px, look for JPx, and vice versa.

For example, connector JPD1 is the mated main

Operator Display connector. JD1 represents the
Jack Pins
jack connections (in the harness). PD1
represents the pin connections (on the Operator
Display).

Table 5-2. Electrical Connector Locations and Functions

Connector Function or Routing Location

H-2 Travel Alarm Forward of Battery Connector
JPA Ambient Temperature Sensor Forward of Fuse/Relay Card
JPAB ePort Battery Side Battery Connector
JPB1 Power Amp Fans Near Power Amps
JPB3 Left Side Brake Near Left Traction Motor
JPB4 Right Side Brake Near Right Traction Motor
JPBL10
JPBL11
JPBL12 Blue Spot Light Near Blue Spot Light
JPBL13
JPBL14

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Electrical Connections

Connector Function or Routing Location

JPC3 USB
JPC4 Optional Lever #1 Connector
JPC6 Display Inputs and Outputs
JPC9 FlashWare
JPC10 CAN Digital Inputs/Outputs
JPC12 Handle
JPC12A Lever Option Harness Vehicle Manager
JPC12B Lever Option Harness
JPC14 Bus+ and Bus– CAN Communications
JPC18 Some Coils, Horn, and Travel Alarm
JPC20 Proportional Coils
JPC22 Digital Inputs
JPC24 Inputs from Display, Battery, and Temp Sensor
JPD1 Display
Operator Display
JPD2 Display
JPDS Deadman Pedal Left Side of Operator Compartment
JPEPS Power Source Limit Battery Connector Battery Connector
JPFA Operator Fan Near Operator Fan
JPF1 B– Aux Power, B+ Power Amp (B+K3)
JPF2 B+ Connector (B+K1, B+K2, B+K4)
Fuse/Relay Card
JPF3 B– Connector on Fuse Relay Card
JPF4 Key Switch, EPO, Battery Sense
JPH1 Control Handle Control Handle
JPH2 Mast mounted solenoids Mast
JPL1 Lift Power Amp Lift Power Amp
JPL2 Lift Encoder
Near Lift Motor
JPL3 Lift Motor Temperature Sensor
JPL4AC Lift Power Contactor Configuration (Model 4250)
Near Fuse/Relay Card
JPL4DC Lift Power Contactor Configuration (Model 4150)
JPSI ePort Truck Side Battery Connector
JPS1 Contactor Panel Interface Near Contactor Panel
JPS2 Steering Position Sensor Near Steering Hub
JPS5 High Speed Limit Option
JPS6 Lift Limit Switch Option
Forward of Fuse/Relay Card
JPS13 Right Battery Gate Switch
JPS14 Left Battery Gate Switch
JPT1 Mast Tilt Sensing Option Near Lift Motor

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Electrical Connections

Connector Function or Routing Location

JPTL1 Left Traction Amp Left Traction Amp
JPTL2 Left Traction Motor Encoder
Near Left Traction Motor
JPTL3 Left Traction Motor Temperature Sensor
JPTR1 Right Traction Amp Right Traction Amp
JPTR2 Right Traction Motor Encoder
Near Right Traction Motor
JPTR3 Right Traction Motor Temperature Sensor
JPW1 OCSS - Upper Left Emitter Near Steering Hub
JPW2 OCSS - Upper Right Detector
Right Side of Operator Compartment
JPW3 OCSS - Lower Right Emitter
JPW4 OCSS - Lower Left Detector Near Steering Hub
JPW5 Warning Light Near Warning Light
JPWL1
JPWL2
JPWL3 Working Light Option Near Working Light
JPWL4
JPWL5
JPY1 Weight Pressure Sensor Option Near Hydraulic Manifold
JP3CB ePort Can Bus Near Vehicle Manager
JSX13 Power Source Limit Forward of Fuse/Relay Card
TS1 Terminal Strip for Optional Equipment To Right of Control Handle

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Electrical Connections

Vehicle Manager Connectors

Refer to Figure 5-2 for Vehicle Manager

connector locations.

Figure 5-2. Vehicle Manager Connectors

22 12 10 6 6 4 24 13

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

8 14 10 18 11 20 7 12 3 4

P14 P18 P20 P12 P4

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Electrical Connections

Fuse/Relay Card Connectors

Refer to Figure 5-3 for Fuse/Relay Card

connector locations.

Figure 5-3. Fuse/Relay Card Component and Connector Location

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Fuse/Relay Card Troubleshooting

Fuse/Relay Card approximately 1100 ohms. Replace as

necessary.
Troubleshooting
Refer to “Fuse/Relay Card Connectors” on
page 5-11 for Fuse/Relay Card component and
connector location information.
4. Measure the resistance between circuits 2
Fuses and 3. Welded tips have a resistance less
than 0.5 ohm. Otherwise, there should be
Fuses for system power (FU5 and 6) and Aux an open circuit. Replace as necessary.
power (FU7 and 8) are present on the
Fuse/Relay Card. Refer to page 5-6 for Capacitor and FGND
inspection and testing of fuses.
Problems with the filter capacitors (C1, C2, or
Relays C3) are most frequently seen on lift trucks
equipped with an RF scanner unit. Visually
Relays should be checked when indicated by a inspect the capacitors for any sign of damage.
test or when troubleshooting any of the The capacitors may be physically different from
symptoms listed in the following table. the one pictured. Inspect the mounting screw in
the upper left mounting hole of the Fuse/Relay
Relay Circuit Possible Symptoms Card (marked FGND). If necessary, clean or
Key-ON Key-ON options do not
replace this screw to make sure of a solid
K1 connection to the frame.
aux power power up with the lift truck.
Subsystem Contactors, solenoids,
K2 power brake, horn, or fans do not
operate.
Amp Amps do not power up or
*K3 power have stopped
communicating.
Keep alive Keep-alive accessories for
K4 power Cold Storage do not
function.
*B+ power for amplifiers may come from K2
(JPF1-6) or K3 (JPF1-3). Refer to schematic.

Inspection

Visually inspect the relay and socket for

discoloration, melting, or other signs of heating.
Replace as necessary. If the socket is melted or
damaged, replace the Fuse/Relay Card.

Test
1. Perform “Test O32 - Toggle Relay Enable”
(page 6-115).
2. Turn the key switch OFF and remove the
relay (refer to Removal and Replacement).
3. Measure the resistance across pins 1-A
and 1-B. Resistance should measure

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Fuse/Relay Card Troubleshooting

To test, measure the resistance from the FGND Inrush Protection

screw to any piece of bare metal on the frame
with a DMM. Resistance should be less than A resettable fuse protects the VM battery sense
0.5 ohm. circuit and can be reset by turning the lift truck
OFF momentarily. Opening the fuse frequently
manifests as an FH code along with other
F-series codes.
NOTE: This test should be performed after the
lift truck has had a chance to come to
room temperature.

To test, remove JPF4 from the Fuse/Relay

Card. Measure the resistance from PF4-1 to
PF4-7. Resistance should be approximately
1.3 ohms. Replace the Fuse/Relay Card as
necessary.

Input Diodes
NOTE: Remove connectors JPF1 through JPF4
before performing this test.

To test the relay coil input diodes, locate CR5

and CR6 on the Fuse/Relay Card. Use a DMM
set to the diode function to measure the voltage.
Put the black probe on the banded (right) side of
the diode and the red probe on the non-banded
(left) side. Voltage should be approximately 0.5V
across each diode. An open circuit is shown if
the diodes are tested in the reverse direction.
Replace the Fuse/Relay Card as necessary.

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

DC Motors

DC Motors The commutator must be smooth and clean to

provide maximum brush life. When
commutators are not correctly maintained,
Types of DC Motors carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
There are two primary types of DC Motors (refer the armature.
to Figure 5-4):
• A series-wound motor has only two Remove the brushes from the brush box.
external connections because the Inspect the contact surface and brush length. If
armature and field windings are connected the brush surface has grooves or pit marks, it
internally. indicates the presence of a burr on the
• A permanent magnet motor has two commutator surface.
external connections. The field is produced
by an internal magnet. Good commutation is indicated by a dark
brown polished commutator and an evenly
NOTE: Field connections may be labeled A or S. polished brush wearing surface. See Table 5-3,
Series wound motor field connections “Commutator Surfaces.”
may be labeled D.
If the commutator appears rough, pitted, or has
Figure 5-4. Motor Circuits
signs of burning or heavy arcing between the
Series-Wound Motor commutator bars, remove the motor for
Permanent Magnet
S/D servicing.
Motor
MS+
A2 Service

MS Some conditions, identified in Table 5-3, may

be resolved by cleaning the commutator with a
MP special polishing stone. Polishing the
A1
MS– commutator should only be attempted for the
specified conditions. Refer to “Polishing the
A Commutator” on page 7-58.

Inspection Some conditions can be resolved by recutting

the commutator on a lathe. This requires
special equipment and training and should only
Inspect the commutator for surface condition
be performed at a qualified DC motor repair
and high mica. Most armatures have the mica
facility.
undercut. If the armature on your motor does
not, do not attempt to cut it.

Figure 5-5. Mica Undercutting

Mica Segment

NORMAL
UNDERCUT

High Mica

HIGH MICA

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

DC Motors
Table 5-3. Commutator Surfaces
Condition Probable Cause Commutator Surface

Good condition-light film Uniform coloring indicates satisfactory operation

of the machine and brushes. Acceptable film
color may differ from light to dark due to film
thickness.

Satisfactory This condition can appear in alternating bars as

condition-light and dark shown or every 3rd or 4th bar. This is caused by
pattern imbalances in the windings or other motor
differences. It is not an indication of commutator
problems. The motor should have no issues
running, but the condition may indicate a need
for more frequent inspections.

Unsatisfactory Threading or streaked film on the commutator

condition-streaky film with surface. May be accompanied by rattling or loud
no commutator wear operation. This condition is frequently due to
incorrect brush grade. Environmental conditions,
such as freezer or low humidity, can be a
contributing factor. This condition may be
repaired with a polishing stone if caught soon
enough. Refer to “Polishing the Commutator” on
page 7-58.

Unsatisfactory Patchy colors of differing densities and shape.

condition-uneven film This condition is generally due to unclean
operating conditions and does not indicate
damage to the commutator. Clean the
commutator with a polishing stone (refer to
“Polishing the Commutator” on page 7-58) and
compressed air. Consider more frequent
scheduled maintenance intervals.

Unsatisfactory condition- Dark areas can be isolated or regular. This

film with dark areas condition indicates the commutator is
out-of-round. Continued use may result in
failure and damage to other systems. The motor
should be replaced or recut at a qualified repair
facility.

Unsatisfactory Bars are low on entry and leaving edges causing

condition-example of the brushes to ride on the middle of the bars.
incorrect commutator Continued use may result in failure and damage
machining to other systems. The motor should be replaced
or recut at a qualified repair facility. Consider
more frequent scheduled maintenance intervals.

Unsatisfactory Bars are low in the middle causing brushes to

condition-example of ride on entry and leaving bar edges. Continued
incorrect commutator use may result in failure and damage to other
machining systems. The motor should be replaced or recut
at a qualified repair facility. Consider more
frequent scheduled maintenance intervals.

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

DC Motors

Condition Probable Cause Commutator Surface

Unsatisfactory This is a further development of the third

condition-streaky film with example. Earlier corrective action should have
commutator wear been taken. Continued use may result in failure
and damage to other systems. The motor should
be replaced or recut at a qualified repair facility.
Consider more frequent scheduled maintenance
intervals.

Unsatisfactory Darkening of commutator in sequences two pole

condition-double pole pitches apart. This condition may result from an
pitch armature fault or some other fault. Continued
use may result in failure and damage to other
systems. The motor should be replaced or recut
at a qualified repair facility.

Unsatisfactory This condition may result from storage of the

condition-brush contact machine for long periods of time with the brushes
mark in position. It may also result from operation in
prolonged stall conditions. Storage marks are
easily removed with a polishing stone (refer to
“Polishing the Commutator” on page 7-58). Stall
marks should be cleaned and inspected for
damage or shorts. The motor should be replaced
if damage occurred.

Unsatisfactory This condition is caused by high mica in every

condition-bar edge slot and can be caused by incorrect or excessive
burning-cause high mica stoning. The same effect can occur on one bar
only. Chattering or loud operation may also be
noticed. Continued operation results in increased
brush wear and may result in commutator
damage. The motor should be replaced or recut
at a qualified repair facility.

Unsatisfactory This condition is due to sparking under the

condition-small bright brush. This is caused by overloaded machines or
spots low brush pressure. Check the brush spring
tension (refer to “Motor Brush Spring Tension” on
page 7-58). If not corrected, this condition results
in damage to the commutator. This condition
may be repaired with a polishing stone (refer to
“Polishing the Commutator” on page 7-58) if
caught early and no scoring occurred. If
damaged, the motor should be replaced or recut
at a qualified repair facility.

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

DC Motors

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

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

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

AC Motors

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 5-6.

Figure 5-6. AC Motor Circuitry

AC
3φ

V W

Open Winding

If the AC motor fails with an open winding, the

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

Use a clamping ammeter to measure current in

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

Shorted Winding

If the AC motor fails with a shorted winding, the

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

Use a clamping ammeter to measure current in

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

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Communication Error Code Troubleshooting

Communication Error Code

Troubleshooting
Intermittent Communication Codes

If possible, determine what the operator was

doing when the codes were generated; driving,
plugging, lifting, sounding horn, and so on.

Focus on these circuits for shorts to frame and

external noise being generated that can
interfere with the communication circuits.
Determine where in the SelfTest Cycle the code
is generated (for instance, when the traction
motor is energized or when the horn was
sounded).

Intermittent Codes During SelfTest

Make sure the key switch is turned OFF for at

least five seconds before turning it back to the
ON position. Test the key switch for high
resistance.

Test for shorts to frame. See “Shorts to Frame

Test” on page 5-3. If nothing is found, replace
the key switch.

Intermittent Codes During Travel and/or

Plugging

If the lift truck is equipped with an optional

travel alarm, disconnect the wires to the relay.
If the code goes away, troubleshoot the travel
alarm circuitry.
NOTE: The condition of the travel alarm
suppressor module cannot be checked
with a DMM. If the suppressor module is
suspected to be bad, replace it.

Test and clean the static straps.

Test for shorts to frame. See “Shorts to Frame

Test” on page 5-3.

Communication Code Every Time Key

Is Turned ON

Use “Test I23 - CAN Communication Test”

(page 6-86) to troubleshoot per code shown.

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Troubleshooting Power Source Limit Faults

Troubleshooting Power Source • The power source provides a minimum 10

second warning before opening its main
Limit Faults contactor.
The Power Source Limit (PSL) option provides
The PSL option is activated when the Battery
notification of power system related faults. Lift
Gate option is enabled in FlashWare.
trucks equipped with the PSL option enables
the lift truck’s power source (lithium-ion NOTE: The power source opens the PSL Control
battery, hydrogen fuel cell) to initiate lift truck Assembly Relay (K520) for the Battery
reactions. Gate input into the VM.
• PSL limits travel speed prior to a power
source opening its main contactor. Refer to Diagnosis and Repair if the Check
Battery Gate/Speed Limited message persists.
• The power source generates its own error
codes and status messages.

Diagnosis and Repair

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

1 Disconnect SBX JPEPS-1 D520-2 Perform Step 2

connector and
2 D520/ohms JPEPS-2 D520-4 Perform Step 3 Troubleshoot
0 ohms
wiring
3 JS13-1 JSX13-1 Perform Step 4

4 Disconnect JS13-3 JSX13-3 Perform Step 5

JSX-13 and
PS-13/ohms Replace PSL
5 JS13-2 JSX13-2 Open circuit Perform Step 6 control
assembly

T/S Battery
Run “Test I88 -
Verify EPS error Gate switch or
6 Battery Gate 2”
or code Battery Gate
(page 6-93)
jumper.

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Troubleshooting Public Standard Interface

Troubleshooting Public
Standard Interface
The Public Standard Interface (PSI) option
provides notification of power system related
faults. Lift trucks equipped with the PSI option
provides bi-directional CAN communication
between the lift truck and its power source
(lithium-ion battery, hydrogen fuel cell) to
initiate lift truck reactions.
• The Energy Power Source (EPS) monitors a
“Wake” input (B–Key) from the lift truck.
• The EPS generates its own error codes and
status messages.
• The EPS provides a minimum 10 second
warning before opening its main contactor.

PSI is activated when the EPS option is enabled

in FlashWare.

Refer to Diagnosis and Repair if codes persist.

Diagnosis and Repair - Code UA

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

1 Disconnect SBX JPAB-A S1-1 Perform Step 2 Troubleshoot

0 ohms
2 connector, S1/ohms JPAB-D S1-3 Perform Step 3 wiring

Disconnect SBX connector

3 Connect S1/ohms JPAB-A JPAB-D Open circuit Perform Step 4
Key Switch OFF Replace key
Disconnect SBX connector switch
Troubleshoot
4 Connect S1/ohms JPAB-A JPAB-D 0 ohms
EPS
Key Switch ON

Diagnosis and Repair - Code UB

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

1 Disconnect SBX JPAB-B JC20-11 Perform Step 2

Troubleshoot
connector, JPC18 and 0 ohms Troubleshoot
2 JPAB-C JC18-13 wiring
JPC20/ohms EPS/VM

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Hydraulic Troubleshooting

Hydraulic
Troubleshooting
Auxiliary Hydraulic Pressure

After elevating 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.

The auxiliary hydraulic system pressure is not

adjustable; however, correct function of the
sideshift and tilt capabilities is dependent on
adequate pressure.

Pressure Measurement
A calibrated pressure gauge capable of
measuring 3000 psi (20684 kPa) at mid-range
is required to measure the system pressure.
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the front covers.
3. Connect the pressure gauge to the
auxiliary pressure test port (G2) on the
main hydraulic manifold.
4. Reconnect the battery connector and turn
the key switch ON.
5. Tilt the mast back against the stops.
6. Continue to tilt the mast backward. The
correct pressure is nominally 2000 psi
(13789 kPa), unless there is an
attachment. If the pressure is too high,
replace SOL5. If the pressure is too low,
check the pump, SOL4, and/or SOL5.
7. Turn the key switch OFF and disconnect
the battery connector.
8. Remove the pressure gauge.
9. Reinstall the front covers.

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

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. See “Bleeding the
Hydraulic System” on page 7-82.

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

Lift Function
No Lift - Lift motor does not run
Possible Cause Action
Bad optional lift limit switch Run “Test I05 - Lift Limit (S12)” on page 6-80.

No Lift - Lift motor runs

Possible Cause Action
Priority bypass solenoid Run “Test A81 - Priority Bypass Current (SOL4)” on page 6-68.
(SOL4) not energizing Check for contamination. Flush, fill, and bleed the hydraulic
system if contamination is present.
Dump solenoid (SOL3) not Run “Test O09 - Lift Relief Solenoid (SOL3)” on page 6-104. Check
energizing for contamination. Flush, fill, and bleed the hydraulic system if
contamination is present.
Lift/lower solenoid (SOL2) Run “Test A34 - Lift/Lower Current (SOL2)” on page 6-48. Check
open for contamination. Flush, fill, and bleed the hydraulic system if
contamination is present.
Bad lift pump Replace the lift pump.

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Lift Function

Slow Lift - Lift motor runs

Possible Cause Action

Bad battery Adjust the lift cutout as necessary. See “Lift Cutout Adjustment” on
page 5-5. Replace the battery with a fully-charged battery. Test the
battery for bad cells.
Bad proportional lift/lower Inspect for binding. Run “Test O12 - Lift/Lower Solenoid (SOL2)”
valve on page 6-106.
Relief valve SOL3 stuck open Test the system pressure. Check for contamination. Replace the
valve if contamination is present. Flush, fill, and bleed the
hydraulic system. Run “Test O09 - Lift Relief Solenoid (SOL3)” on
page 6-104.
Plugged or malfunctioning Check for contamination in the valve. Replace the flow control
flow control valve in the lift valves if contamination is present. Flush, fill, and bleed the
cylinder hydraulic system.
Bad lift pump Test the system pressure.
Binding in the mast Inspect the mast and bearings for signs of binding.
Bad lift motor 4150 DC Lift Trucks: Test the lift motor. See “DC Motors” on
page 5-14. Check the amp draw.
4250 AC Lift Trucks: Run “Test O28 - Ramp Lift Motor (AC Lift)” on
page 6-111 and/or “Test I20 - Lift RPM (AC Lift only)” on
page 6-85.
Bad lift motor encoder Run “Test I20 - Lift RPM (AC Lift only)”.

Unable to Pick Up a Load

Possible Cause Action
Battery problems Adjust the lift cutout as necessary.
Replace the battery with a fully-charged battery.
Test the battery for bad cells. See “Battery Procedures” on
page 7-52.
Incorrect lift pressure Check and adjust the lift pressure setting.
adjustment
Bad lift pump Test the system pressure.
Bad lift motor 4150 DC Lift Trucks: Test the lift motor. See “DC Motors” on
page 5-14. Check the amp draw.
4250 AC Lift Trucks: Run “Test O28 - Ramp Lift Motor (AC Lift)” on
page 6-111 and/or “Test I20 - Lift RPM (AC Lift only)” on
page 6-85.
Binding in the mast Inspect the mast and bearings for signs of binding.

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Lower Function

Lower Function
Slow Lower
Possible Cause Action
Binding proportional valve Check the valve operation. Run “Test O12 - Lift/Lower Solenoid
(SOL2)” on page 6-106.
Binding in the mast Inspect the mast and bearings for signs of binding.
Plugged or malfunctioning Check for contamination in the valve. Flush, fill, and bleed the
flow control valve hydraulic system if contamination is present. Replace the flow
control valves in the main lift cylinders if no contamination is
found.

Intermittent Lower
Possible Cause Action
Bad load hold solenoid Run “Test O11 - Load Hold Solenoid (SOL1)” on page 6-105.
Binding proportional valve Check the valve operation. Run “Test O12 - Lift/Lower Solenoid
(SOL2)” on page 6-106.
Plugged or malfunctioning Remove and inspect the valve if still slow. Check for contamination
flow control valve in the valve. Flush, fill, and bleed the hydraulic system if
contamination is present. Replace the flow control valves in the
main lift cylinders if no contamination is found.

Load Drifting/Settling
Possible Cause Action
Load holding solenoid Run “Test O11 - Load Hold Solenoid (SOL1)” on page 6-105. Check
for contamination in the valve. Replace the relief valve if
contamination is present. Flush, fill, and bleed the hydraulic
system.

Auxiliary Functions
No Aux Functions
Possible Cause Action
SOL4 not functioning Perform “Test O36 - Priority Bypass Solenoid (SOL4)” on
correctly page 6-117.

Aux Functions in One Direction Only

Possible Cause Action
SOL6 not functioning Perform “Test O04 - Aux. Direction Solenoid (SOL6)” on
correctly page 6-101.

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Auxiliary Functions

No Sideshift
Possible Cause Action
Configuration Make sure Sideshift is enabled in FlashWare and on the lift truck.
Refer to “Configure Mode” on page 3-11. Check the selected
percentage for Sideshift speed. Refer to “Maintenance Mode” on
page 3-20.
No input Perform “Test A73 - Sideshift Right (S9)” on page 6-59 and “Test
A74 - Sideshift Left (S8)” on page 6-60 or “Test A74 - Sideshift
Left/Right (SW4) (Optional Handle)” on page 6-61.
SOL9L/9R not functioning Perform “Test O08 - Sideshift Solenoid (SOL9L, SOL9R)” on
correctly page 6-103.

No Tilt
Possible Cause Action
Configuration Check the selected percentage for Tilt speed. Refer to “Maintenance
Mode” on page 3-20.
No input Perform “Test A71 - Tilt Down (S7)” on page 6-56 and “Test A72 -
Tilt Up (S6)” on page 6-57, or “Test A72 - Tilt Up/Down (SW4)
(Optional Handle)” on page 6-58.
SOL10 not functioning Perform “Test O07 - Tilt Solenoid (SOL10)” on page 6-102.
correctly

Unrequested Tilt
Possible Cause Action
SOL10 stuck ON Perform “Test O07 - Tilt Solenoid (SOL10)” on page 6-102.

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Symptom Tables: Drive Units

Symptom Tables: Drive

Units
See “Drive Units” on page 7-34 for standard
drive unit repair procedures.

Oil Leaks
Possible Cause Action
Damaged sealing rings Replace the sealing rings, bearing shims, and drive
shaft bearings, if needed.
Worn or damaged drive shaft Replace the sealing rings, bearing shims, drive
shaft bearings, and drive shaft.
Housing/cover joint Reseal.
Worn or damaged housing Replace the drive unit.

Drive Wheel Wobbles

Possible Cause Action
Worn or damaged drive shaft bearings Replace the sealing rings, bearing shims, and drive
shaft bearings.
Worn or damaged drive shaft Replace the sealing rings, bearing shims, drive
shaft bearings, and drive shaft.
Loose wheel mounting hardware Inspect the housing and drive shaft for damage;
re-torque the mounting hardware.

Noise
Possible Cause Action
Worn or damaged drive shaft bearings Replace the sealing rings, bearing shims, and drive
shaft bearings.
Worn or damaged pinion bearings Replace the pinion bearing and pinion shaft nut.
Worn or damaged gear set (drive shaft is in Replace the sealing rings, bearing shims, drive
good condition) shaft bearings, pinion bearings, pinion shaft nut,
and gear set.
Worn or damaged gear set (drive shaft is worn Replace the sealing rings, bearing shims, drive
or damaged) shaft bearings, pinion bearings, pinion shaft nut,
gear set, and drive shaft.
Worn or damaged helical gear and pinion Replace the helical gear and pinion.
Oil level low Add oil.

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Symptom Tables: Travel Functions

Symptom Tables: Travel

Functions
Slow or Sluggish Acceleration
Possible Cause Action
Dragging brake Replace the brake or worn parts (see notes 1 and 2).
Worn wheel bearings Replace the wheel bearings (see note 1).
Debris in wheel axle Remove debris (see notes 1 and 2).
Binding drive unit Remove the motor and check movement (see notes 1 and 2).
Note 1: Perform “Test A11 - Left Traction Current” on page 6-39 and “Test A67 - Right Traction
Current” on page 6-53 with the drive tires off the floor and the lift truck correctly blocked. At full
travel speed, readings should be approx. 30A to 50A. Focus on the corresponding drive unit if one
test is significantly higher than the other.
Note 2: Install drive wheel fenders if the lift truck operates in a dusty or dirty environment. Refer to
the parts manual.

Slow Travel
Possible Cause Action
Note: Determine if the problem is mechanical or electrical.
Mechanical:
Dragging brake Replace the brake or worn brake parts (see note).
Debris in wheel axle Remove debris (see note).
Binding drive unit Remove the motor and check movement (see note).
Binding in control handle Run “Test A22 - Traction Request” on page 6-45 to determine if the
controller is still seeing a 100% request.
Note: Perform “Test A11 - Left Traction Current” on page 6-39 and “Test A67 - Right Traction
Current” on page 6-53 with the drive tires off the floor and the lift truck correctly blocked. At full
travel speed, readings should be approx. 30A to 50A. Focus on the corresponding drive unit if one
test is significantly higher than the other.
Electrical:
Bad mast speed limit switch Run “Test I02 - Mast Tilt Speed Reduction (S11)” on page 6-79.
(S11) or associated wiring
Incorrect reading from the Run “Test I89 - Steer Position Sensor” on page 6-94.
steer position sensor
Speed limited due to traction Run “Test A08 - Left Traction Motor Temp” on page 6-36, “Test A10
motor or TPA temperature - Left Traction Power Amp Temp” on page 6-38, “Test A65 - Right
(temperature icon Traction Power Amp Temp” on page 6-52, and “Test A68 - Right
illuminated) Traction Motor Temp” on page 6-54.
Bad encoder pulses from the Run “Test I19 - Left Traction RPM” on page 6-84 and/or “Test I82 -
traction motor encoder Right Traction RPM” on page 6-91.

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Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Sluggish or No Steering

Sluggish or No Steering
Possible Cause Action
Pump Check the working pressure (may need to install a fitting to access
and test pressure). The working pressure should be approximately
1000 psi (6895 kPa).
Pressure relief set too low Check the relief (bypass) pressure (may need to install a fitting to
access and test pressure). The relief pressure should be 1550 psi
(12410 kPa). Adjust the relief pressure (the relief pressure
adjustment screw is located on the steering valve - under the
plastic plug) if necessary.

Pressure Test Fitting Relief Pressure Adjustment Screw

(under plastic plug)

Motor Check the amperage, inspect the brushes and holders, and motor
cables.
Mechanical Check the steer chain, pump coupling, and steerable wheel
bearings.

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Symptom Tables: Electrical Symptoms

Symptom Tables:
Electrical Symptoms
NOTE: Reference the electrical schematics.
NOTE: For intermittent issues with optional
devices such as RF units, check the
Fuse/Relay Card “Capacitor and FGND”
on page 5-12.

Electrical Motors
Motor Arcing (DC Motors only)
Possible Cause Action
Worn brushes or incorrect Replace the brushes and brush springs.
brush tension
Partially shorted motor Replace the motor.
armature or field
Rough or pitted motor Replace the motor.
commutator

Motor Overheating
Possible Cause Action
Dragging brake Replace the brake or worn brake parts (see note). See “Drive Units”
on page 7-34.
Application exceeds the Check with the Service Manager to verify the application.
designed workload -- short
runs with
plugging/acceleration or
heavy-duty lifting cycles
Bad battery Check the voltage, both open circuit and under load. Replace with
a fully-charged good battery if necessary.
Incorrect BSOC Cutout value Check the battery specific gravity at cutout, after the battery has
stabilized. Compare to the battery manufacturer specifications for
a discharged battery. Adjust the BSOC Cutout as needed.
Cable, terminal, or wiring Replace the wiring or cables as necessary.
problems. Look for discolored Check the cable connection torque.
terminals, loose or damaged
crimps
Worn, damaged, or bad Inspect the motor brushes.
brushes or springs (DC Check the brush spring tension.
Motors only)
Binding gearbox or pump Check the gearbox or pump for binding (see note for traction
motors; check the amp draw for the lift motor). Clean,
repair/replace as necessary.
Hydraulic fluid viscosity too Replace the hydraulic fluid with the correct fluid. See “Lubrication
high or too low Specification Chart” on page A-2.
Pressure relief too high Adjust SOL3.
Note: Perform “Test A11 - Left Traction Current” on page 6-39 and “Test A67 - Right Traction
Current” on page 6-53 with the drive tires off the floor and the lift truck correctly blocked. At full
travel speed, readings should be approx. 30A to 50A. Focus on the corresponding drive unit if one
test is significantly higher than the other.

5-30 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section 5. Troubleshooting

Operator Display

Operator Display
Scrambled or Intermittent Display
Possible Cause Action
Loose harness or display Reseat the harness connections. Check the schematic for
connectors display-related connectors.
Intermittent wires or Test for continuity while flexing the harness. Replace the individual
connectors in the harness wire or the entire wiring harness if discontinuity is found.
Electrical noise in motors Check the tightness of the motor power cable connections. Check
the motor brushes for arcing. Replace if necessary.
Worn or missing static straps Replace as necessary.

Dead Lift Truck

Display is Dark - No functions operate
Possible Cause Action
No LED illuminated on circuit Refer to the “Pinout Matrix” on page 8-13. Check for B+ at the
cards following locations with respect to TP4:
• FU5
• JPF4-10
• JPC14-12
Check for B– at the following locations with respect to TP1:
• FU6
• JPF3-3, 4, 5, 6, 7
• JPC14-1, 2, 8, 9 and 10
Refer to the Diagnosis and Repair table in “Test A14 - Ext. Supply
Sense (12VDC)” on page 6-41 if all of the above locations have the
correct voltages.

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Section 5. Troubleshooting Models 4150/4250 Maintenance Manual

Dead Lift Truck

5-32 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Section 6. Messages, Codes, and Tests

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Summary List

Summary List
Messages
Step Off the Deadman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-7
Release Control Handle to Resume Operation . . . . . . . . . . . . . . . . . .. . .. . 6-7
Lift CutOut Pending... Low battery . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-7
EPO Depressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-7
Scheduled Maintenance Due . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-7
Lift Cutout, Scheduled Maintenance Due . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-8
Battery Low, No Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-8
Speed Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-8
Press Bypass Switch to Continue Lifting . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-8
Release Bypass Switch to Continue Lifting . . . . . . . . . . . . . . . . . . . . .. . .. . 6-8
Stalled, Release Control Handle to Resume Operation . . . . . . . . . . . .. . .. . 6-9
Release Handle Button to Resume Operation . . . . . . . . . . . . . . . . . . .. . .. . 6-9
Release Lift to Resume Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-9
Release Tilt to Resume Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-9
Release Side Shift to Resume Operation . . . . . . . . . . . . . . . . . . . . . . .. . .. 6-10
Release Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 6-10
Press TILT BACK to Unclamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 6-10
Lower Mast or Tilt Back to Resume Travel and Lift . . . . . . . . . . . . . . .. . .. 6-10
Lower Below Limit Switch To Initialize Bypass Functions . . . . . . . . . .. . .. 6-10
Lift Stalled, Re-key to Resume Operation . . . . . . . . . . . . . . . . . . . . . .. . .. 6-10
Check Battery Gates/Speed Limited . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 6-11
Entrance Beam Blocked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 6-11
Invalid Option Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 6-11
View SWM Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 6-11
Loss of Connection to the SWM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 6-11
Log In to Enable Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 6-11

Codes
Code 1H: Overheated, Allow Time to Cool. . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 2A: Left Traction Motor Approaching Overtemp . . . . . . . . . . . . . . . . . 6-12
Code 2E: Left Traction Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . 6-12
Code 2G: Phase Open on Left Traction Motor . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 2H: Failure Detected in Left Traction Motor Speed Feedback Encoder 6-13
Code 2L: Left TPA Severe Undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 2M: Left TPA Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 2Q: Left TPA Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 2T: Left TPA Current Calibration Error . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 2U: Left TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . 6-14
Code 2V: Left TPA High DC Bus Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 2W: Left TPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 2X: Left TPA Power Supply Out-of-Range. . . . . . . . . . . . . . . . . . . . . . 6-14
Code 2Y: Incorrect Left TPA Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 42: LPC Detected Closed When Commanded Open . . . . . . . . . . . . . . 6-15
Code 43: LPC Detected Open When Commanded Closed . . . . . . . . . . . . . . 6-15
Code 4B: Steer Contactor Detected Closed When Commanded Open . . . . . 6-15
Code 4C: Steer Contactor Detected Open When Commanded Closed . . . . . 6-15

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Codes

Code 4F: TPC Detected Closed When Commanded Open . . . . . . . .. .. . .. . 6-15

Code 4G: TPC Detected Open When Commanded Closed . . . . . . . .. .. . .. . 6-16
Code 4J: TPC Contactor Coil Open or Shorted TPC . . . . . . . . . . . .. .. . .. . 6-16
Code 4K: LPC Contactor Coil Open or Shorted . . . . . . . . . . . . . . . .. .. . .. . 6-16
Code 59: CAN Transmission Buffer Error. . . . . . . . . . . . . . . . . . . .. .. . .. . 6-16
Code 5A: CAN-Bus Error Overflow . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-16
Code 5B: CAN Transmission Buffer Error . . . . . . . . . . . . . . . . . . .. .. . .. . 6-16
Code 5F: No Communications Received by VM from Right TPA . . .. .. . .. . 6-17
Code 5G: No Communications Received by VM from Left TPA . . . .. .. . .. . 6-17
Code 5J: No Communications Received by VM from LPA . . . . . . . .. .. . .. . 6-17
Code 5M: Left TPA NMT Start Timeout. . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-17
Code 5P: LPA NMT Start Timeout . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-17
Code 5U: Right TPA NMT Start Timeout. . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-17
Code 5Y: Incorrect Right TPA Installed. . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-18
Code 61: Mast Switch Not Sensed . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-18
Code 6D: Pressure Sensor Output Voltage Out-of-Range . . . . . . . .. .. . .. . 6-18
Code 7A: Lift Motor Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-18
Code 7E: Lift Motor Temperature Sensor Out-of-Range . . . . . . . . .. .. . .. . 6-18
Code 7F: LPA Overtemp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-18
Code 7G: LPA Motor Phase Open . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-19
Code 7H: Lift Motor Feedback Encoder Failure Detected . . . . . . . .. .. . .. . 6-19
Code 7L: LPA Severe Undervoltage. . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-19
Code 7M: LPA Failed to Precharge . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-19
Code 7Q: LPA Low Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-19
Code 7T: LPA Current Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-20
Code 7U: LPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . .. .. . .. . 6-20
Code 7V: LPA High Voltage on DC Bus . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-20
Code 7W: LPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-20
Code 7X: LPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . .. .. . .. . 6-20
Code 7Y: Incorrect LPA Installed . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-21
Code 80: Throttle Potentiometer (VR1) Voltage Out-of-Range . . . . .. .. . .. . 6-21
Code 81: Lift/Lower Potentiometer (VR2) Voltage Out-of-Range . . .. .. . .. . 6-21
Code 82: Handle Heater Open . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-21
Code 83: Throttle Potentiometer (VR1) Out-of-Neutral . . . . . . . . . .. .. . .. . 6-21
Code 84: Brakes Inoperable - Not Applied . . . . . . . . . . . . . . . . . . .. .. . .. . 6-21
Code 87: Mast Tilt Centering Pot (VR6) Out-of-Range. . . . . . . . . . .. .. . .. . 6-22
Code 88: 5V Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-22
Code 8A: OCSS Photo Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-22
Code 8F: Lift/Lower Potentiometer Out-of-Neutral . . . . . . . . . . . . .. .. . .. . 6-22
Code 8J: Ambient Temperature Sensor Out-of-Range . . . . . . . . . .. .. . .. . 6-22
Code 8L: Brake Feedback Current Out-of-Range . . . . . . . . . . . . . .. .. . .. . 6-22
Code 8M: Internal Handle Heater Failure. . . . . . . . . . . . . . . . . . . .. .. . .. . 6-23
Code 8P: Tilt Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . . .. .. . .. . 6-23
Code 8R: Tilt Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-23
Code 8S: Sideshift Potentiometer Out-of-Range . . . . . . . . . . . . . . .. .. . .. . 6-23
Code 8T: Sideshift Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-23
Code 8U: Attachment Function 1 Out-of-Range . . . . . . . . . . . . . . .. .. . .. . 6-23
Code 8V: Attachment Function 1 Out-of-Neutral . . . . . . . . . . . . . .. .. . .. . 6-24
Code 8W: Attachment Function 2 Out-of-Range. . . . . . . . . . . . . . .. .. . .. . 6-24
Code 8X: Attachment Function 2 Out-of-Neutral . . . . . . . . . . . . . .. .. . .. . 6-24
Code 8Z: Drive Train Error Detected . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-24
Code A0: Incorrect Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-24

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Analog Tests

Code A2: Software Compatibility Issue with VM and Left TPA. . . . . . ... .. 6-25
Code A3: Software Compatibility Issue with VM and Right TPA . . . . ... .. 6-25
Code A4: Software Compatibility Issue with VM and LPA . . . . . . . . . ... .. 6-25
Code A5: Left TPA Internal Software Fault . . . . . . . . . . . . . . . . . . . . ... .. 6-25
Code A6: Right TPA Internal Software Fault . . . . . . . . . . . . . . . . . . . ... .. 6-25
Code A7: LPA Internal Software Fault . . . . . . . . . . . . . . . . . . . . . . . ... .. 6-25
Code AG: Communications To/From Operator Display Failed . . . . . ... .. 6-26
Code AH: Bad Operator Display Checksum . . . . . . . . . . . . . . . . . . . ... .. 6-26
Code AL: VM Battery Backed Up RAM Failed . . . . . . . . . . . . . . . . . . ... .. 6-26
Code AP: Left TPA Software Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 6-26
Code AR: Right TPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 6-26
Code AT: LPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 6-26
Code EC: COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 6-27
Code FE: Internal VM Circuit for BSOC Not Calibrated . . . . . . . . . . ... .. 6-27
Code FG: +5V Reference Voltage and +12V Power Supply Failure . . . ... .. 6-27
Code FH: Battery Voltage Out-of-Range . . . . . . . . . . . . . . . . . . . . . . ... .. 6-27
Code FN: Relays Did Not Open at Power Off . . . . . . . . . . . . . . . . . . . ... .. 6-27
Code FT: VM Internal Software Error . . . . . . . . . . . . . . . . . . . . . . . . ... .. 6-28
Code G2: Bad Steer Position Reference Input . . . . . . . . . . . . . . . . . . ... .. 6-28
Code HA: Right Traction Motor Overtemp. . . . . . . . . . . . . . . . . . . . . ... .. 6-28
Code HE: Right Traction Motor Temperature Sensor Out-of-Range. . ... .. 6-28
Code HF: Right TPA Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 6-28
Code HG: Right Traction Motor Phase Open . . . . . . . . . . . . . . . . . . . ... .. 6-29
Code HH: Right Traction Motor Feedback Encoder Failure . . . . . . . . ... .. 6-29
Code HL: Right TPA Severe Undervoltage . . . . . . . . . . . . . . . . . . . . . ... .. 6-29
Code HM: Right TPA Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . ... .. 6-29
Code HQ: Right TPA Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 6-29
Code HT: Right TPA Current Sensor Fault . . . . . . . . . . . . . . . . . . . . ... .. 6-30
Code HU: Right TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . ... .. 6-30
Code HV: Right TPA High DC Bus Voltage . . . . . . . . . . . . . . . . . . . . ... .. 6-30
Code HW: Right TPA Software Error . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 6-30
Code HX: Right TPA Power Supply Out-of-Range . . . . . . . . . . . . . . . ... .. 6-30
Code M9: Lift Limited... Installed Battery is Too Light . . . . . . . . . . . ... .. 6-31
Code T0: Aux Relief SOL5 Open Circuit or Constant Low . . . . . . . . . ... .. 6-31
Code T3: Proportional Lower SOL2 Open Circuit or Constant Low . . ... .. 6-31
Code T4: Priority Bypass SOL4 Open Circuit or Constant Low . . . . . ... .. 6-31
Code UA: The B– Key switch input is not sensed by the EPS . . . . . . ... .. 6-31
Code UB: EPS communication issue OR issue with the EPS. . . . . . . ... .. 6-32
Code VC: Internal Error in VM Communications . . . . . . . . . . . . . . . ... .. 6-32

Analog Tests
Test A04 - Travel Pot (VR1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Test A05 - Lift/Lower Pot (VR2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Test A08 - Left Traction Motor Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Test A09 - Lift Motor Temp (AC Lift only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Test A10 - Left Traction Power Amp Temp . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Test A11 - Left Traction Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Test A13 - Weight Sensor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Test A14 - Ext. Supply Sense (12VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Test A15 - Battery Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Test A19 - Lift Power Amp Temp (AC Lift only) . . . . . . . . . . . . . . . . . . . . . . . 6-43
Test A20 - Lift Current (AC Lift only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Input Tests

Test A22 - Traction Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-45

Test A23 - Lift Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-46
Test A26 - Pot Supply (5VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-47
Test A34 - Lift/Lower Current (SOL2) . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-48
Test A35 - Brake Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-49
Test A36 - Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-50
Test A40 - Handle Heater Reference Voltage (optional) . . . . . . . . . . . .. . .. . 6-51
Test A65 - Right Traction Power Amp Temp . . . . . . . . . . . . . . . . . . .. . .. . 6-52
Test A67 - Right Traction Current . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-53
Test A68 - Right Traction Motor Temp . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-54
Test A69 - Mast Tilt Centering Pot (VR6) . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-55
Test A71 - Tilt Down (S7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-56
Test A72 - Tilt Up (S6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-57
Test A72 - Tilt Up/Down (SW4) (Optional Handle) . . . . . . . . . . . . . . .. . .. . 6-58
Test A73 - Sideshift Right (S9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-59
Test A74 - Sideshift Left (S8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-60
Test A74 - Sideshift Left/Right (SW4) (Optional Handle) . . . . . . . . . .. . .. . 6-61
Test A75 - Attach Fcn 1 (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-62
Test A75 - Attach Fcn 1 (SW3) (Optional Handle) . . . . . . . . . . . . . . .. . .. . 6-63
Test A76 - Attach Fcn 2 (S5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-64
Test A76 - Attach Fcn 2 (SW2) (Optional Handle) . . . . . . . . . . . . . . .. . .. . 6-65
Test A77 - EPO (S21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-66
Test A80 - Aux Select Current (SOL6) . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-67
Test A81 - Priority Bypass Current (SOL4) . . . . . . . . . . . . . . . . . . . .. . .. . 6-68
Test A82 - Aux. Relief Current (SOL5) . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-69
Test A96 - EPS Current Actual . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-70
Test A97 - EPS Voltage Actual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-71
Test A98 - EPS Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-72
Test A99 - H2O Snse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-73
Test A100 - BSM Comm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-74
Test A103 - Max EPS Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-75
Test A104 - Max EPS Regen Charge . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-76

Input Tests
Test I00 - Deadman (S2) . . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-78
Test I02 - Mast Tilt Speed Reduction (S11) ........ . .. .. . .. . . . . . . . . . 6-79
Test I05 - Lift Limit (S12) . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-80
Test I13 - Lift Contactor (DC Lift) . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-81
Test I14 - Steer Contactor . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-82
Test I15 - Horn (S3, SW1) . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-83
Test I19 - Left Traction RPM . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-84
Test I20 - Lift RPM (AC Lift only) . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-85
Test I23 - CAN Communication Test . . . . . ........ . .. .. . .. . . . . . . . . . 6-86
Test I65 - Tilt Position SW (S18) . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-88
Test I80 - OCSS - Low . . . . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-89
Test I81 - OCSS - High . . . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-90
Test I82 - Right Traction RPM . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-91
Test I87 - Battery Gate 1 . . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-92
Test I88 - Battery Gate 2 . . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-93
Test I89 - Steer Position Sensor . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-94
Test I91 - iPort Communication . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-95

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Output Tests

Output Tests
Test O00 - TPC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . . 6-98
Test O01 - Steer Contactor (STR) . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . . 6-99
Test O02 - Lift Power Contactor (LPC) . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-100
Test O04 - Aux. Direction Solenoid (SOL6) . . . . . . . . . . . . . . .. . .. .. . . . 6-101
Test O07 - Tilt Solenoid (SOL10) . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-102
Test O08 - Sideshift Solenoid (SOL9L, SOL9R) . . . . . . . . . . . .. . .. .. . . . 6-103
Test O09 - Lift Relief Solenoid (SOL3) . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-104
Test O11 - Load Hold Solenoid (SOL1) . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-105
Test O12 - Lift/Lower Solenoid (SOL2) . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-106
Test O18 - Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-107
Test O19 - Ramp Sounder . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-108
Test O20 - Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-109
Test O23 - Toggle Amplifier Fan . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-110
Test O28 - Ramp Lift Motor (AC Lift) . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-111
Test O29 - Ramp Traction Motors . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-112
Test O30 - Electric Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-114
Test O32 - Toggle Relay Enable . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-115
Test O33 - Handle Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-116
Test O36 - Priority Bypass Solenoid (SOL4) . . . . . . . . . . . . . . .. . .. .. . . . 6-117
Test O37 - Aux. Relief Solenoid (SOL5) . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-118
Test O45 - HSA1 Solenoid (SOL7C, SOL7R) . . . . . . . . . . . . . .. . .. .. . . . 6-119
Test O47 - Customer Output . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-120

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Messages and Codes

Messages and Codes

Section 6. Messages, Codes, and Tests

Messages
Message Shown: Step Off the Deadman
Icon Code Title/Reason Tests to Run Notes/Corrective Action

Step Off the Deadman “Test I00 - Deadman (S2)” Release the deadman.
Deadman (S2) is activated while the lift (Page 6-78)
truck is trying to perform SelfTest.

Message Shown: Release Control Handle to Resume Operation

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

Release Control Handle to Resume “Test A04 - Travel Pot Release the throttle, step
Operation (VR1)” (Page 6-34) on the deadman, resume
Control handle moved before deadman travel.
pressed.

Message Shown: Lift CutOut Pending...Low battery

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

Lift CutOut Pending...Low battery None Message is shown for five

Battery low. minutes, then lift is
disabled. Change the
battery.

Message Shown: EPO Depressed

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

EPO Depressed “Test A77 - EPO (S21)” Lift the EPO button and
VM senses the EPO switch is open (IN). (Page 6-66) cycle the key switch to
clear.

Message Shown: Scheduled Maintenance Due

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

Scheduled Maintenance Due None Perform scheduled

This message occurs when scheduled maintenance. Reset
maintenance is due and Maintenance Maintenance Minder in
Minder is enabled in Configure Mode. Configure Mode.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Messages

Message Shown: Lift Cutout, Scheduled Maintenance Due

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

Lift Cutout, Scheduled Maintenance None Lift is disabled. Perform

Due scheduled maintenance.
This message occurs when scheduled Reset Maintenance Minder
maintenance is due and Maintenance in Configure Mode.
Minder is enabled in Configure Mode.

Message Shown: Battery Low, No Lift

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

Battery Low, No Lift If charging or changing the Lift is disabled.

Lift interrupt occurred due to the battery does not clear the Charge/change the
battery state-of-charge. message, run “Test A15 - battery.
Battery Volts” (Page 6-42)

Message Shown: Speed Limited

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

Speed Limited “Test A08 - Left Traction Traction or lift speed is

An overtemperature condition is Motor Temp” (Page 6-36) reduced when a traction
detected. “Test A09 - Lift Motor motor or the lift motor
Temp (AC Lift only)” becomes overheated. Allow
(Page 6-37) time for the lift truck to
“Test A10 - Left Traction cool.
Power Amp Temp”
(Page 6-38)
“Test A19 - Lift Power Amp
Temp (AC Lift only)”
(Page 6-43)
“Test A65 - Right Traction
Power Amp Temp”
(Page 6-52)
“Test A68 - Right Traction
Motor Temp” (Page 6-54)

Message Shown: Press Bypass Switch (^) To Continue Lifting

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

Press Bypass Switch to Continue “Test I05 - Lift Limit (S12)” Lift is disabled unless the
Lifting (Page 6-80) bypass switch (UP button)
Lift Inhibit Switch (S12) was crossed. is activated. Lower the
carriage below the lift
inhibit switch.

Message Shown: Release Bypass Switch (^) To Continue Lifting

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

Release Bypass Switch to Continue None Release the UP arrow on

Lifting the operator display.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Messages

Message Shown: Stalled, Release Control Handle to Resume Operation

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

Stalled, Release Control Handle to “Test I19 - Left Traction Travel or lift speed is
Resume Operation RPM” (Page 6-84) limited when the
No encoder pulses are received by the “Test I82 - Right Traction corresponding power amp
Power Amplifiers. RPM” (Page 6-91) is not receiving encoder
“Test I20 - Lift RPM pulses. Cycle the key
(AC Lift only)” (Page 6-85) switch to clear.

Message Shown: Release Handle Button to Resume Operation

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

Release Handle Button to Resume “Test I15 - Horn (S3, SW1)” This message appears prior
Operation (Page 6-83) to an out-of-range code
Digital input from the handle activated “Test A71 - Tilt Down (S7)” being shown.
at startup. (Page 6-56)
“Test A72 - Tilt Up (S6)”
(Page 6-57)
“Test A72 - Tilt Up/Down
(SW4) (Optional Handle)”
(Page 6-58)
“Test A73 - Sideshift Right
(S9)” (Page 6-59)
“Test A74 - Sideshift Left
(S8)” (Page 6-60)
“Test A74 - Sideshift
Left/Right (SW4) (Optional
Handle)” (Page 6-61)
“Test A75 - Attach Fcn 1
(S4)” (Page 6-62)
“Test A76 - Attach Fcn 2
(S5)” (Page 6-64)

Message Shown: Release Lift to Resume Operation

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

Release Lift to Resume Operation “Test A05 - Lift/Lower Pot Release the lift control,
Lift pot out of Learned neutral position (VR2)” (Page 6-35) step on the deadman
at startup. pedal.

Message Shown: Release Tilt to Resume Operation

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

Release Tilt to Resume Operation “Test A72 - Tilt Up/Down Release the tilt control.
Applies to lift trucks equipped with an (SW4) (Optional Handle)”
optional handle. Tilt control out of (Page 6-58)
Learned neutral at startup.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Messages

Message Shown: Release Side Shift to Resume Operation

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

Release Side Shift to Resume “Test A74 - Sideshift Release the sideshift
Operation Left/Right (SW4) (Optional control.
Applies to lift trucks equipped with an Handle)” (Page 6-61)
optional handle. Sideshift control out of
Learned neutral at startup.

Message Shown: Release Horn Button

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

Release Horn Button “Test I15 - Horn (S3, SW1)” Release the horn button.
Digital input from the handle activated (Page 6-83)
longer than ten seconds.

Message Shown: Press TILT BACK to Unclamp

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

Press TILT BACK to Unclamp “Test A72 - Tilt Up/Down N/A

Informational message to advise the (SW4) (Optional Handle)”
operator to activate the Tilt Back (Page 6-58)
button when the lift truck is equipped
with a clamp.

Message Shown: Lower Mast or Tilt Back to Resume Travel and Lift
Icon Code Title/Reason Tests to Run Notes/Corrective Action

Lower Mast or Tilt Back to Resume “Test I02 - Mast Tilt Speed Follow the instructions on
Travel and Lift Reduction (S11)” the display. Perform tests if
Informational message for lift trucks (Page 6-79) the message still scrolls.
equipped with bottler’s tilt. “Test I65 - Tilt Position SW
(S18)” (Page 6-88)

Message Shown: Lower Below Limit Switch To Initialize Bypass Functions

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

Lower Below Limit Switch To None Lower below the lift limit
Initialize Bypass Functions switch.

Message Shown: Lift Stalled, Re-key to Resume Operation

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

Lift Stalled, Re-key to Resume “Test I20 - Lift RPM Lift speed is limited. Cycle
Operation (AC Lift only)” (Page 6-85) the key switch to clear.
LPA is not receiving encoder pulses.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Messages

Message Shown: Check Battery Gates/Speed Limited

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

Check Battery Gates/Speed Limited “Test I87 - Battery Gate 1” Travel speed limited to
Battery Gate Switch open. (Page 6-92) 1.0 mph (1.6 km/h). Clear
“Test I88 - Battery Gate 2” condition.
(Page 6-93)

Message Shown: Entrance Beam Blocked

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

Entrance Beam Blocked “Test I80 - OCSS - Low” Clear condition. Clean the
Optional OCSS beam blocked. (Page 6-89) photo eyes.
“Test I81 - OCSS - High”
(Page 6-90)

Message Shown: Invalid Option Enabled

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

Invalid Option Enabled Use FlashWare to set a Cycle the key switch to
FlashWare options incorrectly configured. valid configuration. clear.
Verify options are configured correctly in
FlashWare. Some options are to be used
for a specific model. If selected when they
should not be selected, this message is
shown.

Message Shown: View SWM Display

Icon Code Title/Reason Tests to Run Notes/Corrective Action
View SWM Display Check to see that JPC9 is connected. iPORT related
message. Refer to iPORT Kit Installation and Maintenance
Instructions, iWAREHOUSE Essential Installation and
Maintenance Instructions and User Guide, or
iWAREHOUSE Evolution Installation and Maintenance
Instructions and User Guide.

Message Shown: Loss of connection to the SWM

Icon Code Title/Reason Tests to Run Notes/Corrective Action
Loss of Connection to the SWM iPORT related message. Refer to iPORT Kit Installation
Communication between the SWM and and Maintenance Instructions, iWAREHOUSE Essential
the VM was interrupted. Installation and Maintenance Instructions and User Guide,
or iWAREHOUSE Evolution Installation and Maintenance
Instructions and User Guide.

Message Shown: Log in to enable truck

Icon Code Title/Reason Tests to Run Notes/Corrective Action
Log In to Enable Truck iPORT related message. Refer to iPORT Kit Installation
Operator not logged on to the SWM. and Maintenance Instructions, iWAREHOUSE Essential
Installation and Maintenance Instructions and User Guide,
or iWAREHOUSE Evolution Installation and Maintenance
Instructions and User Guide.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Codes

Codes
NOTE: Codes C46 and C47 are iPORT related
codes. Refer to iPORT Kit Installation
and Maintenance Instructions. All “M”
Series codes are iBATTERY related error
codes. Refer to iBATTERY Battery
Monitoring System Installation and
Maintenance Instructions.

Message Shown: CODE 1H Overheated, Allow Time to Cool

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

Code 1H: Overheated, Allow Time to “Test A10 - Left Traction Cycle the key switch to
Cool Power Amp Temp” clear after the TPA cools.
The left TPA reported its internal (Page 6-38)
temperature is less than –40°F (–40°C) “Test I89 - Steer Position
or greater than +203°F (+95°C). Sensor” (Page 6-94)

Message Shown: CODE 2A Overheated, Allow Time to Cool

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

Code 2A: Left Traction Motor “Test A08 - Left Traction Travel speed is linearly
Approaching Overtemp Motor Temp” (Page 6-36) derated starting at 266°F
The TPA senses that the Traction Motor “Test I89 - Steer Position (130°C). Travel speed is
is approaching overtemperature. Sensor” (Page 6-94) limited to 1 mph
Traction performance is limited. (1.6 km/h) at 300°F
(149°C). Cycle the key
switch to clear after the
traction motor cools.

Message Shown: CODE 2E Inform Service

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

Code 2E: Left Traction Motor Temp “Test A08 - Left Traction Travel is limited to 6.5 mph
Sensor Out-of-Range Motor Temp” (Page 6-36) (10.4 km/h). The code
The Traction Motor temperature sensor clears when the reason for
is open or shorted. the fault is corrected.

Message Shown: CODE 2G Inform Service

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

Code 2G: Phase Open on Left “Test O29 - Ramp Traction Travel is disabled. Cycle
Traction Motor Motors” (Page 6-112) the key switch to clear.
The TPA detected no current draw in
one of the three phases of the motor.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Codes

Message Shown: CODE 2H Inform Service

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

Code 2H: Failure Detected in Left “Test I19 - Left Traction Travel is limited to 1 mph
Traction Motor Speed Feedback RPM” (Page 6-84) (1.6 km/h). This code is
Encoder shown during Run if a
single channel is bad.
STALLED is shown if one
or both channels are bad at
SelfTest. Cycle the key
switch to clear.

Message Shown: CODE 2L Inform Service

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

Code 2L: Left TPA Severe None Travel performance may be

Undervoltage limited. Cycle the key
switch to clear. Check the
wiring/contactor tips.
Replace the battery with a
fully charged battery.

Message Shown: CODE 2M Inform Service

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

Code 2M: Left TPA Pre-Charge Failed None Travel is disabled. Check
Left TPA failed to precharge correctly. for B+ at the left TPA+
terminal. Cycle the key
switch to clear. Replace the
left TPA if the code does not
clear. The VM cannot cause
this code.

Message Shown: CODE 2Q Inform Service

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

Code 2Q: Left TPA Low Voltage None Travel performance may be
Left TPA has detected less than 17V at limited. Cycle the key
the + terminal. switch to clear. Check the
wiring/ contactor tips.
Replace the battery with a
fully charged battery.

Message Shown: CODE 2T Inform Service

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

Code 2T: Left TPA Current None Travel is limited to 2.5 mph
Calibration Error (4.0 km/h). Cycle the key
The TPA sensed a current calibration switch to clear. Replace the
error. left TPA if the code does not
clear. The VM cannot cause
this code.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Codes

Message Shown: CODE 2U Inform Service

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

Code 2U: Left TPA Overcurrent or None Travel is disabled. Cycle

Short Circuit the key switch to clear.
The TPA sensed current in excess of Check for shorted traction
400A. motor power cables.
Replace the left TPA if the
code does not clear. The
VM cannot cause this code.

Message Shown: CODE 2V Inform Service

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

Code 2V: Left TPA High DC Bus None Travel is disabled. Cycle
Voltage the key switch to clear.
The left TPA detected an overvoltage Test voltage at the left
condition at the + terminal. TPA+. Replace the left TPA
if OK. The VM cannot
cause this code.

Message Shown: CODE 2W Inform Service

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

Code 2W: Left TPA Internal Fault None Cycle the key switch to
TPA internal circuitry has clear. Replace the left TPA
malfunctioned. if the code does not clear.

Message Shown: CODE 2X Inform Service

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

Code 2X: Left TPA Power Supply None Travel is restricted to 1

Out-of-Range mph (1.6 km/h). Cycle the
The power supply output in the left TPA key switch to clear.
is less than 4.5V, greater than 5.5V, or Disconnect the (+) wire to
too much current is being drawn by an the temp and speed
external component. sensors. Troubleshoot the
wires and sensors if the
code changes. Replace the
left TPA if not OK. The VM
cannot cause this code.

Message Shown: CODE 2Y Inform Service

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

Code 2Y: Incorrect Left TPA Installed None Replace with correct the
Incorrect left traction power amplifier TPA. Travel is limited to 2.5
installed. Should be 500A, 400A was mph (4.0 km/h).
installed.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Codes

Message Shown: CODE 42 Inform Service

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

Code 42: LPC Detected Closed When “Test I13 - Lift Contactor Lift is disabled. Cycle the
Commanded Open (DC Lift)” (Page 6-81) key switch to clear.
AC Lift - the LPA detected an incorrect “Test O02 - Lift Power
voltage at the B+ terminal on the Contactor (LPC)”
amplifier. (Page 6-100)
DC Lift - the VM detected an incorrect
voltage at JPC22-20.

Message Shown: CODE 43 Inform Service

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

Code 43: LPC Detected Open When “Test I13 - Lift Contactor Cycle the key switch to
Commanded Closed (DC Lift)” (Page 6-81) clear.
AC Lift - the LPA detected an incorrect “Test O02 - Lift Power
voltage at the B+ terminal on the Contactor (LPC)”
amplifier. (Page 6-100)
DC Lift - the VM detected an incorrect
voltage at JPC22-20.

Message Shown: CODE 4B Inform Service

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

Code 4B: Steer Contactor Detected “Test I14 - Steer Cycle the key switch to
Closed When Commanded Open Contactor” (Page 6-82) clear.
The VM measured greater than “Test O01 - Steer
+10VDC at JPC22-19 when the STR Contactor (STR)”
coil was de-energized. (Page 6-99)

Message Shown: CODE 4C Inform Service

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

Code 4C: Steer Contactor Detected “Test I14 - Steer Cycle the key switch to
Open When Commanded Closed Contactor” (Page 6-82) clear.
The VM measured less than +10VDC at “Test O01 - Steer
JPC22-19 when the STR coil was Contactor (STR)”
commanded closed. (Page 6-99)

Message Shown: CODE 4F Inform Service

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

Code 4F: TPC Detected Closed When “Test O00 - TPC Contactor” Travel is disabled. Cycle
Commanded Open (Page 6-98) the key switch to clear.
The right TPA detected an incorrect
voltage at the B+ terminal on the
amplifier.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Codes

Message Shown: CODE 4G Inform Service

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

Code 4G: TPC Detected Open When “Test O00 - TPC Contactor” Travel is disabled. Cycle
Commanded Closed (Page 6-98) the key switch to clear.
The TPA detected the TPC open after
power-up.

Message Shown: CODE 4J Inform Service

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

Code 4J: TPC Contactor Coil Open or “Test O00 - TPC Contactor” Travel is disabled. Cycle
Shorted TPC (Page 6-98) the key switch to clear.
TPC contactor coil is open or shorted.

Message Shown: CODE 4K Inform Service

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

Code 4K: LPC Contactor Coil Open or “Test O02 - Lift Power Lift is disabled. Cycle the
Shorted Contactor (LPC)” key switch to clear.
The LPC contactor coil is open or (Page 6-100)
shorted.

Message Shown: CODE 59 Inform Service

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

Code 59: CAN Transmission Buffer “Test I23 - CAN All functions are disabled.
Error Communication Test” Cycle the key switch to
The VM detected a CAN transmission (Page 6-86) clear.
buffer error.

Message Shown: CODE 5A Inform Service

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

Code 5A: CAN-Bus Error Overflow “Test I23 - CAN All functions are disabled.
CAN-Bus error overflow detected by Communication Test” Cycle the key switch to
VM. Refer to EPS manufacturer Service (Page 6-86) clear.
Manual if no power from EPS.

Message Shown: CODE 5B Inform Service

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

Code 5B: CAN Transmission Buffer “Test I23 - CAN Cycle the key switch to
Error Communication Test” clear.
CAN transmission buffer error. (Page 6-86)

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Codes

Message Shown: CODE 5F Inform Service

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

Code 5F: No Communications “Test I23 - CAN Travel is disabled. Cycle

Received by VM from Right TPA Communication Test” the key switch to clear.
The VM did not receive CAN (Page 6-86)
communications from the right TPA.

Message Shown: CODE 5G Inform Service

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

Code 5G: No Communications “Test I23 - CAN Travel is disabled. Cycle

Received by VM from Left TPA Communication Test” the key switch to clear.
The VM did not receive CAN (Page 6-86)
communications from the left TPA.

Message Shown: CODE 5J Inform Service

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

Code 5J: No Communications “Test I23 - CAN Lift is disabled. Cycle the
Received by VM from LPA Communication Test” key switch to clear.
AC lift only. The VM did not receive CAN (Page 6-86)
communications from the LPA.

Message Shown: CODE 5M Inform Service

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

Code 5M: Left TPA NMT Start “Test I23 - CAN Replace the left TPA if the
Timeout Communication Test” code does not clear.
No communications received from left (Page 6-86)
TPA within one minute.

Message Shown: CODE 5P Inform Service

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

Code 5P: LPA NMT Start Timeout “Test I23 - CAN Replace the LPA if the code
AC Lift only. No communications Communication Test” does not clear.
received from the LPA within one (Page 6-86)
minute.

Message Shown: CODE 5U Inform Service

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

Code 5U: Right TPA NMT Start “Test I23 - CAN Replace the right TPA if the
Timeout Communication Test” code does not clear.
No communications received from the (Page 6-86)
right TPA within one minute.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Codes

Message Shown: CODE 5Y Inform Service

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

Code 5Y: Incorrect Right TPA None Replace with the correct
Installed power amp.
Incorrect right traction power amplifier
installed. Should be 500A, 400A was
installed.

Message Shown: CODE 61 Inform Service

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

Code 61: Mast Switch Not Sensed “Test I02 - Mast Tilt Speed Travel is limited to 2.5 mph
Mast Switch change of state not Reduction (S11)” (4.0 km/h). Clears when
detected within allotted lift request (Page 6-79) the switch change of state
time. “Test O12 - Lift/Lower is detected.
Solenoid (SOL2)”
(Page 6-106)

Message Shown: CODE 6D Inform Service

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

Code 6D: Pressure Sensor Output “Test A13 - Weight Sensor A high number is shown
Voltage Out-of-Range Voltage” (Page 6-40) for weight.
The VM determined that the pressure
sensor voltage exceeded the
programmed limits.

Message Shown: CODE 7A Overheated, Allow Time to Cool

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

Code 7A: Lift Motor Overtemp “Test A09 - Lift Motor Lift is disabled. Allow time
AC Lift only. Lift motor temperature Temp (AC Lift only)” to cool. Cycle the key
exceeded 300°F (149°C). (Page 6-37) switch to clear.

Message Shown: CODE 7E Inform Service

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

Code 7E: Lift Motor Temperature “Test A09 - Lift Motor Lift performance is
Sensor Out-of-Range Temp (AC Lift only)” disabled by the LPA. Cycle
AC Lift only. Lift motor temperature (Page 6-37) the key switch to clear.
sensor voltage is out-of-range.

Message Shown: CODE 7F Overheated, Allow Time to Cool

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

Code 7F: LPA Overtemp “Test A19 - Lift Power Amp Lift is disabled. Cycle the
AC Lift only. The LPA reported its Temp (AC Lift only)” key switch to clear.
internal temperature is less than –40°F (Page 6-43)
(–40°C) or greater than +203°F (+95°C).

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Codes

Message Shown: CODE 7G Inform Service

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

Code 7G: LPA Motor Phase Open “Test O28 - Ramp Lift Lift is disabled. Cycle the
AC Lift only. The LPA detected no Motor (AC Lift)” key switch to clear.
current draw in one of the three phases (Page 6-111)
of the motor.

Message Shown: CODE 7H Inform Service

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

Code 7H: Lift Motor Feedback “Test I20 - Lift RPM Lift is limited to approx.
Encoder Failure Detected (AC Lift only)” (Page 6-85) 10 fpm (3 m/min). Cycle
AC Lift only. The LPA detected incorrect the key switch to clear.
pulses from the lift motor encoder.

Message Shown: CODE 7L Inform Service

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

Code 7L: LPA Severe Undervoltage None Lift performance may be

limited. Cycle the key
switch to clear. Check the
wiring/contactor tips.
Replace the battery with a
fully charged battery.

Message Shown: CODE 7M Inform Service

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

Code 7M: LPA Failed to Precharge None Lift is disabled. Check for
AC Lift only. The LPA failed to B+ at the LPA+ terminal.
precharge. Cycle the key switch to
clear. Replace the LPA if
the code does not clear.
The VM cannot cause this
code.

Message Shown: CODE 7Q Inform Service

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

Code 7Q: LPA Low Voltage None Lift performance may be

LPA detected less than 17V at the + limited. Cycle the key
terminal. switch to clear. Check the
wiring/ contactor tips.
Replace the battery with a
fully charged battery.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Codes

Messashownge Shown: CODE 7T Inform Service

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

Code 7T: LPA Current Sensor Fault None Lift is limited to 60% of
AC Lift only. The LPA sensed a current maximum request. Replace
calibration error. the LPA if cycling the key
switch does not clear this
code. The VM cannot cause
this code.

Message Shown: CODE 7U Inform Service

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

Code 7U: LPA Overcurrent or Short None Lift is disabled. Cycle the
Circuit key switch to clear. Check
AC Lift only. The LPA sensed current in for shorted lift motor
excess of 500A. cables. Replace the LPA if
the code does not clear.
The VM cannot cause this
code.

Message Shown: CODE 7V Inform Service

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

Code 7V: LPA High Voltage on DC Bus None Lift is disabled. Cycle the
AC Lift only. The LPA detected that the key switch to clear. Test
voltage at the + terminal is overvoltage. the voltage at LPA+.
Replace the LPA if OK. The
VM cannot cause this code.

Message Shown: CODE 7W Inform Service

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

Code 7W: LPA Internal Fault None Cycle the key switch to
AC Lift only. Internal circuitry has clear. Replace the LPA if
malfunctioned. the code does not clear.
The VM cannot cause this
code.

Message Shown: CODE 7X Inform Service

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

Code 7X: LPA Power Supply None Cycle the key switch to
Out-of-Range clear. Disconnect the
AC Lift only. The power supply output (+) wire to the temp and
in the LPA is less than 4.5V, greater speed sensors.
than 5.5V, or too much current is being Troubleshoot the wires and
drawn by an external component. sensors if OK. Replace the
LPA if the code does not
clear. The VM cannot cause
this code.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Codes

Message Shown: CODE 7Y Inform Service

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

Code 7Y: Incorrect LPA Installed None Replace with the correct
AC Lift only. Incorrect LPA installed. LPA.
Incorrect amp capacity for application.

Message Shown: CODE 80 Inform Service

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

Code 80: Throttle Potentiometer “Test A04 - Travel Pot Travel is disabled. Cycle
(VR1) Voltage Out-of-Range (VR1)” (Page 6-34) the key switch to clear.

Message Shown: CODE 81 Inform Service

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

Code 81: Lift/Lower Potentiometer “Test A05 - Lift/Lower Pot Lift is disabled. Cycle the
(VR2) Voltage Out-of-Range (VR2)” (Page 6-35) key switch to clear.

Message Shown: CODE 82 Inform Service

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

Code 82: Handle Heater Open “Test A40 - Handle Heater Cycle the key switch to
The circuit for the optional heater in the Reference Voltage clear.
control handle is open. (optional)” (Page 6-51)

Message Shown: CODE 83 Inform Service

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

Code 83: Throttle Potentiometer “Test A04 - Travel Pot Travel is disabled. Return
(VR1) Out-of-Neutral (VR1)” (Page 6-34) the control handle to
Throttle potentiometer (VR1) out of neutral. Cycle the key
Learned neutral value. switch to clear.

Message Shown: CODE 84 Inform Service

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

Code 84: Brakes Inoperable - Not “Test O30 - Electric Travel is disabled at
Applied Brakes” (Page 6-114) startup. Make sure the
The traction motor bearing encoder brake release bolts are
indicated movement during SelfTest. removed from the brake
assembly. Cycle the key
switch to clear.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Codes

Message Shown: CODE 87 Incorrect mast tilt pot reading...Tilt-Centering disabled

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

Code 87: Mast Tilt Centering Pot “Test A69 - Mast Tilt Cycle the key switch to
(VR6) Out-of-Range Centering Pot (VR6), clear.
Optional” (Page 6-55)

Message Shown: CODE 88 Inform Service

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

Code 88: 5V Power Supply “Test A26 - Pot Supply Cycle the key switch to
Out-of-Range (5VDC)” (Page 6-47) clear.
Control handle 5V power supply in the
VM out-of-range.

Message Shown: CODE 8A Inform Service

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

Code 8A: OCSS Photo Sensor Fault “Test I80 - OCSS - Low” Cycle the key switch to
The VM senses the beams are ON with (Page 6-89) clear.
the deadman pedal up. “Test I81 - OCSS - High”
(Page 6-90)

Message Shown: CODE 8F Inform Service

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

Code 8F: Lift/Lower Potentiometer “Test A05 - Lift/Lower Pot Lift and lower are disabled.
Out-of-Neutral (VR2)” (Page 6-35) Return the control handle
Lift/Lower potentiometer (VR2) out of to neutral. Cycle the key
Learned neutral value. switch to clear.

Message Shown: CODE 8J Inform Service

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

Code 8J: Ambient Temperature “Test A36 - Ambient Cycle the key switch to
Sensor Out-of-Range Temperature” (Page 6-50) clear.

Message Shown: CODE 8L Inform Service

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

Code 8L: Brake Feedback Current “Test O30 - Electric Cycle the key switch to
Out-of-Range Brakes” (Page 6-114) clear.
The current measured in the brake Note: The brake is fully
feedback circuit is zero, or outside the engaged or fully disengaged
reference range. when this code is present.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Codes

Message Shown: CODE 8M Inform Service

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

Code 8M: Internal Handle Heater “Test A40 - Handle Heater Self resetting.
Failure Reference Voltage
The internal heater in the control (optional)” (Page 6-51)
handle malfunctioned.

Message Shown: CODE 8P Inform Service

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

Code 8P: Tilt Potentiometer “Test A72 - Tilt Up/Down Cycle the key switch to
Out-of-Range (SW4) (Optional Handle)” clear. Check for the correct
(Page 6-58) handle configuration in
FlashWare.

Message Shown: CODE 8R Inform Service

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

Code 8R: Tilt Out-of-Neutral “Test A72 - Tilt Up (S6)” Return the switch to
Tilt potentiometer out-of-neutral or (Page 6-57) neutral and cycle the key
switch detected closed at startup. “Test A72 - Tilt Up/Down switch to clear.
(SW4) (Optional Handle)”
(Page 6-58)

Message Shown: CODE 8S Inform Service

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

Code 8S: Sideshift Potentiometer “Test A74 - Sideshift Cycle the key switch to
Out-of-Range Left/Right (SW4) (Optional clear. Check for the correct
Handle)” (Page 6-61) handle configuration in
FlashWare.

Message Shown: CODE 8T Inform Service

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

Code 8T: Sideshift Out-of-Neutral “Test A74 - Sideshift Left Return the switch to
Sideshift potentiometer out-of-neutral (S8)” (Page 6-60) neutral and cycle the key
or switch detected closed at startup. “Test A74 - Sideshift switch to clear.
Left/Right (SW4) (Optional
Handle)” (Page 6-61)

Message Shown: CODE 8U Inform Service

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

Code 8U: Attachment Function 1 “Test A75 - Attach Fcn 1 Cycle the key switch to
Out-of-Range (S4)” (Page 6-62) clear. Check for the correct
handle configuration in
FlashWare.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Codes

Message Shown: CODE 8V Inform Service

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

Code 8V: Attachment Function 1 “Test A75 - Attach Fcn 1 Return the switch to
Out-of-Neutral (S4)” (Page 6-62) neutral and cycle the key
Function 1 potentiometer “Test A75 - Attach Fcn 1 switch to clear.
out-of-neutral or switch detected closed (SW3) (Optional Handle)”
at startup. (Page 6-63)

Message Shown: CODE 8W Inform Service

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

Code 8W: Attachment Function 2 “Test A76 - Attach Fcn 2 Cycle the key switch to
Out-of-Range (SW2) (Optional Handle)” clear. Check for the correct
(Page 6-65) handle configuration in
FlashWare.

Message Shown: CODE 8X Inform Service

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

Code 8X: Attachment Function 2 “Test A76 - Attach Fcn 2 Return the switch to
Out-of-Neutral (S5)” (Page 6-64) neutral and cycle the key
Function 2 potentiometer “Test A76 - Attach Fcn 2 switch to clear.
out-of-neutral or switch detected closed (SW2) (Optional Handle)”
at startup. (Page 6-65)

Message Shown: CODE 8Z Inform Service

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

Code 8Z: Drive Train Error Detected None Jack up both drive tires
While traveling in a straight line at and request travel. Repair
2.5 mph (4.0 km/h) or greater with a the drive train as necessary
greater than 50% throttle request, high if only one drive tire turns
current is detected in one traction while both traction motors
motor and not the other. are turning. Cycle the key
switch to clear.

Message Shown: CODE A0 Inform Service

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

Code A0: Incorrect Software None Cycle the key switch to

Incorrect VM installed in the lift truck clear. Upgrade the software
or Flashed with incorrect software. in the lift truck with
FlashWare if this code
appears.

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Codes

Message Shown: CODE A2 Inform Service

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

Code A2: Software Compatibility None Travel is disabled. Cycle

Issue with VM and Left TPA the key switch to clear.
Upgrade the software in the
lift truck with FlashWare if
this code appears.

Message Shown: CODE A3 Inform Service

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

Code A3: Software Compatibility None Travel is disabled. Cycle

Issue with VM and Right TPA the key switch to clear.
Upgrade the software in the
lift truck with FlashWare if
this code appears.

Message Shown: CODE A4 Inform Service

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

Code A4: Software Compatibility None Lift is disabled. Cycle the

Issue with VM and LPA key switch to clear.
AC lift only. Upgrade the software in the
lift truck with FlashWare if
this code appears.

Message Shown: CODE A5 Inform Service

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

Code A5: Left TPA Internal Software None Travel is disabled. Cycle
Fault the key switch to clear.
The Left Traction Power Amplifier Flash the TPA with the
sensed an internal software fault. latest software if the code
does not clear.

Message Shown: CODE A6 Inform Service

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

Code A6: Right TPA Internal Soft- None Travel is disabled. Cycle
ware Fault the key switch to clear.
The Right Traction Power Amplifier Flash the TPA with the
sensed an internal software fault. latest software if the code
does not clear.

Message Shown: CODE A7 Inform Service

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

Code A7: LPA Internal Software Fault None Lift is disabled. Cycle the
The Lift Power Amplifier sensed an key switch to clear. Flash
internal software fault. the LPA with the latest
AC lift only. software if the code does
not clear.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Codes

Message Shown: CODE AG Inform Service

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

Code AG: Communications To/From None Cycle the key switch to

Operator Display Failed clear. Check the cable to
Operator Display communications the display. Replace the
failure detected by the VM. Operator Display if the
code does not clear.

Message Shown: CODE AH Inform Service

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

Code AH: Bad Operator Display None Cycle the key switch to
Checksum clear. Replace the Operator
Display if the code does not
clear.

Message Shown: CODE AL Inform Service

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

Code AL: VM Battery Backed Up RAM None Cycle the key switch to
Failed clear. Replace the VM if the
code does not clear.

Message Shown: CODE AP Inform Service

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

Code AP: Left TPA Software Fault None Travel is disabled. Cycle
the key switch to clear.
Flash the TPA with the
latest software if the code
does not clear.

Message Shown: CODE AR Inform Service

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

Code AR: Right TPA Software Fault None Travel is disabled. Cycle
the key switch to clear.
Flash the TPA with the
latest software if the code
does not clear.

Message Shown: CODE AT Inform Service

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

Code AT: LPA Software Fault None Lift is disabled. Cycle the
AC lift only. key switch to clear. Flash
the LPA with the latest
software if the code does
not clear.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Codes

Message Shown: CODE EC Inform Service

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

Code EC: COP Not Enabled None Cycle the key switch to
clear. Replace the VM if the
code does not clear.

Message Shown: CODE FE Inform Service

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

Code FE: Internal VM Circuit for None Code is shown for 30

BSOC Not Calibrated seconds. Cycle the key
switch to clear. Test the
circuit for “Inrush
Protection” on page 5-13 if
intermittent. Replace the
VM if the code does not
clear.

Message Shown: CODE FG Inform Service

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

Code FG: +5V Reference Voltage and “Test A14 - Ext. Supply Travel, lift, and lower are
+12V Power Supply Failure Sense (12VDC)” disabled. Brake engages.
(Page 6-41) Cycle the key switch to
clear. Test the circuit for
“Inrush Protection” on
page 5-13 if intermittent.

Message Shown: CODE FH Inform Service

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

Code FH: Battery Voltage “Test A15 - Battery Volts” Brake remains engaged.
Out-of-Range (Page 6-42) Cycle the key switch to
Wrong voltage battery or voltage clear. Test the circuit for
out-of-range. “Inrush Protection” on
page 5-13 if intermittent.

Message Shown: CODE FN Inform Service

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

Code FN: Relays Did Not Open at “Test O32 - Toggle Relay Brake engages. Cycle the
Power Off Enable” (Page 6-115) key switch to clear. Test
the circuit for “Inrush
Protection” on page 5-13 if
intermittent.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Codes

Message Shown: CODE FT Inform Service

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

Code FT: VM Internal Software Error None Travel, lift, and lower are
disabled. Brake remains
engaged. Cycle the key
switch to clear. Test the
circuit for “Inrush
Protection” on page 5-13 if
intermittent. Flash the VM
with the latest software if
the code does not clear.

Message Shown: CODE G2 Inform Service

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

Code G2: Bad Steer Position “Test I89 - Steer Position Cycle the key switch to
Reference Input Sensor” (Page 6-94) clear.

Message Shown: CODE HA Overheated, Allow Time to Cool

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

Code HA: Right Traction Motor “Test A68 - Right Traction Travel speed is linearly
Overtemp Motor Temp” (Page 6-54) derated starting at 266°F
(130°C). Travel speed is
limited to 1 mph
(1.6 km/h) at 300°F
(149°C). Cycle the key
switch to clear after the
traction motor cools.

Message Shown: CODE HE Inform Service

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

Code HE: Right Traction Motor “Test A68 - Right Traction Travel is limited to 6.5 mph
Temperature Sensor Out-of-Range Motor Temp” (Page 6-54) (10.4 km/h). Clears when
the reason for the fault is
corrected.

Message Shown: CODE HF Overheated, Allow Time to Cool

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

Code HF: Right TPA Overtemp “Test A65 - Right Traction Cycle the key switch to
The right TPA reported its internal Power Amp Temp” clear after the TPA cools.
temperature is less than –40°F (–40°C) (Page 6-52)
or greater than +203°F (+95°C).

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Codes

Message Shown: CODE HG Inform Service

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

Code HG: Right Traction Motor “Test A67 - Right Traction Travel is disabled. Cycle
Phase Open Current” (Page 6-53) the key switch to clear.

Message Shown: CODE HH Inform Service

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

Code HH: Right Traction Motor “Test I82 - Right Traction Travel is limited to 1 mph
Feedback Encoder Failure RPM” (Page 6-91) (1.6 km/h). This code is
Failure detected in traction motor shown during operation if a
speed feedback encoder. single channel is bad.
STALLED is shown if one
or both channels are bad at
SelfTest. Cycle the key
switch to clear.

Message Shown: CODE HL Inform Service

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

Code HL: Right TPA Severe None Travel performance may be

Undervoltage limited. Cycle the key
switch to clear. Check the
wiring/contactor tips.
Replace the battery with a
fully charged battery.

Message Shown: CODE HM Inform Service

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

Code HM: Right TPA Pre-Charge None Travel is disabled. Check

Failed for B+ at the right TPA+
TPA failed to precharge correctly. terminal. Cycle the key
switch to clear. Replace the
right TPA if the code does
not clear. The VM cannot
cause this code.

Message Shown: CODE HQ Inform Service

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

Code HQ: Right TPA Low Voltage None Travel performance may be
Right TPA detected less than 17V at the limited. Cycle the key
+ terminal. switch to clear. Check the
wiring/contactor tips.
Replace the battery with a
fully charged battery.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Codes

Message Shown: CODE HT Inform Service

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

Code HT: Right TPA Current Sensor None Travel is limited to 2.5 mph
Fault (4.0 km/h). Cycle the key
The right TPA sensed a current switch to clear. Replace the
calibration error. right TPA if the code does
not clear. The VM cannot
cause this code.

Message Shown: CODE HU Inform Service

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

Code HU: Right TPA Overcurrent or None Travel is disabled. Cycle

Short Circuit the key switch to clear.
The right TPA sensed current in excess Check for shorted traction
of 400A. motor power cables.
Replace the right TPA if the
code does not clear. The
VM cannot cause this code.

Message Shown: CODE HV Inform Service

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

Code HV: Right TPA High DC Bus None Travel is disabled. Cycle
Voltage the key switch to clear.
The right TPA detected an overvoltage Test the voltage at the right
condition at the + terminal. TPA+. Replace the right
TPA if OK. The VM cannot
cause this code.

Message Shown: CODE HW Inform Service

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

Code HW: Right TPA Software Error None Cycle the key switch to
TPA internal software error (not clear. Replace the right TPA
required for lift truck operation) if the code does not clear.
malfunctioned.

Message Shown: CODE HX Inform Service

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

Code HX: Right TPA Power Supply None Travel restricted to 1 mph
Out-of-Range (1.6 km/h). Cycle the key
The power supply output in the right switch to clear. Disconnect
TPA is less than 4.5V, greater than the (+) wire to the temp and
5.5V, or too much current is being speed sensors.
drawn by an external component. Troubleshoot the wires and
sensors if the code
changes. Replace the right
TPA if not OK. The VM
cannot cause this code.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests

Codes

Message Shown: CODE M9 Lift limited...Installed battery is too light

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

Code M9: Lift Limited... Installed iBATTERY related message. Refer to iBATTERY Battery
Battery is Too Light Monitoring System Installation and Maintenance
Battery installed in lift truck is below Instructions.
the minimum rated weight.

Message Shown: CODE T0 Inform Service

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

Code T0: Aux Relief SOL5 Open “Test A82 - Aux. Relief Cycle the key switch to
Circuit or Constant Low Current (SOL5)” clear.
(Page 6-69)

Message Shown: CODE T3 Inform Service

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

Code T3: Proportional Lower SOL2 “Test A34 - Lift/Lower Cycle the key switch to
Open Circuit or Constant Low Current (SOL2)” clear.
(Page 6-48)

Message Shown: CODE T4 Inform Service

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

Code T4: Priority Bypass SOL4 Open “Test A81 - Priority Bypass Cycle the key switch to
Circuit or Constant Low Current (SOL4)” clear.
(Page 6-68)

Message Shown: CODE UA Inform Service

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

Code UA: The B– Key switch input is None Travel is limited to 1 mph,
not sensed by the EPS lift is disabled, lower/aux
is functional. Rekey to
clear. Check the wake and
wake RTN at the key
switch and SBX connector.
See “Troubleshooting
Public Standard Interface”
on page 5-21.

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Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual

Codes

Message Shown: CODE UB Inform Service

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

Code UB: EPS communication issue None Travel is limited to 1 mph,

OR issue with the EPS lift is disabled, lower/aux
is functional. Rekey to
clear. Refer to the EPS
manufacturer service
manual.
See “Troubleshooting
Public Standard Interface”
on page 5-21.

Message Shown: CODE VC Inform Service

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

Code VC: Internal Error in VM None Cycle the key switch to

Communications clear. Replace the VM if the
code does not clear.

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Models 4150/4250 Maintenance Manual 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 the technician with a step-by-step
approach to diagnosing a problem and the
necessary corrective action. See the sample
table below.

Example Diagnosis and Repair Table

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

This column identifies

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

This column also

identifies the required
setting on the meter
for this step.

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A04 - Travel Pot (VR1) Analog Tests

Test A04 - Travel Pot Run Test

(VR1) The test is a success if the voltage shown is
within these limits:
This test shows the voltage the VM produces
based on input from the control handle travel Throttle Position Value Shown
potentiometer VR1. Full Tractor-First (TF) 0.45 to 0.8V
NOTE: Run Learn when the throttle (travel)
Neutral 0.9 to 1.3V
assembly is replaced, repaired, or
adjusted. See “Maintenance Mode” on Full Forks-First (FF) 1.4 to 1.8V
page 3-20.
NOTE: Check the handle spring for excessive The test has failed if the voltage reading is
movement if code 83 is shown. outside these limits or does not change in a
smooth, linear fashion. Any voltage fluctuation
indicates a bad cable or potentiometer VR1.

The voltage reading should decrease when the

throttle is moved from the forks-first to the
tractor-first position. The test has failed if these
results are not shown.

Diagnosis and Repair

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

Approx. 5V.
JPC12
If missing, no other
1 Disconnected PC12-1 PC12-12 Perform Step 2 Replace the VM
control handle
/DCV
functions work.

T/S the control

Neutral: approx. 1V
Replace the handle cable and
2 DCV JPC12-3 JPC12-12 Full TF: approx. 0.52V
VM connector(s). Replace
Full FF: approx. 1.6V
the pot if OK.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A05 - Lift/Lower Pot (VR2)

Test A05 - Lift/Lower Pot Run Test

(VR2) The test is a success if the voltage shown is
within these limits:
This test shows the voltage the VM produces
based on input from the control handle Lift/Lower
Value Shown
lift/lower pot VR2. Control Position

NOTE: Run Learn when the lift/lower pot is Full Lift 0.45 to 0.8V
replaced, repaired, or adjusted. See Neutral 0.9 to 1.3V
“Maintenance Mode” on page 3-20.
Full Lower 1.4 to 1.8V
NOTE: Check the handle spring for excessive
movement if code 8F is shown.
The test has failed if the voltage reading is
outside these limits or does not change in a
smooth, linear fashion. Any voltage fluctuation
indicates a bad cable or potentiometer VR2.

The voltage reading should decrease when the

lift/lower knob is moved from lower to lift. The
test has failed if these results are not shown.

Diagnosis and Repair

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

Approx. 5V.
JPC12
If missing, no other
1 Disconnected PC12-1 PC12-12 Perform Step 2 Replace the VM
control handle
/DCV
functions work.

T/S the control

Neutral: 1.17V handle cable and
2 DCV JPC12-2 JPC12-12 Full Lift: 0.62V Replace the VM connector(s).
Full Lower: 1.68V Replace the pot if
OK.

Publication: 1193671C, Revised: 15 Aug 2022 6-35

Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A08 - Left Traction Motor Temp Analog Tests

Test A08 - Left Traction Run Test

Motor Temp 1. Compare the temperatures obtained from
Maintenance Mode to the ambient
temperature with the lift truck at rest and
This test shows the temperature of the left at ambient temperature.
Traction Motor.
2. The test has failed if the temperatures are
not within several degrees.
Limits 3. Refer to Diagnosis and Repair if the
• Normal operation: ambient to 258°F reading on the display is not at ambient
(125°C) temperature to isolate the cause.
• Between 266°F (130°C) and 300°F (149°C),
speed is linearly reduced to 1.0 mph
(1.6 km/h)
• Temperature icon blinks at 266°F (130°C)
• Fault Code 2A is shown and travel is
disabled at 300°F (149°C)

While operating, the VM continually monitors

the temperature of the traction motor.
Performance is reduced until the motor cools
down if the temperature gets too high.

Use Active Maintenance Mode to see the actual

temperature from the temperature sensor. Heat
the lift truck up by driving it hard for approx.
30 minutes. As the motor heats, the
temperature increases.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-20.

Diagnosis and Repair

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

JPTL1
Replace the left
1 Disconnected JTL1-8 JTL1-7 Perform Step 2
<1200 ohms if traction TPA
/ohms
motor is cool; >1200
JPTL3 ohms if hot T/S the traction Replace the
2 Disconnected JTL3-2 JTL3-1 motor temp traction motor
/ohms sensor wires temp sensor

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A09 - Lift Motor Temp (AC Lift only)

Test A09 - Lift Motor

Temp (AC Lift only)
This test shows the temperature of the AC lift
motor.

Limits
• Normal operation: ambient to 294°F
(145°C)
• Temperature icon lights at 295°F (146°C)
• Fault Code 6F is shown and lift is disabled
at 300°F (149°C)

Run Test
From ambient temperature, as lift is operated,
the readings should increase evenly over time.
The test has failed if the readings do not
increase evenly.

Diagnosis and Repair

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

JPL1
1 Disconnected JL1-8 JL1-7 Replace the LPA Perform Step 2
/ohms <1200 ohms if lift
motor is cool; >1200
JPL3 ohms if hot T/S the lift
Replace the lift
2 Disconnected JL3-2 JL3-1 motor temp
motor temp sensor
/ohms sensor wires

Publication: 1193671C, Revised: 15 Aug 2022 6-37

Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A10 - Left Traction Power Amp Temp Analog Tests

Test A10 - Left Traction

Power Amp Temp
This test shows the temperature of the left
traction power amplifier (TPA).

Limits
• Normal operation: ambient to 175°F (79°C)
• Starting at 176°F (80°C), speed is linearly
reduced by the TPA to 0.0 mph at 239°F
(115°C), when traction is disabled
• Temperature icon lights at 185°F (85°C)
• Fault Code 1H is shown at 203°F (95°C)

Run Test
The operator display shows the heatsink
temperature that the traction power amplifier
reads.

From ambient temperature, as drive is

operated, the readings should increase evenly
over time. The test has failed if the readings do
not increase evenly.

Diagnosis and Repair

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

Is TPA heatsink Replace the TPA if

1 N/A N/A Hot to touch Perform Step 2
hot to touch? not hot

Check the
Allow time to Not hot to touch, no
2 N/A N/A cables and Replace the TPA
cool. code
connections

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A11 - Left Traction Current

Test A11 - Left Traction Diagnosis and Repair

Current 1. Check the power cable continuity if any
one phase differs significantly from the
other two. Replace the cables as
This test shows the current in the left traction necessary. See “Power Cable Terminals”
motor power circuit. on page 7-56.
• Troubleshoot the traction motor if the
Limits power cable continuity is OK. See “AC
Motors” on page 5-18.
• Above 266°F (130°C) current is reduced
linearly • The drive unit may be binding if all
phases give high readings. Check the
• Maximum current up to 540A when the drive unit.
deadman pedal is released, unaffected and
unreduced by temperature 2. The power amplifier may be bad. Run
“Test O29 - Ramp Traction Motors” on
Run this test in Active Maintenance Mode for page 6-112.
best results.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-20.

Run Test
The operator display shows the current that the
traction power amplifier reads from the traction
motor.

System Condition Value Shown

Static at Rest <20A

Travel at Full Speed <150A

NOTE: The test may not always reveal a current

problem because Test A11 measures
only one phase.
NOTE: Check all motor and power amplifier
connections for tightness and corrosion.

Check individual phase currents with a

clamping ammeter. The current should ramp
evenly as the lift truck accelerates and
decelerates. Phase currents must be
approximately equal. Gross differences indicate
a problem.

The test has failed if the readings are not within

the reference limits.

Publication: 1193671C, Revised: 15 Aug 2022 6-39

Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A13 - Weight Sensor Voltage Analog Tests

Test A13 - Weight Sensor

Voltage
This test shows the voltage from the optional
pressure sensor used for load weight sensing.

Limits
The operator display shows the voltage present
with different load weights.

Load Weight Value Shown

0 lbs. (no load) Approx. 1V

3000 lbs. (1361 kg) Approx. 3V

The operator display shows 0V if the weight

sensor is disconnected at the VM.

Run Test
The voltage shown on the operator display
should increase and decrease linearly as the
load weight is either increased or decreased.

The test has failed if voltage does not increase

and decrease linearly. The test has failed if the
weight display is inaccurate.

Diagnosis and Repair

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

Replace the
1 JPC24-13 JPC24-10 Perform Step 2
VM
DCV 10.5 to 13V
T/S the
2 JPY1-1 JPY1-3 Perform Step 3
harness

Replace the
3 JPY1-2 JPY1-3 Approx. 1V at 0 psi; Perform Step 4 pressure
Attach pressure increases approx. 1V transducer
gauge to G1/DCV per 1000 psi
(6895 kPa) T/S the
4 JPC24-18 JPC24-10 Replace the VM
harness

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A14 - Ext. Supply Sense (12VDC)

Test A14 - Ext. Supply

Sense (12VDC)
This test shows the output of the internal
+12VDC power supply of the vehicle manager.

Run Test
The operator display should read 10.8 to 13V.
The test has failed if the voltage fluctuates more
than 0.8V in 10 seconds.

Diagnosis and Repair

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

1 DCV Replace the VM Perform Step 2

Re-connect the
Disconnect all JPC6-6 wires one at a time
TP4 10.5 to 13V
2 12V supply wires (VM side) and T/S the circuit Replace the VM
at the VM/DCV that pulls down the
12V

Publication: 1193671C, Revised: 15 Aug 2022 6-41

Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A15 - Battery Volts Analog Tests

Test A15 - Battery Volts

This test shows the voltage the VM is reading
from the battery sense line.

A successful test proves the VM is correctly

reading BATTERY_SENSE_IN at JPC24-24.
NOTE: This voltage is used by the VM to
calculate the battery state-of-charge.

Run Test
The test is a success if the voltage shown is
within these limits:

Nominal Battery
Value Shown
Voltage

36V 33.0 to 39.0V

The test has failed if the reading fluctuates by

more than 0.8V in 10 seconds with the lift truck
not moving or lifting.

Diagnosis and Repair

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

Check the battery water

level and specific gravity.
1 TP1 Perform Step 2 Check the battery
cables. Replace the
battery

DCV TP4 B+ T/S the harness TP1 to

2 JPF4-1 Perform Step 3
JPF4-1

3 JPF4-7 Perform Step 4 T/S the fuse/relay card

T/S the harness from

4 JPC24-24 Replace the VM the fuse/relay card to
the VM

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A19 - Lift Power Amp Temp (AC Lift only)

Test A19 - Lift Power

Amp Temp (AC Lift only)
This test shows the temperature of the lift
power amplifier (LPA) heatsink.

Limits
• Normal operation: ambient to 175°F (79°C)
• Starting at 176°F (80°C), speed is linearly
reduced to 0 fpm at 239°F (115°C), when
lift is disabled
• Temperature icon illuminates at 185°F
(85°C)
• Fault Code 7F is shown at 203°F (95°C)

Run Test
The operator display shows the heatsink
temperature that the lift power amplifier reads.

The readings should increase evenly over time

as the lift is operated. The test has failed if not.

Diagnosis and Repair

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

Is LPA heatsink
Not hot, replace
1 hot to the N/A N/A Hot to touch Perform Step 2
the LPA
touch?

Allow time to Check the Replace the LPA if

Cool to touch/no
2 cool. Does code N/A N/A cables and the code does not
code
clear? connections clear

Publication: 1193671C, Revised: 15 Aug 2022 6-43

Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A20 - Lift Current (AC Lift only) Analog Tests

Test A20 - Lift Current Diagnosis and Repair

(AC Lift only) 1. Check the power cable continuity if any
one phase differs significantly from the
other two. Replace the cables as
This test shows lift motor current through the necessary.
lift power amplifier (LPA).
• Troubleshoot the lift motor if the power
cable continuity is OK. See “AC Motors”
Run this test in Active Maintenance Mode for
on page 5-18.
best results.
• The lift pump may be binding if all
NOTE: For more information on how to use phases give high readings.
Maintenance Mode, refer to page 3-20.
2. The power amplifier may be bad. Run
“Test O28 - Ramp Lift Motor (AC Lift)” on
page 6-111.

The lift carriage and forks move during

this test.

The area around the forks must be clear.

The ceiling clearance should allow for
the highest lift.

Limits
• 0 to 500A lifting
• Maximum current 675A

Run Test
The operator display shows the current that the
lift power amplifier reads from one phase of the
lift motor.
NOTE: A current problem may not be revealed
because only one phase is measured.
NOTE: Check all motor and power amplifier
connections for tightness and corrosion.

Check individual phase currents with a

clamping ammeter. The current should ramp
evenly as the lift accelerates and decelerates.
Phase currents must be approximately equal.
Gross differences indicate a problem.

The test has failed if the readings are not within

the reference limits.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A22 - Traction Request

Test A22 - Traction

Request
This test shows the percentage of traction
throttle request from the control handle travel
pot (VR1) being read by the VM.

Run Test
NOTE: Run Learn after you replace, repair, or
adjust the throttle assembly. See
“Maintenance Mode” on page 3-20.

The operator display shows the percentage of

throttle request that the VM reads from the
control handle throttle potentiometer (VR1) and
sends to the TPA.

Acceptable values are:

Throttle Position Value Shown

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.

The test has failed if the percentages are not

within the reference limits.
NOTE: Any travel limiting conditions will result
in less than 100% shown on the display.

Diagnosis and Repair

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

Test should pass. Check the traction

Run “Test A04 - Compare Test A04 system for speed
Travel Pot results with the limits due to motor
1 N/A N/A Replace the TPA
(VR1)” on results from A22. temperature, limit
page 6-34 Max throw should switches, or
show max values. configured speed.

Publication: 1193671C, Revised: 15 Aug 2022 6-45

Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A23 - Lift Request Analog Tests

Test A23 - Lift Request

This test shows the percentage of lift throttle
request from the control handle lift/lower pot
(VR2) being read by the VM.

Run Test
NOTE: Run Learn after you replace, repair, or
adjust the lift/lower potentiometer
(VR2). See “Maintenance Mode” on
page 3-20.

The operator display shows the percentage of

lift request that the VM reads from the
lift/lower pot (VR2).

Acceptable values are:

Throttle Position Value Shown

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.

The test has failed if percentages are not within

the reference limits.
NOTE: Any lift limiting conditions will result in
less than 100% shown on the display.

Diagnosis and Repair

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

Compare Test A05 Check the lift

Run “Test A05 -
results with the system for limits
Lift/Lower Pot
1 N/A N/A results from A23. Replace the LPA due to motor
(VR2)” on
Max throw should temperature or
page 6-35
show max values switches

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A26 - Pot Supply (5VDC)

Test A26 - Pot Supply

(5VDC)
This test shows the output of the VM internal
+5VDC power supply.

This test measures the +5VDC power supply

voltage for power to control handle switches
and potentiometers.

Run Test
The test has failed if the operator display does
not read 5VDC ±0.25V.

Diagnosis and Repair

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

T/S the control

handle cable.
JPC12
T/S the control
1 disconnected/ PC12-1 PC12-12 Approx. 5V Replace the VM
handle and
DCV
adjoining cables
if OK

Publication: 1193671C, Revised: 15 Aug 2022 6-47

Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A34 - Lift/Lower Current (SOL2) Analog Tests

Test A34 - Lift/Lower

Current (SOL2)
This test shows the current the proportional
lift/lower solenoid coil (SOL2) is drawing.

Run this test in Active Maintenance Mode for

best results.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-20.

Run Test
Acceptable values are:

State Value Shown

Neutral Approx. 0.0A

Full Lower Approx. 1.15A

The test has failed if these results are not

shown.

Diagnosis and Repair

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

JPC20
T/S the wires
1 Disconnected/ PC20-15 PC20-16 Approx. 15 ohms Perform Step 2
and coil
ohms

2 DCV JPC20-15 TP4 B+ Perform Step 3

Check the valve

Ramp from B+ when Replace the VM
Test activated/ for mechanical
3 JPC20-16 B– off, to approx. 20V
DCV binding or
at full lower
contamination

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A35 - Brake Armature

Test A35 - Brake

Armature
This test shows the voltage the VM measures
across the brake coil driver.

Run this test in Active Maintenance Mode for

best results.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-20.

Run Test
Acceptable values are:

Deadman Pedal Value Shown

Up B+

0V for 1 second; increases to

Down
12 to 14V

The test has failed if these results are not

shown.

Diagnosis and Repair

Replace the VM if the voltage is not as specified.
Run “Test O30 - Electric Brakes” on page 6-114
if the voltage is as specified.

Publication: 1193671C, Revised: 15 Aug 2022 6-49

Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A36 - Ambient Temperature Analog Tests

Test A36 - Ambient

Temperature
This test shows the ambient temperature of the
area around the lift truck.

Run Test
The operator display should show the room
temperature where the lift truck is located.

The test has failed if not.

Diagnosis and Repair

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

T/S the wiring.

Disconnect
1 JA-1 JA-2 Approx. 5V Perform Step 2 Replace the VM if
JPA/DCV
good

2 JPC24 JPC24-23 JPA-1

Replace the
Disconnected/ 0 ohms T/S the wiring
3 JPC24-7 JPA-2 temp sensor
ohms

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A40 - Handle Heater Reference Voltage (optional)

Test A40 - Handle

Heater Reference
Voltage (optional)
This test shows the voltage the vehicle manager
(VM) sees going through the internal control
handle heater (HTR6).
NOTE: Heater operation requires activation of
the ambient temperature sensor.
Heaters turn on at 40°F (4.4°C).

Run Test

Heater OFF Heater ON

0V Approx. 6.0V

The test has failed if the values shown do not

match the values given in the table. Verify the
option is turned ON. Refer to Diagnosis and
Repair.

Diagnosis and Repair

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

Check the cable

wiring. Replace
Disconnect Approx.
1 JC12-7 JC12-12 Perform Step 2 the handle or
JPC12/ohms 12 ohms
internal heater
if OK

Heater ON:
Disconnect PC12-7 PC12-12
2 approx. 4.4V Perform Step 1 Replace the VM
JPC12/DCV on VM on VM
Heater OFF: 0V

Publication: 1193671C, Revised: 15 Aug 2022 6-51

Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A65 - Right Traction Power Amp Temp Analog Tests

Test A65 - Right Traction

Power Amp Temp
This test shows the temperature of the right
traction power amplifier (TPA).

Limits
• Normal operation: ambient to 175°F (79°C)
• Starting at 176°F (80°C), speed is linearly
reduced by the TPA to 0.0 mph at 239°F
(115°C), when traction is disabled
• Temperature icon illuminates at 185°F
(85°C)
• Fault Code 1H is shown at 203°F (95°C)

Run Test
The operator display shows the heatsink
temperature that the traction power amplifier
reads.

The readings for ambient temperature should

increase evenly over time as drive is operated.
The test has failed if not.

Diagnosis and Repair

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

Is TPA heatsink Replace the TPA if

1 Hot to touch Perform Step 2
hot to touch? not hot
N/A N/A Check the
Allow time to Not hot to touch, no
2 cables and Replace the TPA
cool. code
connections

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A67 - Right Traction Current

Test A67 - Right Traction Diagnosis and Repair

Current • Check the power cable continuity if any
one phase differs significantly from the
other two. Replace the cables as
This test shows the current in the right traction necessary. See “Power Cable Terminals”
motor power circuits. on page 7-56
• Troubleshoot the traction motor if the
Limits power cable continuity is OK. See “AC
Motors” on page 5-18
• Above 266°F (130°C) current is reduced
linearly • The drive unit may be binding if all phases
give high readings. Check the drive unit
• Maximum current up to 540A when the
deadman pedal is released, unaffected and NOTE: The power amplifier may be bad. Run
unreduced by temperature “Test O29 - Ramp Traction Motors” on
page 6-112.
Run this test in Active Maintenance Mode for
best results.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-20.

Run Test
The operator display shows the current that the
TPA reads from the traction motor.

System Condition Value Shown

Static at Rest <20A

Travel at Full Speed <150A

NOTE: The test may not always reveal a current

problem because this test measures
only one phase.
NOTE: Check all motor and power amplifier
connections for tightness and corrosion.

Check individual phase currents with a

clamping ammeter. The current should ramp
evenly as the lift truck accelerates and
decelerates. Phase currents must be
approximately equal. Gross differences indicate
a problem.

The test has failed if the readings are not within

the reference limits.

Publication: 1193671C, Revised: 15 Aug 2022 6-53

Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A68 - Right Traction Motor Temp Analog Tests

Test A68 - Right Traction Run Test

Motor Temp 1. Compare the temperatures obtained with
Active Maintenance Mode to the ambient
temperature with the lift truck at rest and
This test shows the temperature of the right at ambient temperature.
traction motor.
2. The test has failed if the temperatures are
not within several degrees.
Limits 3. Use the Diagnosis and Repair chart to
• Normal operation: ambient to 258°F isolate the cause if the lift truck is not at
(125°C) ambient temperature.
• Between 266°F (130°C) and 300°F (149°C),
speed is linearly reduced to 1.0 mph
(1.6 km/h)
• Temperature icon illuminates at 266°F
(130°C)
• Fault Code 2A is shown and travel is
disabled at 300°F (149°C)

The VM continually monitors the temperature

of the traction motor while operating.
Performance is reduced until the motor cools
down if the temperature gets too high.

Use Active Maintenance Mode to see the actual

temperature from the temperature sensor.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-20.

Heat the lift truck up by driving it hard for

approx. 30 minutes. As the motor heats, the
temperature increases.

Diagnosis and Repair

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

JPTR1
Replace the
1 Disconnected/ JTR1-8 JTR1-7 Perform Step 2
right TPA
ohms <1200 ohms if traction
motor is cool; T/S the
JPTR3 >1200 ohms if hot Replace the
traction
2 Disconnected/ JTR3-2 JTR3-1 traction motor
motor temp
ohms temp sensor
sensor wires

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A69 - Mast Tilt Centering Pot (VR6), Optional

Test A69 - Mast Tilt The test has failed if the voltage reading is
outside these limits or does not change in a
Centering Pot (VR6), smooth, linear fashion. Any voltage fluctuation
indicates a bad cable or potentiometer VR6.
Optional
The voltage reading should decrease when
tilting forward and increase when tilting back.
This test shows the voltage the VM produces
The test has failed if these results are not
based on input from the mast tilt centering pot
shown.
(VR6).
NOTE: Run Learn after you replace, repair, or
adjust VR6. See “Maintenance Mode” on
page 3-20.

Run Test
Run this test in Active Maintenance Mode for
best results.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-20.

The test is a success if the voltage shown is

within these limits:

Mast Tilt Position Value Shown

Full Tilt Forward Position 1.0 to 1.6V

Neutral Position 2.0 to 2.4V

Full Tilt Back Position 2.7 to 3.3V

Diagnosis and Repair

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

1 JPC20-5 JPC24-5 10.5 to 13V Perform Step 2 Replace the VM

T/S the wiring

from the VM to
the 5V power
2 JPT5-3 JPT5-4 4.5 to 5.5V Perform Step 3
supply. Replace
the power
DCV
supply if OK

Neutral: 2.0 to 2.4V T/S the wiring

Full tilt forward: 1.0 to from JPC24-22
3 JPC24-22 JPC24-5 1.6V Replace the VM to JPT1-4.
Full tilt back: 2.7 to Replace the pot
3.3V if OK

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A71 - Tilt Down (S7) Analog Tests

Test A71 - Tilt Down (S7)

This test shows the voltage at the tilt down
switch (S7) on a standard control handle.

Run Test
Acceptable values are:

State Value Shown

Neutral Approx. 5V

Switch
Approx. 0.0V
Activated

The test has failed if these results are not

shown.

Diagnosis and Repair

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

Note: A breakout cable or box is required to measure control handle voltages.

JPC12
1 >4V Perform Step 2 Replace the VM
Disconnected/DCV

Repair or replace
JPC12-6 JPC12-12 the control
S7 open: >4V
2 DCV Replace the VM handle, cable, or
S7 closed: <1V
S7 (in the
handle)

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A72 - Tilt Up (S6)

Test A72 - Tilt Up (S6)

This test shows the voltage at the tilt up switch
(S6) on a standard control handle.

Run Test
Acceptable values are:

State Value Shown

Neutral Approx. 5V

Switch Activated Approx. 0.0V

The test has failed if these results are not

shown.

Diagnosis and Repair

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

Note: A breakout cable or box is required to measure control handle voltages.

JPC12
1 >4V Perform Step 2 Replace the VM
Disconnected/DCV

Repair or replace
JPC12-5 JPC12-12 the control
S6 open: >4V
2 DCV Replace the VM handle, cable, or
S6 closed: <1V
S6 (in the
handle)

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A72 - Tilt Up/Down (SW4) (Optional Handle) Analog Tests

Test A72 - Tilt Up/Down

(SW4) (Optional Handle)
This test shows the voltages at the tilt up/down
switch (SW4) on an optional control handle.

Run Test
Acceptable values are:

State Value Shown

Full Tilt Up 2.80 to 4.69V

Neutral 2.11 to 2.79V

Full Tilt Down 0.21 to 2.10V

The test has failed if the voltage reading is

outside these limits or does not change linearly.
Any voltage fluctuation indicates a bad cable or
switch.

Diagnosis and Repair

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

Note: A breakout cable or box is required to measure control handle voltages.

Neutral: approx.
2.44V Repair or replace
Full Tilt Down: the control handle,
1 DCV JPC12-8 JPC12-12 Replace the VM
approx. 0.6V cable, or SW4 (in
Full Tilt Up: approx. the handle)
4.36V

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A73 - Sideshift Right (S9)

Test A73 - Sideshift Right

(S9)
This test shows the voltage at the sideshift right
switch (S9) on a standard control handle.

Run Test
Acceptable values are:

State Value Shown

Neutral Approx. 5V

Sideshift Right Switch

Approx. 0.0V
Activated

The test has failed if the voltage is outside these

limits or does not change.

Diagnosis and Repair

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

Note: A breakout cable or box is required to measure control handle voltages.

JPC12
1 >4V Perform Step 2 Replace the VM
Disconnected/DCV

Repair or
JPC12-9 JPC12-12 replace the
S9 Open: >4V Replace the
2 DCV control handle,
S9 Closed: <1V VM
cable, or S9 (in
the handle)

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A74 - Sideshift Left (S8) Analog Tests

Test A74 - Sideshift Left

(S8)
This test shows the voltage at the sideshift left
switch (S8) on a standard control handle.

Run Test
Acceptable values are:

State Value Shown

Neutral 5V

Sideshift Left Switch

Approx. 0.0V
Activated

The test has failed if the voltage is outside these

limits or does not change.

Diagnosis and Repair

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

Note: A breakout cable or box is required to measure control handle voltages.

JPC12 Perform
1 >4V Replace the VM
Disconnected/DCV Step 2
JPC12-8 JPC12-12 Repair or replace the
S8 Open: >4V Replace the
2 DCV control handle, cable,
S8 Closed: <1V VM
or S8 (in the handle)

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A74 - Sideshift Left/Right (SW4) (Optional Handle)

Test A74 - Sideshift

Left/Right (SW4)
(Optional Handle)
This test shows the voltages at the sideshift
switch (SW4) on an optional control handle.

Run Test
Acceptable values are:

State Value Shown

Sideshift Left Activated 2.80 to 4.69V

Neutral 2.11 to 2.79V

Sideshift Right
0.21 to 2.10V
Activated

The test has failed if the reading is outside

these limits or does not change linearly.

Diagnosis and Repair

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

Note: A breakout cable or box is required to measure control handle voltages.

Neutral: approx. 2.44V

Repair or replace
Full Sideshift Right:
Replace the the control handle,
1 DCV JPC12-5 JPC12-12 approx. 0.6V
VM cable, or SW4 (in the
Full Sideshift Left:
handle)
approx. 4.36V

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A75 - Attach Fcn 1 (S4) Analog Tests

Test A75 - Attach Fcn 1

(S4)
This test shows the voltage at the attachment
function 1 switch (S4) on a standard control
handle.

Run Test
Acceptable values are:

State Value Shown

Neutral Approx. 5V

Function Activated Approx. 0.0V

The test has failed if the voltage is outside these

limits or does not change.

Diagnosis and Repair

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

Note: A breakout cable or box is required to measure control handle voltages.

JPC12 Perform
1 JPC12-12 >4V Replace the VM
Disconnected/DCV Step 2

Repair or replace
JPC12-4 the control
De-activated: approx. 5V Replace the
2 DCV TP4 handle, cable, or
Activated: <1V VM
S4 (in the
handle)

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A75 - Attach Fcn 1 (SW3) (Optional Handle)

Test A75 - Attach Fcn 1

(SW3) (Optional Handle)
This test shows the voltage at the attachment
function 1 switch (SW3) on an optional control
handle.

Run Test
Acceptable values are:

State Value Shown

Neutral Approx. 4.36V

Function Activated Approx. 0.57V

The test has failed if the voltage is outside these

limits or does not change.

Diagnosis and Repair

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

Note: A breakout cable or box is required to measure control handle voltages.

Repair or replace
De-activated: approx. 4.3V the control
Replace the
1 DCV JPC12-4 TP4 Fully activated: variable handle, cable, or
VM
down to approx. 0.6V SW3 (in the
handle)

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A76 - Attach Fcn 2 (S5) Analog Tests

Test A76 - Attach Fcn 2

(S5)
This test shows the voltage at the attachment
function 2 switch (S5) on a standard control
handle.

Run Test
Acceptable values are:

State Value Shown

Neutral Approx. 5V

Function Activated Approx. 0.0V

The test has failed if the voltage is outside these

limits or does not change.

Diagnosis and Repair

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

Note: A breakout cable or box is required to measure control handle voltages.

JPC12
1 Disconnected/ JPC12-12 >4V Perform Step 2 Replace the VM
DCV

JPC12-11 Repair or replace

the control
De-activated: approx. 5V Replace the
2 DCV TP4 handle, cable, or
Activated: <1V VM
S5 (in the
handle)

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A76 - Attach Fcn 2 (SW2) (Optional Handle)

Test A76 - Attach Fcn 2

(SW2) (Optional Handle)
This test shows the voltage at the attachment
function 2 switch (SW2) on an optional control
handle.

Run Test
Acceptable values are:

State Value Shown

Neutral Approx. 4.36V

Function Activated Approx. 0.57V

The test has failed if the voltage is outside these

limits or does not change.

Diagnosis and Repair

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

Note: A breakout cable or box is required to measure control handle voltages.

Repair or replace
De-activated: approx. 4.3V the control
Replace the
1 DCV JPC12-11 TP4 Fully activated: variable handle, cable, or
VM
down to approx. 0.6V SW2 (in the
handle)

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A77 - EPO (S21) Analog Tests

Test A77 - EPO (S21)

This test shows the voltage at the emergency
power off Switch (S21).

Run Test
Acceptable values are:

State Value Shown

EPO Button Raised Approx. B+

EPO Button Pressed 0V

The test has failed if these results are not

shown.

Diagnosis and Repair

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

T/S the switch,

Closed: approx. B+ Replace the
1 DCV JPC22-21 TP4 wiring, and
Open: <0.5V VM
connections

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A80 - Aux Select Current (SOL6)

Test A80 - Aux Select

Current (SOL6)
This test shows the current at the aux select
solenoid (SOL6).

Run Test
Acceptable values are:

State Value Shown

Sideshift Left
1.4A
Tilt Forward

The test has failed if these results are not

shown.
NOTE: Disable TiltCntr in Configure Mode
Menu if “CNTR ON” is shown.

Diagnosis and Repair

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

JPC18 and
JPC20 T/S the wires
1 JPC18-1 Approx. 18 ohms Perform Step 2
Disconnected and coil
/ohms
JC20-13
No function
Check SOL6 for
requested: B+
2 DCV TP4 mechanical binding. Replace the VM
Tilt Forward: approx.
Replace SOL6
10V

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A81 - Priority Bypass Current (SOL4) Analog Tests

Test A81 - Priority

Bypass Current (SOL4)
This test shows the current at the priority
bypass solenoid (SOL4).

Run Test
Acceptable values are:

State Value Shown

Neutral Approx. 0A

Lifting, No Aux Approx. 1.15A

*Sideshift (speed set to 70%) Approx. 0.70A

*Tilt Approx. 0.55A

*Values listed differ depending on the configured

Sideshift percentage.

The test has failed if these results are not

shown.
NOTE: Disable TiltCntr in Configure Mode
Menu if “CNTR ON” is shown.

Diagnosis and Repair

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

JPC20 T/S the

1 Disconnected PC20-17 PC20-18 Approx. 20 ohms Perform Step 2 wires and
/ohms coil

2 DCV JPC20-17 TP4 B+ Perform Step 3

OFF: B+
Check the valve Replace the
Test Tilting Fwd: ramps to approx.
for mechanical VM
3 Activated/ JPC20-18 B– 26V
binding/
DCV Tilting Back: approx. 1V less
contamination
Sideshifting: approx. 25V

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A82 - Aux. Relief Current (SOL5)

Test A82 - Aux. Relief

Current (SOL5)
This test shows the current at the aux relief
solenoid (SOL5).

Run Test
Acceptable values are:

State Value Shown

Neutral Approx. 0A

Aux Requests with No

Approx. 0.45A
Attachments

The test has failed if these results are not

shown.
NOTE: Disable TiltCntr in Configure Mode
Menu if “CNTR ON” is shown.

Diagnosis and Repair

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

JPC20
T/S the wires
1 Disconnected PC20-19 PC20-20 Approx. 30 ohms Perform Step 2
and coil
/ohms

2 DCV JPC20-19 TP4 B+ Perform Step 3

OFF: B+ Replace the

Check the valve for
Test ON: approx. 24V (normal VM
3 JPC20-20 B– mechanical binding
ON/DCV mast configuration, no
/contamination
attachment)

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A96 - EPS Current Actual Analog Tests

Test A96 - EPS Current

Actual
NOTE: The Energy Power Source (EPS) sends
Analog Test values to the lift truck. The
values are dependent on the EPS
installed in the lift truck. Refer to the
EPS manufacturer Service Manual for
specific values.

Battery current as read by the EPS. Discharge

current is a negative value. Regenerated current
is a positive value.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A97 - EPS Voltage Actual

Test A97 - EPS Voltage

Actual
NOTE: The Energy Power Source (EPS) sends
Analog Test values to the lift truck. The
values are dependent on the EPS
installed in the lift truck. Refer to the
EPS manufacturer Service Manual for
specific values.

Battery voltage as read by the EPS.

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A98 - EPS Temp Analog Tests

Test A98 - EPS Temp

NOTE: The Energy Power Source (EPS) sends
Analog Test values to the lift truck. The
values are dependent on the EPS
installed in the lift truck. Refer to the
EPS manufacturer Service Manual for
specific values.

Battery temperature as read by the EPS.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A99 - H2O Snse

Test A99 - H2O Snse

Battery water sensed by the battery sensor
module (BSM). Values are shown as True or
False. False indicates water level is low.

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A100 - BSM Comm Analog Tests

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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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Tests Test A103 - Max EPS Discharge

Test A103 - Max EPS

Discharge
NOTE: The Energy Power Source (EPS) sends
Analog Test values to the lift truck. The
values are dependent on the EPS
installed in the lift truck. Refer to the
EPS manufacturer Service Manual for
specific values.

Maximum amount of current the EPS can

discharge. The value varies, depending on the
displayed state-of-charge (DSOC)/actual
state-of-charge (SOC), state-of-health (SOH),
and temperature.

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test A104 - Max EPS Regen Charge Analog Tests

Test A104 - Max EPS

Regen Charge
NOTE: The Energy Power Source (EPS) sends
Analog Test values to the lift truck. The
values are dependent on the EPS
installed in the lift truck. Refer to the
EPS manufacturer Service Manual for
specific values.

Maximum amount of Regen current the EPS

can accept. The value varies, depending on the
displayed state-of-charge (DSOC)/actual
state-of-charge (SOC), state-of-health (SOH),
and temperature.

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Models 4150/4250 Maintenance Manual 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 the technician with a step-by-step
approach to diagnosing a problem and the
necessary corrective action. See the sample
table below.

Example Diagnosis and Repair Table

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

This column identifies

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

This column also

identifies the required
setting on the meter
for this step.

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test I00 - Deadman (S2) Input Tests

Test I00 - Deadman (S2)

This test shows what the VM is reading from
the deadman switch (S2).

Run Test
The state of the deadman switch (S2) is shown:

Deadman Pedal Value Shown

Up Off

Down On

The test has failed if these results are not

shown.

Diagnosis and Repair

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

Note: With the deadman pedal fully pressed, the gap between the proximity switch and flag should be
0.05 to 0.07 in. (1.3 to 1.8 mm).

Deadman UP: approx. 5V

1 JPC22-8 Replace the VM Perform Step 2
Deadman DOWN: <1V
DCV JPC22-11 T/S the switch,
2 JPC10-1 Approx. 12V wiring, and Replace the VM
connections

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Input Tests Test I02 - Mast Tilt Speed Reduction (S11)

Test I02 - Mast Tilt Speed

Reduction (S11)
This test monitors the state of the mast tilt
speed reduction switch (S11) on lift trucks
above S/N 50500 and shows what the VM is
reading from the switch.
NOTE: S11 is also used for the hi-speed limit
function of the bottler’s tilt option.

Run Test
Monitor the following results when the test is
run:

High Speed Limit Switch

Value Shown
Sensor

Near Metal Belw

Away From Metal Abve

The test has failed if these results are not

shown.
NOTE: The correct gap for the switch is 0.11
±0.04 in. (2.79 ±1 mm).

Diagnosis and Repair

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

1 JPC20-8 JPC24-8 Perform Step 2 Replace the VM

Approx. 12V T/S the wiring
2 JPS5-4 JPS5-2 Perform Step 3
and connections
DCV
3 JPC22-22 JPC24-8 Switch Not Activated: Replace the VM Perform Step 4
approx. 5V T/S the wiring Adjust/replace
4 JPS5-1 JPS5-2 Switch Activated: approx. 0V and connections the switch

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test I05 - Lift Limit (S12) Input Tests

Test I05 - Lift Limit (S12)

This test monitors the state of the optional lift
limit switch (S12) and shows what the VM is
reading from the switch.
NOTE: Lift trucks below S/N 50501 with a
quad mast use S12 for mast tilt speed
reduction.

Run Test
Observe the following results when the test is
run:

Mast Value Shown

Below Switch (closed) Belw

Above Switch (open) Abve

The test has failed if these results are not

shown.
NOTE: The correct gap for the switch is 0.11
±0.04 in. (2.79 ±1 mm).

Diagnosis and Repair

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

T/S the wiring and

1 JPS6-4 JPS6-3 Approx. 12V Perform Step 2 connections.
Perform Step 3 if OK
DCV Switch Not Activated:
approx. 5V
2 JPS6-1 TP4 Perform Step 4 Replace the switch
Switch Activated:
approx. 0V

JPC20 and
JPC24
3 PC20-6 PC24-6 Approx. 12V Perform Step 4 Replace the VM
Disconnected
/DCV

Switch Not Activated:

approx. 5V Replace the T/S the wiring and
4 DCV JPC22-6 TP4
Switch Activated: VM connections
approx. 0V

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Input Tests Test I13 - Lift Contactor (DC Lift)

Test I13 - Lift Contactor

(DC Lift)
This test reports the absence or presence of B+
on the load side of the LPC contactor.

It is necessary to manually activate the

contactor to see the transition or perform the
test in Active Maintenance Mode.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-20.

Energizing the lift contactor causes the

lift motor to run.

Run Test
Observe the following results when the test is
run:

LPC Contactor Value Shown

Open Out

Closed In

The test has failed if these results are not

shown. Check fuse FU3 and the LPC contactor
tips.

Diagnosis and Repair

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

Remove FU3/
1 FU1+ FU1– 0 ohms Perform Step 2 Replace the fuse
ohms

T/S the wiring

and connections.
Tips open: <0.5V; Check the
2 DCV JPC22-20 TP4 Replace the VM
Tips closed: B+ contactor tips.
Check for shorts
to the frame.

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test I14 - Steer Contactor Input Tests

Test I14 - Steer Contactor

This test reports the absence or presence of
voltage to the load side of the STR contactor.

Run Test
Must be in Active Maintenance Mode to perform
this test.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-20.

Observe the following results when the test is

run:

STR Contactor Value Shown

Open Out

Closed In

The test has failed if these results are not

shown.

Check fuse FU1 and the STR contactor tips.

Diagnosis and Repair

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

Remove FU1/
1 FU1+ FU1– 0 ohms Perform Step 2 Replace the fuse
ohms

Check the wiring

Tips open: B+ and
2 STR-1 STR-2 Perform Step 3
Tips closed: approx. 0V connections.
Replace the tips
DCV
T/S the wiring
Tips open: 0V from the
3 JPC22-19 TP4 Replace the VM
Tips closed: B+ contactor to the
VM

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Input Tests Test I15 - Horn (S3, SW1)

Test I15 - Horn (S3, SW1)

This test checks the input from the horn switch
(S3 on standard handle, SW1 on optional
control handle) to the VM.

Run Test
Observe the following results when the test is
run:

Horn Switch Position Value Shown

Out Off

Pressed On

The test has failed if these results are not

shown.

Diagnosis and Repair

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

Standard Handle

Button pressed: T/S the

JPC12
0 ohms connector and
1 Disconnected/ JC12-10 JC12-12 Replace the VM
Button released: >1 cable or replace
ohms
megohm the horn switch

Optional Handle

Unplug cable R/R the cable or

1 JC12-10 PH1-10 0 ohms Perform Step 2
/ohms connectors

Note: A breakout cable or box is required to measure control handle voltages.

Button pressed: <1V T/S the control

2 DCV JPC12-10 JPC12-12 Button released: Replace the VM handle wiring
approx. 5V and switch

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test I19 - Left Traction RPM Input Tests

Test I19 - Left Traction

RPM
This test shows the output from the speed
encoder on the left traction motor as seen by
the left traction power amplifier (TPA).

Do this test in an area free of

obstructions with ample room for
maneuvering.

Run this test in Active Maintenance Mode for

best results.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-20.

Run Test
The operator display should show a linear
increase to maximum RPM.

The test has failed if the RPM does not show a

linear increase.

Diagnosis and Repair

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

1 JPTL1-26 JPTL1-7 Perform Step 2 Replace the TPA

4.5 to 5.5V T/S or replace
2 JPTL2-1 JPTL2-4 Perform Step 3
the harness

3 JPTL1-31 JPTL1-7; Perform Step 4 Perform Step 5

DCV after
4 JPTL1-32 JPTL1-7 is Replace the TPA Perform Step 6
Stationary: >3.5V or <0.5V
tested for
5 JPTL2-3 Running: approx. 2V
B–, use TP4 R/R the Replace the
for easier harness speed encoder
6 JPTL2-2 access

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Input Tests Test I20 - Lift RPM (AC Lift only)

Test I20 - Lift RPM

(AC Lift only)
This test shows the input from the speed
encoder on the lift motor as seen by the lift
power amplifier (LPA).

Do this test in an area free of

obstructions with ample room for lifting.

Run this test in Active Maintenance Mode for

best results.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-20.

Run Test
The operator display should show a linear
increase to maximum RPM.

The test has failed if the RPM does not show a

linear increase.

Diagnosis and Repair

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

1 JPL1-26 JPL1-7 Perform Step 2 Replace the LPA

4.5 to 5.5V T/S or replace
2 JPL2-1 JPL2-4 Perform Step 3
the harness

JPTL1-7;
after JPTL1-7
3 JPL1-31 is tested for Perform Step 4 Perform Step 5
DCV B–, use TP4 for
easier access
Stationary: >3.5V or <0.5V
Running: approx. 2V Replace the
4 JPL1-32 JPL1-7 Perform Step 6
LPA

5 JPL2-3 R/R the Replace the

JPL1-7
6 JPL2-2 harness speed encoder

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test I23 - CAN Communication Test Input Tests

Test I23 - CAN

Communication Test
This test verifies that the VM is communicating
with the left traction power amplifier (TPA),
right traction power amplifier, and (4250 Only)
lift power amplifier (LPA).

The cause could be a bad cable or connection if

the fault code is intermittent. It could also be
caused by a static discharge. Check the static
straps, the terminating resistor, or wiring on
the left traction amp JTL1-21 and JTL1-34.
Additionally, it can be caused by an optional
device or bad DC motor brushes.

Run Test
The operator display (OD) shows:
• V if VM is communicating with any
amplifier
• L if the left side TPA is communicating
with the VM
• R if the right side TPA is communicating
with the VM
• P (4250 only) if the LPA is communicating
with the VM

The test has failed if V, L, R, or P (4250 only) are

not shown.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Input Tests Diagnosis and Repair

Diagnosis and Repair

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

If all letters are missing (not shown):

T/S B+ from the K2 or

1 DCV JPTL1-1 B– B+ Perform Step 2
K3 relay

2 JPTL1 and JPC14 JPL1-23 JPC14-11 Perform Step 3

Disconnected/ 0 ohms R/R the harness
3 ohms JPTL1-35 JPC14-4 Replace the VM

If letter P is missing (4250 Only):

1 JPL1-1 Perform Step 2

DCV B– (On Amp) B+
2 JPL1-11 Perform Step 3

3 JPL1-23 JPC14-11 Perform Step 4 R/R the harness

JPTL1 and JPC14
Disconnected/ 0 ohms Replace the
4 ohms JPL1-35 JPC14-4
LPA

If letter L is missing:

1 JPTL1-1 Perform Step 2

DCV B– (On Amp) B+
2 JPTL1-12 Perform Step 3

3 JPTL1-23 JPC14-11 Perform Step 4 R/R the harness

JPTL1 and JPC14
Disconnected/ 0 ohms Replace the
4 ohms JPTL1-35 JPC14-4
LTPA

If letter R is missing:

1 JPTR1-1 Perform Step 2

2 DCV JPTR1-11 B– (On Amp) B+ Perform Step 3

3 JPTR1-12 Perform Step 4

R/R the harness
4 JPTR1 and JPC14 JPTR1-23 JPC14-11 Perform Step 5
Disconnected/ 0 ohms Replace the
5 ohms JPTR1-35 JPC14-4
RTPA

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test I65 - Tilt Position SW (S18) Input Tests

Test I65 - Tilt Position SW

(S18)
NOTE: This test applies to lift trucks equipped
with optional bottler’s tilt.

Use this test to verify the state of the mast tilt

switch (S18).

Run Test
Observe the following results when the test is
run:

Tilt Position Switch (S18) Value Shown

Pressed In

Released Out

The test has failed if these results are not

shown.

Check that the tilt position switch has the

correct clearance; adjust the switch so that it
deactivates when the mast is tilted past 3°
forward. See “Mast Tilt Position Switch
Adjustment” on page 7-144.

Diagnosis and Repair

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

T/S the wiring and

1 JPT1-1 JPT1-3 Approx. 12V Perform Step 2 connections. Perform
Step 3 if OK

Replace the switch if

DCV Switch Not Activated: the voltage stays
approx. 5V high (5V).
2 JPT1-2 TP4 Perform Step 4
Switch Activated: Replace the VM if the
approx. 0V voltage stays low
(B–).

JPC20 and 24
PC20-5 PC24-5
3 Disconnected Approx. 12V Perform Step 4 Replace the VM
(on VM) (on VM)
/DCV

Switch Not Activated:

approx. 5V T/S the wiring and
4 DCV JPC22-5 TP4 Replace the VM
Switch Activated: connections
approx. 0V

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Input Tests Test I80 - OCSS - Low

Test I80 - OCSS - Low Run Test

NOTE: The operator must be on the deadman
This test shows the output from the optional pedal.
OCSS - lower beam.
Make sure the beam is not blocked. The
NOTE: This test shows best results in Active
operator display shows the state of the beam:
Maintenance Mode.

For more information on how to use Deadman Pedal Value Shown

Maintenance Mode, refer to page 3-20. Down ON

Up OFF

The test has failed if these results are not

shown.

Diagnosis and Repair

Deadman Pedal
LED Status
Position

Up or Down Green ON +12V present at the detector

Receiver (3 Wires) The receiver is receiving the light
Down Yellow ON
beam (correctly aligned)

Emitter (2 Wires) Down Green ON +12V present at the emitter

Troubleshoot according to the following table if

an LED does not illuminate as described above:

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

1 JPW3-1 JPW3-2 Perform Step 3 Perform Step 2

Check the
2 PC20-9 PC10-3 wiring and Replace the VM
connections
Approx. 12V
3 JPW4-1 JPW4-4 Perform Step 5 Perform Step 4

Check the
4 DCV PC20-2 PC18-5 wiring and Replace the VM
connections

Check the wiring and

connections if 5V is missing.
Beam blocked:
Replace the VM if okay.
approx. 5V
5 JPC22-13 TP4 Replace the VM Replace the emitter or
Beam
detector if 5V does not
unobstructed: 0V
change state when the beam
is blocked

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test I81 - OCSS - High Input Tests

Test I81 - OCSS - High Run Test

NOTE: The operator must be on the deadman
This test shows the output from the optional pedal.
OCSS - upper beam.
Make sure the beam is not blocked. The
NOTE: This test shows best results in Active
operator display shows the state of the beam:
Maintenance Mode.

For more information on how to use Deadman Pedal Value Shown

Maintenance Mode, refer to page 3-20. Down ON

Up OFF

The test has failed if these results are not

shown.

Diagnosis and Repair

Deadman Pedal
LED Status
Position

Up or Down Green ON +12V present at the detector

Receiver (3 Wires) The receiver is receiving the light
Down Yellow ON
beam (correctly aligned)

Emitter (2 Wires) Down Green ON +12V present at the emitter

Troubleshoot according to the following table if

an LED does not illuminate as described above:

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

1 JPW1-1 JPW1-2 Perform Step 3 Perform Step 2

Check the
2 PC20-1 PC10-3 wiring and Replace the VM
connections
Approx. 12V
3 JPW2-1 JPW2-4 Perform Step 5 Perform Step 4

Check the
4 DCV PC20-10 PC18-6 wiring and Replace the VM
connections

Check the wiring and

connections if 5V is missing.
Beam blocked:
Replace the VM if okay.
approx. 5V Replace the
5 JPC22-14 TP4 Replace the emitter or
Beam unobstructed: VM
detector if 5V does not change
0V
state when the beam is
blocked

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Input Tests Test I82 - Right Traction RPM

Test I82 - Right Traction

RPM
This test shows the output from the speed
encoder on the right traction motor as seen by
the right traction power amplifier (TPA).

Do this test in an area free of

obstructions with ample room for
maneuvering.

Run this test in Active Maintenance Mode for

best results.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-20.

Run Test
The operator display should show a linear
increase to maximum RPM.

The test has failed if the RPM does not show a

linear increase.

Diagnosis and Repair

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

Replace the
1 JPTR1-26 JPTR1-7 Perform Step 2
TPA
4.5 to 5.5V
R/R the
2 JPTR2-1 JPTR2-4 Perform Step 3
harness

3 DCV JPTR1-31 Perform Step 4 Perform Step 5

JPTR1-7; after Replace the
4 JPTR1-32 Stationary: >3.5V or Perform Step 6
JPTR1-7 is tested TPA
<0.5V
for B–, use TP4
5 JPTR2-3 Running: approx. 2V
for easier access R/R the Replace the
6 JPTR2-2 harness motor encoder

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test I87 - Battery Gate 1 Input Tests

Test I87 - Battery Gate 1

This test checks the input from the left battery
gate switch (S22A) to the VM.

Run Test
The test has failed if these results are not
shown.

Battery Gate Value Shown

Removed Out

Installed In

NOTE: The correct gap for the switch is 0.11

±0.04 in. (2.79 ±1.00 mm).

Diagnosis and Repair

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

1 JPC20-3 JPC24-3 Perform Step 2 Replace the VM

Approx. 12V T/S the wiring and
2 JPS14-3 JPS14-2 Perform Step 3
connections
DCV
3 JPC22-3 JPC24-3 Gate removed: approx. Replace the VM Perform Step 4
5V T/S the wiring Adjust/replace the
4 JPS14-1 JPS14-2 Gate installed: <0.5V and connections switch

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Input Tests Test I88 - Battery Gate 2

Test I88 - Battery Gate 2

This test checks the input from the right battery
gate switch (S22B) to the VM.
NOTE: If the lift truck is equipped with the PSL
option and the Battery Gate Switch is
operational, refer to “Troubleshooting
Power Source Limit Faults” on
page 5-20.

Run Test
The test has failed if these results are not
shown.

Battery Gate Value Shown

Removed Out

Installed In

NOTE: The correct gap for the switch is 0.11

±0.04 in. (2.79 ±1.00 mm).

Diagnosis and Repair

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

1 JPC20-4 JPC24-4 Perform Step 2 Replace the VM

Approx. 12V T/S the wiring and
2 JPS13-3 JPS13-2 Perform Step 3
connections
DCV
3 JPC22-4 JPC24-4 Gate removed: approx. Replace the VM Perform Step 4
5V T/S the wiring Adjust/replace the
4 JPS13-1 JPS13-2 Gate installed: <0.5V and connections switch

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test I89 - Steer Position Sensor Input Tests

Test I89 - Steer Position NOTE: Adjust the prox. switch position if the
results are erratic. The gap between the
Sensor bottom face of the sensor and the upper
surface of the steer plate should
measure 0.060 +0.04/–0.03 in.
This test shows feedback from the steer position (1.5 +1.0/–0.7 mm) (alignment tool,
sensor. P/N 939-350/ALT, is available from the
Parts Distribution Center).

Do this test in an area free of

obstructions with ample room for Steer Tire Value Steer Tone
(when in Active
maneuvering. Position Shown Maintenance Mode)

NOTE: Steer tire rotation is opposite that of the 90° (full clockwise)
101 High
steer tiller. to 67°

67° to 41° 100 Medium

Run Test 41° to 18° 000 Low

Audible “steer tones” are enabled when this test 18° to –18° (wheels
001 None
is run in Active Maintenance Mode. centered)

NOTE: For more information on how to use –18° to –41° 011 Low
Maintenance Mode, refer to page 3-20.
–41° to –67° 010 Medium

The numbers listed in the table are shown on –90° (full

110 High
the display as the steer tire rotates. The test has clockwise) to –67°
failed if they do not change or are erratic.
Error Condition 111
Make sure the steer position proximity switch is
not damaged. Replace components as
necessary.

Diagnosis and Repair

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

JPC24
Replace the
1 Disconnected/ JPC24-1 Perform Step 2
10.5 to 13V VM
DCV

2 JPS2-1 Perform Step 3

TP4
3 JPC24-17 Perform Step 4 T/S the wiring
DCV Over metal: <2V
4 JPC24-20 Perform Step 5 and sensor
Not over metal: >7V
5 JPC22-9 Replace the VM

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Input Tests Test I91 - iPort Communication

Test I91 - iPort

Communication
Test I91 is an iPORT related code. Refer to
iPORT Kit Installation and Maintenance
Instructions, iWAREHOUSE Essential
Installation and Maintenance Instructions and
User Guide, or iWAREHOUSE Evolution
Installation and Maintenance Instructions and
User Guide.

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test I91 - iPort Communication Input Tests

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Models 4150/4250 Maintenance Manual 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 the technician with a step-by-step
approach to diagnosing a problem and the
necessary corrective action. See the sample
table below.

Example Diagnosis and Repair Table

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

This column identifies

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

This column also

identifies the required
setting on the meter
for this step.

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test O00 - TPC Contactor Output Tests

Test O00 - TPC Contactor

This test toggles the traction power contactor
(TPC) ON and OFF.

Run Test
Acceptable values are:
TPC Contactor Value Shown

Closed ON

Open OFF

The test is a success if the TPC tracks the

On/Off shown on the display. The test has
failed if these results are not shown.

Diagnosis and Repair

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

T/S the wires,

JPTR1
connections, and
1 Disconnected JTR1-6 Approx. 38 ohms Perform Step 2
JTR1-13 contactor coil for
/ohms
opens or shorts

2 TP4 B+ Perform Step 3 Replace the right

DCV Test ON: approx. 22V Check for traction power
3 B+ JPTR1-6 amplifier
Test OFF: 0V binding

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests Test O01 - Steer Contactor (STR)

Test O01 - Steer

Contactor (STR)
This test toggles the steer contactor (STR) ON
and OFF.

Run Test
Acceptable values are:
STR Contactor Value Shown

Closed ON

Open OFF

The test is a success if the STR contactor tracks

the On/Off shown on the display. The test has
failed if these results are not shown.

Diagnosis and Repair

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

JPC18 and T/S the wires,

JPF2 connections, and
1 JPC18-11 JPF2-1 Approx. 38 ohms Perform Step 2
Disconnected/ contactor coil for
ohms opens or shorts

T/S the wire and

connections
2 STR-X TP4 B+ Perform Step 3
(including SPL9 and
DCV JPF2-1)

TP1 or Test ON: approx. 23V Check for

3 STR-Y Replace the VM
STR-X Test OFF: 0V binding

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test O02 - Lift Power Contactor (LPC) Output Tests

Test O02 - Lift Power

Contactor (LPC)
This test toggles the lift power contactor (LPC)
ON and OFF.

Run Test
Acceptable values are:
LPC Contactor Value Shown

Closed ON

Open OFF

The test is a success if the LPC contactor tracks

the On/Off shown on the display. The test has
failed if these results are not shown.

Diagnosis and Repair

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

Model 4150

JPF2 and
T/S the wires,
JPC18
1 JF2-1 JPC18-9 Approx. 18 ohms Perform Step 2 connections, and
Disconnected
contactor coil
/ohms

T/S the K2 relay

2 JPF2-1 TP4 B+ Perform Step 3 and the
fuse/relay card
DCV
Check the
TP1 (B+) JPC18-9 Test ON: approx. 23V
3 contactor for Replace the VM
or LPC-X or LPC-Y Test OFF: 0V
binding

Model 4250

T/S the wires,

JPL1 connections
1 Disconnected JL1-13 JL1-6 Approx. 37 ohms Perform Step 2 (including JPL4),
/ohms and the
contactor coil

2 JPL1-13 TP4 B+ Perform Step 3

DCV Check the Replace the LPA

TP1 (B+) JPL1-6 or Test ON: approx. 20V
3 contactor for
or LPC-X LPC-Y Test OFF: 0V
binding

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests Test O04 - Aux. Direction Solenoid (SOL6)

Test O04 - Aux. Direction The percentage shown on the operator display
starts at 0%. Use the UP button to increase the
Solenoid (SOL6) percentage up to 90% in 15% increments.
Ammeter Reading Value Shown
This test ramps the auxiliary direction solenoid
0 to 1.3A Ramp (15% increments)
(SOL6) from 0% to 90% in 15% increments.
0.000A 0%
A successful test proves the wiring and the
related circuitry in the VM are all functioning The test has failed if these results are not
correctly. shown. Reconnect the wire at SOL6-1.

It does not prove that the auxiliary direction

solenoid itself is mechanically functional.

Run Test
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from aux select
SOL6-1.
3. Connect an ammeter in series with the
aux select solenoid as follows:
• (–) lead to terminal of SOL6-1
• (+) lead to wire removed from SOL6-1
4. Reconnect the battery connector and turn
the key switch ON. Start the test.

Diagnosis and Repair

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

JPC18 and
JPC20 T/S the wiring and
1 JC20-13 JC18-1 Approx. 18 ohms Replace the VM
Disconnected coils
/ohms

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test O07 - Tilt Solenoid (SOL10) Output Tests

Test O07 - Tilt Solenoid

(SOL10)
This test toggles the tilt solenoid (SOL10) ON
and OFF.
NOTE: This test does not prove that the
solenoid valve itself is mechanically
functional.

Run Test
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from the tilt solenoid
at SOL10-1.
3. Connect an ammeter in series with the tilt
solenoid as follows:
• (–) lead to terminal of SOL10-1
• (+) lead to wire removed from SOL10-1
4. Reconnect the battery connector and turn
the key switch ON. Start the test.

Ammeter Reading Value Shown

0.500 to 1.000A ON

0.000 to 0.020A OFF

The test has failed if these results are not

shown. Reconnect the wire at SOL10-1.

Diagnosis and Repair

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

JPF2 T/S the wiring,

1 Disconnected JPC18-15 JF2-8 Approx. 28 ohms Perform Step 2 connections, and
/ohms solenoid coil

TP1 (B+) De-energized: 0V Check for binding. T/S the B+K2.

2 DCV or SOL10-2 Energized: approx. Replace the Replace the VM
SOL10-1 23V solenoid if OK

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests Test O08 - Sideshift Solenoid (SOL9L, SOL9R)

Test O08 - Sideshift 5. Turn the key switch OFF and disconnect
the battery connector.
Solenoid (SOL9L, SOL9R) 6. Disconnect the wire from the right
sideshift solenoid at SOL9R-1.
This test toggles the sideshift solenoids (SOL9L, 7. Connect an ammeter in series with the
SOL9R) ON and OFF. right sideshift solenoid as follows:
• (–) lead to terminal of SOL9R-1
Run Test • (+) lead to wire removed from SOL9R-1
1. Turn the key switch OFF and disconnect 8. Reconnect the battery connector and turn
the battery connector. the key switch ON. Start the test.
2. Disconnect the wire from the left sideshift
Ammeter Reading Value Shown
solenoid at SOL9L-1.
3. Connect an ammeter in series with the left 0.500 to 1.000A ON
sideshift solenoid as follows: 0.000 to 0.020A OFF
• (–) lead to terminal of SOL9L-1
• (+) lead to wire removed from SOL9L-1 The test has failed if these results are not
shown. Reconnect the wire to SOL9R-1.
4. Reconnect the battery connector and turn
the key switch ON. Start the test. NOTE: Individual coils are approx. 29 ohms.

Ammeter Reading Value Shown

0.500 to 1.000A ON

0.000 to 0.020A OFF

The test has failed if these results are not

shown. Reconnect the wire to SOL9L-1
and proceed to Diagnosis and Repair.
Proceed to Step 5 for a similar procedure
for SOL9R if the test passes.

Diagnosis and Repair

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

JPC18 T/S the wiring,

1 Disconnected JPC18-14 JF2-8 Approx. 14 ohms Perform Step 2 coils, and
/ohms connections

T/S the wiring

and
2 SOL9L-2
connections.
Check for binding. Perform Step 3
DCV JPC18-14 Approx. 22V Replace the
solenoid T/S the wiring
and
3 SOL9R-2
connections.
Replace the VM

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test O09 - Lift Relief Solenoid (SOL3) Output Tests

Test O09 - Lift Relief 4. Reconnect the battery connector and turn
the key switch ON. Start the test.
Solenoid (SOL3) Ammeter Reading Value Shown

This test ramps the proportional lift relief 0.000 to 1.000A Ramp (15% increments)
(SOL3) solenoid from 0% to 90% in 15%
0.000A 0%
increments.

A successful test proves the wiring and the The percentage shown on the operator display
related circuitry in the VM are all functioning starts at 0%. Use the UP button to increase the
correctly. percentage up to 90% in 15% increments.

NOTE: This test does not prove that the lift The test has failed if these results are not
relief solenoid itself is mechanically shown. Reconnect the wire to SOL3-1.
functional.

Run Test
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from SOL3-1.
3. Connect an ammeter in series with the lift
relief solenoid as follows:
• (–) lead to terminal of SOL3-1
• (+) lead to wire removed from SOL3-1

Diagnosis and Repair

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

JPC20 and
JPF2 T/S the wiring and
1 JC20-12 JPF2-8 Approx. 32 ohms Perform Step 2
Disconnected coil
/ohms

T/S the wiring,

2 DCV SOL3-1 TP4 B+ Perform Step 3 connections, and
the fuse/relay card

Ramp from B+
Test Check the valve for T/S the B+K2.
when OFF to
3 Activated/ JC20-12 TP4 binding/ Replace the VM if
approx. 9V when
DCV contamination OK
full lower

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests Test O11 - Load Hold Solenoid (SOL1)

Test O11 - Load Hold 5. Reconnect the battery connector and turn
the key switch ON. Start the test.
Solenoid (SOL1) Ammeter Reading Value Shown

This test toggles the load holding (L/H) Solenoid 0.500 to 1.000A ON
ON and OFF.
0.000 to 0.020A OFF

The test has failed if these results are not

Make sure the carriage is fully lowered shown. Reconnect the wire to SOL1-1.
before performing this test.

NOTE: The carriage may lower if there is a fault

in the proportional lift/lower circuit or
in the proportional lift/lower valve itself.
Fully lower the carriage before entering
this test to guard against unexpected
motion of the carriage.

Run Test
1. Lower the forks to the floor.
2. Turn the key switch OFF and disconnect
the battery connector.
3. Disconnect the wire from the load holding
solenoid at SOL1-1.
4. Connect an ammeter in series with the
L/H solenoid as follows:
• (–) lead to terminal of SOL1-1
• (+) lead to wire removed from SOL1-1

Diagnosis and Repair

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

JPC18 and
T/S the wiring,
JPF2
1 JC18-10 JPF2-8 Approx. 29 ohms Perform Step 2 connections, and
Disconnected/
the solenoid coil
ohms

T/S the wiring,

connections, and
2 SOL 1-1 B+ Perform Step 3
the fuse/relay
card
DCV TP4
Check for
Solenoid OFF: B+
binding.
3 JC18-10 Solenoid ON: Replace the VM
Replace the
approx. 13V
solenoid

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test O12 - Lift/Lower Solenoid (SOL2) Output Tests

Test O12 - Lift/Lower 3. Connect an ammeter in series with the

lift/lower Solenoid as follows:
Solenoid (SOL2) • (–) lead to terminal SOL2-1
• (+) lead to wire removed from SOL2-1
This test ramps the proportional lift/lower 4. Reconnect the battery connector and turn
(SOL2) solenoid from 0% to 90% in 15% the key switch ON. Start the test.
increments.
Ammeter
A successful test proves the wiring and the Value Shown
Reading
related circuitry in the VM are all functioning
correctly. 0 to 1.300A Ramp (15% increments)

NOTE: This test does not prove the lift/lower 0 0%

solenoid itself is mechanically
functional. The percentage shown on the operator display
starts at 0%. Use the UP button to increase the
NOTE: Ramping the proportional lift/lower
percentage up to 90% in 15% increments.
solenoid should not allow the carriage to
lower, since the load hold (SOL1) valve
The test has failed if these results are not
should be closed. The carriage may
shown. Reconnect the wire to SOL2-1.
lower if there is a fault in the load hold
circuit or a fault in the load hold
solenoid itself.

To guard against unexpected motion of

the carriage, fully lower the carriage
before entering this test.

Run Test
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from SOL2-1.

Diagnosis and Repair

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

JPC20
T/S the wires and
1 Disconnected JPC20-16 JPC20-15 Approx. 16 ohms Perform Step 2
coil
/ohms

2 DCV JPC20-15 B+ Perform Step 3

Solenoid OFF: B+
Test TP4 Replace the VM
Solenoid ON: Check for binding/
3 Activated JPC20-16
approx. 21V when contamination
/DCV
full power

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests Test O18 - Horn

Test O18 - Horn

This test toggles the horn ON and OFF.

Run Test
The horn should sound when the test is
activated. The test has failed if these results are
not heard.

Diagnosis and Repair

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

Test
1 Activated/ HRN– Replace horn Perform Step 2
DCV HRN+ B+
Check the wiring
2 DCV TP4 Perform Step 3
to SPL9

Check all wiring and

Test Check the wiring.
Test OFF: <1V connections for
3 Activated/ TP1 or B+ HRN– Replace the VM if
Test ON: B+ opens, shorts, or
DCV OK
high resistance

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test O19 - Ramp Sounder Output Tests

Test O19 - Ramp

Sounder
Use this test to verify the operation of the
sounder on the operator display card. A
successful test proves the sounder is
functioning.

Run Test
This test sends a signal to the sounder on the
operator display card.

Press ENTER. The sounder should emit a short,

warning tone. The test has failed if this sound is
not heard.

Diagnosis and Repair

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

T/S the wiring. If good,

Replace the
1 DCV JPD1-1 JPC24-2 Test ON: voltage ramps up replace the operator
VM
display

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests Test O20 - Travel Alarm

Test O20 - Travel Alarm Run Test

Connect a voltmeter between JPF2-2 and
This test verifies the operation of the optional JPC18-18.
travel alarm.
Voltage Output Value Shown
A successful test proves the wiring and related
0.0 to 1.0V OFF
circuitry in the VM are functioning correctly.
NOTE: A device is needed that will load down 22.0V ON
the circuit to test the output portion of
the vehicle manager (VM). The load The travel alarm must be activated when the
holding coil on the hydraulic manifold operator display shows ON. The test has failed if
can be used for that purpose. Remove these results are not shown.
the load holding coil and carefully
connect its wires into the circuit.

Use extreme caution to prevent its wires

from shorting to any components.

Diagnosis and Repair

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

Replace the
1 H-2 Perform Step 2
alarm
H-1 B+ T/S the wiring
Test Activated/
2 Perform Step 3 back to the
DCV
TP4 horn and SPL9

R/R the wire to

3 JPC18-18 <1V Perform Step 4
H-2

Connect the load

Replace the
4 holding coil and TP1 JPC18-18 B+ Replace the VM
alarm
activate test/DCV

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test O23 - Toggle Amplifier Fan Output Tests

Test O23 - Toggle

Amplifier Fan
On lift trucks equipped with an optional cooling
fan, this test toggles the power amplifier cooling
fan ON and OFF.

A successful test proves the fan, wiring, and

related circuitry in the VM are working
correctly.
NOTE: The cooling fan turns ON when the
internal temperature of the LTPA, RTPA,
or LPA reaches 134°F (56.7°C).

Run Test
Fan Value Shown

On PWM 100%

Off PWM 0%

The test has failed if these results are not

shown.

Diagnosis and Repair

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

1 TP1 JPC18-17 PMW 0 and 100% Perform Step 2 Replace the VM

Test
Activated/DCV T/S the wires T/S the K2
2 JPF2-1 TP4 B+
and fan circuitry

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests Test O28 - Ramp Lift Motor (AC Lift)

Test O28 - Ramp Lift

Motor (AC Lift)
This test ramps the lift motor by gradually
increasing the command to the lift power
amplifier via the CAN Bus.

This test verifies that the lift power amplifier

can drive the lift motor.

Running this test for an extended period

of time can cause damage to the lift
motor, lift power amplifier, or wiring.

Run Test
The requested percent of ON time is shown. Use
the UP button to increase RPM in increments of
15%, from 0 to 90%.

Press the DOWN button to decrease the request

to 0 and exit the test.

The test has failed if the RPM does not increase

or decrease as described.

Diagnosis and Repair

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

Test the cables to the lift

motor if the current does
not ramp on one or two
phases. Replace the lift
Current motor if OK.
Current must be
probe (amp Replace the lift power
even on all phases Replace the
1 clamp) on N/A N/A amplifier if phases are
and ramp up as the LPA
phases U, V, low or unequal.
percentage increases
and W Check for binding if
phases are equal and
high but the lift motor
runs slowly. Replace the
lift motor if not binding

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test O29 - Ramp Traction Motors Output Tests

Test O29 - Ramp Traction Run Test

Motors 1. Step on the deadman pedal and run the
test.
This test ramps the traction motors by 2. Press ENTER once to run the motors in
gradually increasing the command to the reverse. Press a second time to run the
traction power amplifiers via the CAN Bus. This motors in forward. The requested percent
test verifies that the TPAs can generate current of ON time is shown.
and drive the traction motors. 3. Use the UP button to increase RPM in
increments of 15%, from 0 to 90%.
4. Press the DOWN button to decrease the
Running this test for an extended period request to 0, and exit the test.
of time can cause damage to the traction 5. Observe both traction motors; they both
motors, traction power amplifiers, or should be moving close to the same rate of
wiring. speed.
Refer to Diagnosis and Repair if one motor is
faster than the other.

The traction motors rotate during this

test. Jack the drive wheels off the floor.
Use extreme care when the lift truck is
jacked up, elevated, or placed on blocks
or jack stands. Never block the lift truck
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an
overhead hoist to stabilize the mast, if
jacking higher than described in
“Jacking Safety” on page 2-9. Keep
hands and feet clear while jacking the
lift truck. After the lift truck is elevated
to the required height, place blocks of a
solid material that will support the
weight of the lift truck, or jack stands
that will support the weight of the lift
truck, beneath the specified locations
shown in this maintenance manual, for
support. Lower the lift truck onto the
blocks or jack stands. Never rely on the
jack or jack stand alone to support the
lift truck.

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests Diagnosis and Repair

Diagnosis and Repair

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

Test the cables to the traction

motor if the current does not ramp
Current Replace on one or two phases. Replace the
Current must be
probe the traction motor if OK. Replace the
even on all phases
(amp associated traction power amplifier if phases
1 N/A N/A and ramp up as the
clamp) on traction are low or unequal.
percentage
phases U, power Check for binding if phases are
increases
V, and W amplifier equal and high but the traction
motor runs slowly. Replace the
traction motor if not binding

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test O30 - Electric Brakes Output Tests

Test O30 - Electric Brakes

This test checks for correct brake coil operation
in both brakes.
NOTE: The deadman pedal must be pressed for
the test to perform correctly.

Run Test
Observe the following results:
Brake Value Shown

Applied OFF

Released ON

NOTE: Use the UP or DOWN button to cycle the

test.

The test has failed if these results are not

shown.

Diagnosis and Repair

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

JPF2 and Right Side:

T/S the wires,
JPC20 JF2-3
1 JC20-14 Approx. 17 ohms Perform Step 2 fuse/relay card,
Disconnected Left Side:
and coil
/ohms JF2-5

T/S the wiring

and the
Inspect the fuse/relay card
Brake De-energized: B+ brake if no B+. Replace
2 DCV JPC20-14 TP4
Energized: approx. 0V assembly for the VM if the
binding voltage does not
drop when
energized

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests Test O32 - Toggle Relay Enable

Test O32 - Toggle Relay It may be possible to quickly test a relay by

swapping K1 or K4 with the suspected relay
Enable and performing the test again. Refer to relay
troubleshooting procedures on page 5-12.

This test toggles fuse/relay card relays K1, K2, NOTE: Removing K1 disables any key-power
K3, and K4 ON and OFF. accessories installed on the lift truck.

The test has failed if results do not match the

Run Test preceding table. Refer to Diagnosis and Repair.
NOTE: OFF is shown when entering the test
even if the relays are closed.

Press the ENTER button to toggle the test.

The following table gives the expected value at

each relay test point during the test.

Expected Values
Relay Lead Toggled Key
(+) (–) ON OFF OFF
K1 JPF2-9 or *TP1
K2 JPF2-1 or *TP2 <1V
TP4 B+ <1V
K3 JPF1-5 or *TP3
K4 JPF2-4 or *TP4 <1V
* TPs located on the Fuse/Relay Card

Diagnosis and Repair

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

T/S the
1 JF4-13 fuse/relay Perform Step 2
card

Check the diodes

Test OFF: B+ on the fuse/relay
DCV TP4 card (refer to
Test ON: <1V T/S the wire to
Section 5). Replace
2 JPC14-6 the fuse/relay
the fuse/relay card
card
and the VM if bad.
Replace the VM if
OK

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test O33 - Handle Heater Output Tests

Test O33 - Handle

Heater
This test proves the control handle heater is
working correctly.

Run Test
The operator display shows 25% if the voltage
from the VM to the handle heater is correct.

The test is a success if the shown value is

correct.
Test OFF Test ON

0 25%

The test has failed if not. Refer to Diagnosis and

Repair.

Diagnosis and Repair

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

Test OFF: 0V
Disconnect
1 PC12-7 PC12-12 Test ON: approx. Perform Step 2 Replace the VM
JPC12/DCV
1.1V

2 JP12-12 Open Circuit Perform Step 3

Disconnect JP12-7 Replace the cable
3 JH1-7 Perform Step 4
JPC12 and from the VM to the
JH1/ohms 0 ohms Replace the handle
4 JP12-12 JH1-13
handle

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests Test O36 - Priority Bypass Solenoid (SOL4)

Test O36 - Priority 4. Reconnect the battery connector and turn

the key switch ON. Start the test.
Bypass Solenoid (SOL4) Ammeter Reading Value Shown

This test ramps the priority bypass solenoid 0.000 to 1.000A Ramp (15% increments)
(SOL4) from 0% to 90%.
0.00A 0%

The requested percent of ON time is shown. Use

the UP button to increase RPM percentage in The test has failed if these results are not
increments of 15%, from 0 to 90%. shown. Reconnect the wire to SOL4-1.

Press the DOWN button to decrease the request

to 0 and exit the test.

A successful test proves the wiring and related

circuitry in the VM are all functioning correctly.
NOTE: This test does not prove the priority
bypass solenoid (SOL4) valve itself is
mechanically functional.

Run Test
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from the priority
bypass solenoid (SOL4) at SOL4-1.
3. Connect an ammeter in series with the
priority bypass solenoid (SOL4) as follows:
• (–) lead to terminal of SOL4-1
• (+) lead to wire removed from SOL4-1

Diagnosis and Repair

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

JPC20
T/S the wires
1 Disconnected/ PC20-17 PC20-18 Approx. 20 ohms Perform Step 2
and coil
ohms

2 DCV JPC20-17 TP4 B+ Perform Step 3

Ramp from B+ when Check the valve Replace the VM

Test Activated/
3 JPC20-18 B– OFF to B+ minus 9V for binding/
DCV
when 90% ON contamination

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test O37 - Aux. Relief Solenoid (SOL5) Output Tests

Test O37 - Aux. Relief 3. Connect an ammeter in series with the

proportional auxiliary relief solenoid
Solenoid (SOL5) (SOL5) as follows:
• (–) lead to terminal of SOL5-1
This test ramps the proportional auxiliary relief • (+) lead to wire removed from SOL5-1
(SOL5) solenoid (PROP RELIEF) from 0% to 4. Reconnect the battery connector and turn
90%. the key switch ON. Start the test.

The requested percent of ON time is shown. Use Ammeter Reading Value Shown
the UP button to increase RPM percentage in
increments of 15%, from 0 to 90%. 0.000 to 0.700A Ramp (15% increments)

0.00A 0%
Press the DOWN button to decrease the request
to 0 and exit the test.
The test has failed if these results are not
A successful test proves the wiring and related shown. Reconnect the wire to SOL5-1.
circuitry in the VM are all functioning correctly.
NOTE: This test does not prove the proportional
auxiliary relief solenoid (SOL5) valve
itself is mechanically functional.

Run Test
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from the proportional
auxiliary relief solenoid (SOL5) at SOL5-1.

Diagnosis and Repair

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

JPC20
T/S the wires
1 Disconnected/ PC20-20 Approx. 29 ohms Perform Step 2
PC20-19 and coil
ohms

2 DCV TP4 B+ Perform Step 3

Check for
Ramp from B+ when Replace the VM
Test Activated/ binding.
3 JPC20-20 B– OFF to B+ minus 9V
DCV Replace the
when 90% ON
solenoid

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Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests Test O45 - HSA1 Solenoid (SOL7C, SOL7R)

Test O45 - HSA1 5. Turn the key switch OFF and disconnect
the battery connector.
Solenoid (SOL7C, SOL7R) 6. Disconnect the wire from the right
sideshift solenoid at SOL7R-1.
This test turns the optional high speed auxiliary 7. Connect an ammeter in series with the
(HSA1) solenoids (SOL7C, SOL7R) ON and OFF. right sideshift solenoid as follows:
NOTE: This test is checking the VM; this • (–) lead to terminal of SOL7R-1
particular circuit is used to activate two • (+) lead to wire removed from SOL7R-1
coils.
8. Reconnect the battery connector and turn
the key switch ON. Start the test.
Run Test
High Speed
1. Turn the key switch OFF and disconnect Ammeter Operator
Auxiliary 1
the battery connector. Reading Display
Solenoid
2. Disconnect the wire from the HSA1
Open 0.50 to 1.00A ON
solenoid at SOL7C-1.
3. Connect an ammeter in series with the Closed 0.00 to 0.02A OFF
solenoid as follows:
The test has failed if these results are not
• (–) lead to terminal of SOL7C-1
shown. Reconnect the wire at SOL7C-1.
• (+) lead to wire removed from SOL7C-1
4. Reconnect the battery connector and turn The test has passed if these test results are
the key switch ON. Start the test. shown. Reconnect the wire at SOL7C-1, and
perform the same test on SOL7R.
Ammeter Reading Value Shown
NOTE: Individual coils measure approx.
0.500 to 1.000A ON 28 ohms.

0.000 to 0.020A OFF

Diagnosis and Repair

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

JPT18 and JPF2

T/S the wires
1 Disconnected/ JPT18-10 JPF2-8 Approx. 14 ohms Perform Step 2
and coil
ohms

T/S the relays

and the
2 DCV JPF2-8 TP4 B+ Perform Step 3
Fuse/Relay
Card

JP2-8 or
Check for
related
binding.
3 DCV/ Test ON wiring JPC18-12 Approx. 22V Replace the VM
Replace the
(refer to
solenoid
schematic)

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Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual

Test O47 - Customer Output Output Tests

Test O47 - Customer

Output
NOTE: This test only applies to lift trucks with
the customer output option enabled.

This test toggles the device ON and OFF.

Run Test
Use the ENTER button to toggle the test ON and
OFF. The operator display shows ON or OFF.

Diagnosis and Repair

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

Test ON: B+ Replace the

1 Device– Perform Step 2
Test OFF: 0V device
Device+
T/S B+ to the
2 TP4 B+ Perform Step 3
device
DCV
Verify the option
T/S the wiring
Test ON: B+ is enabled with
3 TP1 to the device
Test OFF: 0V FlashWare.
from the VM
Replace the VM.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Section 7. Component Procedures

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

List of Component Procedures

List of Component Procedures

Component Locator Photos . . . . . . . . . . 7-5 Drive and Brake . . . . . . . . . . . . . . . . . 7-33
Side View . . . . . . . . . . . . . . . . . . . . . . 7-5 Drive Units . . . . . . . . . . . . . . . . . . . . . 7-34
Rear View . . . . . . . . . . . . . . . . . . . . . . 7-6 Removal . . . . . . . . . . . . . . . . . . . . . . 7-34
Major Components - Installation. . . . . . . . . . . . . . . . . . . . 7-35
Upper Tractor Compartment . . . . . . 7-7 Adding Oil . . . . . . . . . . . . . . . . . . . . 7-35
Major Components - Repair . . . . . . . . . . . . . . . . . . . . . . . 7-36
Lower Tractor Compartment . . . . . . 7-8 Drive Tire Pressing. . . . . . . . . . . . . . . . 7-45
Major Components - Tractor Front . . . 7-9 Brakes. . . . . . . . . . . . . . . . . . . . . . . . . 7-46
Brake Assembly P/N 1043541 . . . . . 7-46
Special Tools and Decals . . . . . . . . . . . 7-11 Brake Assembly P/N 1094113 . . . . . 7-47
Special Tools . . . . . . . . . . . . . . . . . . . . 7-12 Brake Assembly P/N 1252130 . . . . . 7-49
Decals and Tags . . . . . . . . . . . . . . . . . . 7-13
Electrical Components . . . . . . . . . . . . 7-51
Steering and Controls . . . . . . . . . . . . . 7-17 Battery Procedures . . . . . . . . . . . . . . . 7-52
Steer Caster Assembly . . . . . . . . . . . . . 7-18 Power Cables . . . . . . . . . . . . . . . . . . . . 7-54
Wheel Removal . . . . . . . . . . . . . . . . . 7-18 Motors . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Wheel Installation . . . . . . . . . . . . . . . 7-18 General . . . . . . . . . . . . . . . . . . . . . . 7-56
Steer Caster Removal . . . . . . . . . . . . 7-18 DC Motor Service . . . . . . . . . . . . . . . 7-56
Steer Caster Installation . . . . . . . . . . 7-21 Polishing the Commutator . . . . . . . . 7-58
Steer Caster Disassembly . . . . . . . . . 7-22 AC Motor Service . . . . . . . . . . . . . . . 7-59
Service . . . . . . . . . . . . . . . . . . . . . . . 7-22 Traction Motors . . . . . . . . . . . . . . . . . . 7-62
Reassembly. . . . . . . . . . . . . . . . . . . . 7-22 Lift Motor. . . . . . . . . . . . . . . . . . . . . . . 7-64
ComfortStance Floor. . . . . . . . . . . . . . . 7-23 Power Amplifiers . . . . . . . . . . . . . . . . . 7-65
Floor Plate. . . . . . . . . . . . . . . . . . . . . 7-23 Deadman Pedal . . . . . . . . . . . . . . . . . . 7-66
Strut Removal . . . . . . . . . . . . . . . . . . 7-24 Wiring and Harness Connectors. . . . . . 7-67
Pivot Plate Bearing Replacement . . . . 7-24 General Connector Repair
Control Handle - Procedures. . . . . . . . . . . . . . . . . . 7-67
Standard/Cold Storage . . . . . . . . . . 7-25 Soldering Procedures . . . . . . . . . . . . 7-67
Removal . . . . . . . . . . . . . . . . . . . . . . 7-25 Molex Connectors. . . . . . . . . . . . . . . 7-68
Handle Disassembly . . . . . . . . . . . . . 7-25 AMP Water-Resistant Connectors . . . 7-69
Handle Assembly . . . . . . . . . . . . . . . 7-25 AMP Harness/Traction Power
Installation . . . . . . . . . . . . . . . . . . . . 7-26 Amplifier Connector . . . . . . . . . . . 7-72
Inspection . . . . . . . . . . . . . . . . . . . . . 7-26 Cold Storage . . . . . . . . . . . . . . . . . . . . 7-75
Hand Soldering Procedures . . . . . . . . 7-26 Cold Storage Conditioning . . . . . . . . 7-75
Control Handle -
Optional Variable Flow . . . . . . . . . . 7-28 Hydraulic Components . . . . . . . . . . . . 7-77
Return Spring Replacement. . . . . . . . 7-28 Manifold Solenoids, Fittings,
Handle Removal . . . . . . . . . . . . . . . . 7-28 and Attachments . . . . . . . . . . . . . . 7-78
Disassembly . . . . . . . . . . . . . . . . . . . 7-28 Hydraulic Fluid . . . . . . . . . . . . . . . . . . 7-82
Lift/Lower Potentiometer (VR2) Fluid Level . . . . . . . . . . . . . . . . . . . . 7-82
Replacement. . . . . . . . . . . . . . . . . 7-28 Selecting Hydraulic Fluid Type . . . . . 7-82
Travel Potentiometer (VR1) Bleeding the Hydraulic System . . . . . 7-82
Replacement. . . . . . . . . . . . . . . . . 7-30 Pressure Relief Valve . . . . . . . . . . . . . . 7-83
Sideshift/Tilt Switch Rubber Boot Measuring System Pressure . . . . . . . 7-83
Replacement. . . . . . . . . . . . . . . . . 7-30 Adjusting Pressure . . . . . . . . . . . . . . 7-83
Assembly . . . . . . . . . . . . . . . . . . . . . 7-30 Proportional Lowering Valve
Installation . . . . . . . . . . . . . . . . . . . . 7-31 Adjustment . . . . . . . . . . . . . . . . . . 7-84

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

List of Component Procedures

Carriage Service - Lift-Tek ® . . . . . . . . . 7-85 Inspection. . . . . . . . . . . . . . . . . . . . 7-124

ISS Removal - Mast on Lift Truck. . . . 7-85 Reassembly . . . . . . . . . . . . . . . . . . 7-124
ISS Removal - Mast on Floor . . . . . . . 7-85 Cylinder Removal and Installation . 7-127
ISS Inspection . . . . . . . . . . . . . . . . . . 7-85 Internal Reeving Installation . . . . . . 7-130
Cylinder Seal Replacement . . . . . . . . 7-85 Quad Mast Service . . . . . . . . . . . . . . . 7-132
ISS Installation . . . . . . . . . . . . . . . . . 7-87 Disassembly . . . . . . . . . . . . . . . . . . 7-132
Carriage Service - Cascade™ . . . . . . . . 7-88 Inspection. . . . . . . . . . . . . . . . . . . . 7-133
Sideshift Cylinder Seal Reassembly . . . . . . . . . . . . . . . . . . 7-134
Replacement . . . . . . . . . . . . . . . . . 7-88 Cylinder Removal and Installation . 7-138
Fork Positioner . . . . . . . . . . . . . . . . . 7-88 Internal Reeving Installation . . . . . . 7-139
Service . . . . . . . . . . . . . . . . . . . . . . . 7-90 Flow Control Valve Replacement . . . 7-143
Lift Cylinder Service . . . . . . . . . . . . . . . 7-94 Mast Tilt Adjustment . . . . . . . . . . . . . 7-144
All except Model 4250 TT Masts Mast Tilt Position Switch
S/N 50501 Up . . . . . . . . . . . . . . . 7-94 Adjustment . . . . . . . . . . . . . . . . 7-144
Model 4250 TT Masts
S/N 50501 Up . . . . . . . . . . . . . . . 7-94

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
Mast Removal and Installation . . . . . . . 7-98
Partial Removal . . . . . . . . . . . . . . . . . 7-98
Installation after Partial Removal . . . . 7-98
Complete Mast Removal . . . . . . . . . . 7-99
Installation after
Complete Removal . . . . . . . . . . . 7-100
Lift Chains . . . . . . . . . . . . . . . . . . . . . 7-101
Main Lift Chain Adjustment. . . . . . . 7-101
Main Lift Chain Service . . . . . . . . . . 7-102
Free Lift Chain Adjustment . . . . . . . 7-104
Free Lift Chain Service. . . . . . . . . . . 7-105
Roller Bearing (Puck) Adjustment -
TT Mast - S/N 50501 Up . . . . . . . . 7-106
Mast Skewing . . . . . . . . . . . . . . . . . . . 7-107
All except Model 4250 TT Masts
S/N 50501 Up . . . . . . . . . . . . . . 7-107
Model 4250 TT Masts
S/N 50501 Up . . . . . . . . . . . . . . 7-108
2-Stage (TF) Mast Service . . . . . . . . . . 7-109
Disassembly . . . . . . . . . . . . . . . . . . 7-109
Inspection . . . . . . . . . . . . . . . . . . . . 7-110
Reassembly . . . . . . . . . . . . . . . . . . . 7-110
Cylinder Removal and Installation . . 7-112
Internal Reeving Installation . . . . . . 7-115
3-Stage (TT) Mast Service -
below S/N 50501 . . . . . . . . . . . . . 7-116
Disassembly . . . . . . . . . . . . . . . . . . 7-116
Inspection . . . . . . . . . . . . . . . . . . . . 7-116
Reassembly . . . . . . . . . . . . . . . . . . . 7-118
Cylinder Removal and Installation . . 7-120
Internal Reeving Installation . . . . . . 7-122
3-Stage (TT) Mast Service -
S/N 50501 Up. . . . . . . . . . . . . . . . 7-124
Disassembly . . . . . . . . . . . . . . . . . . 7-124

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

List of Component Procedures

7-4 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Side View Component Locator Photos

Component Locator Photos

Section 7. Component Procedures

Side View

Overhead Guard

Mast

Battery
Connector Tilt Cylinder

Load Backrest

Carriage

Battery Gate

Forks
Right Traction Tire

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Component Locator Photos Rear View

Rear View

Control Handle

Operator
Display

Steer Tiller

Deadman Pedal
Steerable Wheel

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Major Components - Upper Tractor Compartment Component Locator Photos

Major Components - Upper Tractor Compartment

Vehicle Operator Fuse/Relay Hydraulic Contactor
Manager Display Horn Card Manifold Panel

Right Traction
Power Amp

Lift Power Amp

(4250 Only)

Left Traction
Power Amp

Steering Valve

FU8
FU6 FU1

FU3

FU7 FU2
FU5

Fuse/Relay Card
Contactor Panel

Operator Display Key Switch EPO

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Component Locator Photos Major Components - Lower Tractor Compartment

Major Components - Lower Tractor Compartment

Hydraulic Steer Motor

Steer Proximity
Sensor
Strut
(ComfortStance Floor only)

Steerable Wheel
Assembly

Deadman
Pedal

Steer Tire ComfortStance

Floor

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Major Components - Tractor Front Component Locator Photos

Major Components - Tractor Front

Steer Motor Brake Release
and Pump Bolts

Tilt Cylinder Tilt Cylinder

Right Traction Lift Motor Left Traction

Motor and Brake and Pump Motor and Brake

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Component Locator Photos Major Components - Tractor Front

7-10 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Special Tools and Decals

Special Tools and Decals

Section 7. Component Procedures

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Special Tools and Decals Special Tools

Special Tools
The following tools are available from your local
authorized Raymond Solutions and Support
Center.

Table 7-1. Special Tools

Tool Part Number Purpose

Set gap between the bottom face of the steer position

Alignment Tool 939-350/ACT
proximity sensor and the upper surface of the steer plate.

Anti-static Field Kit 1-187-059

ESD Protection
Anti-static Wrist Straps 1-187-058/001

Axle Puller 950-350/AXLEPL Steer wheel axle removal

Chain Gauge 939-10606 Lift chain inspection

Connector Unlatching 950-042 Separate AMP connectors

Crimp Tool 1069861 Crimp power cable lugs

Cylinder Head Cap Tool 1217957/72 Removal of cylinder head cap on carriage cylinders for Model
4250 TT masts S/N 50501 Up

Cylinder Retainer 1217957/71 Removal of retainer on carriage cylinders for Model 4250 TT
Socket masts S/N 50501 Up

Model 4150 TF/TT mast main and free lift cylinder end cap
End Cap 1090761/003
removal/installation

Fork Wear Caliper 922-369 Fork inspection

Jack, 5-Ton 990-807 Jacking lift truck

Pin Extraction 950-009 AMP connector pin extraction

Pin Extraction 950-026 MOLEX connector pin extraction

ESD/voltage surge protection for serial type FlashWare

Surge Protector 154-010-801
connections

USB/CAN Interface 230489-001 FlashWare connection to lift truck

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Decals and Tags Special Tools and Decals

Decals and Tags

Table 7-2. Decal and Tag Location Chart

Decal and Specification Locations

Identifier Description Location

1 Raymond (2 places) Tractor frame, aft of battery compartment (both sides)

2 ACR (2 places) Tractor frame, with respect to battery compartment

opening, aligned with front edge of decal 1.5 in. (38 mm)
aft, and bottom edge of decal 0.5 in. (13 mm) above
opening (both sides)

3 Warning Decal (2 places) Both sides of mast, centered

4 Mast Specification Tag Left side of mast, centered

5 Manual Pocket Cover Inside operator compartment, right side, centered top to
bottom, against the front wall

6 Operating Instructions Inside operator compartment, centered on manual

pocket cover

7 EE Compliance (optional) Tractor frame, aft of battery compartment, centered

between opening and Raymond decal (both sides)

8 Battery Removal Warning (2 places) Tractor frame, centered 0.5 in. (13 mm) above battery
compartment opening (both sides)

9 No Riding Centered on load backrest

10 Overhead Guard ANSI/ITSDF Centered inside left side of overhead guard

conformance

11 Warning Decal <S/N 50501 - Operator view, centered on main lift cylinder
(<S/N 50501 - 2 places; 2 in. (5.08 cm) above crosstie (both sides)
>S/N 50500 - 4 places) >S/N 50500 - On mast (both sides), centered below
warning decal (see Identifier 3 above). Operator view (both
sides), centered on main lift cylinder near top, or centered
on crossties (3 stage mast for 4250 only)

12 General Safety Decal Operator view, left side of mast, bottom of decal 19 in.
(48.26 cm) above tractor, left edge of decal 0.81 in.
(20.6 mm) from left edge of mast

13 Specification Tag Inside operator compartment on front wall, top edge of

decal 6 in. (15.24 cm) below bend, right edge of decal
2 in. (5.08 cm) from right side

14 Attachment Tag Centered below specification tag, see Identifier 13 above

Note: Items in italics are safety decals.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Special Tools and Decals Decals and Tags

Figure 7-1. Decal and Specification Tag Locations

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Decals and Tags Special Tools and Decals

Figure 7-2. Decal and Specification Tag Locations

Quad Mast (QM) and Two-Stage Mast (TF) greater than or equal to 83 in. OACH

Two-Stage Mast (TF) less than 83 in. OACH

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Special Tools and Decals Decals and Tags

Figure 7-3. Decal and Specification Tag Locations

Three-Stage Mast (TT) Model 4150

Three-Stage Mast (TT) Model 4250

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Steering and Controls

Steering and Controls

Section 7. Component Procedures

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Steering and Controls Steer Caster Assembly

Steer Caster Assembly Wheel Installation

1. Place the wheel assemblies under the lift
truck and position them in the steer pivot.
Wheel Removal
2. Carefully insert the axle in the steer pivot
1. Position the steerable wheel so the axle and wheels. Do not damage the bearing
nut is visible. seals.
2. Turn the key switch OFF and disconnect 3. Install the axle nut. Tighten the axle nut
the battery connector. until the wheels start to bind when turned
by hand. Loosen the axle nut 1/4 turn.
4. Lower the lift truck to the floor.

Use extreme care when the lift truck is

jacked up, elevated, or placed on blocks
Steer Caster Removal
or jack stands. Never block the lift truck 1. Turn the key switch OFF and disconnect
between the telescopic and the floor. the battery connector.
Attach an appropriately rated rigging
2. Remove the Steer Compartment Cover.
device to the top of the mast, and an
overhead hoist to stabilize the mast, if 3. On lift trucks equipped with the
jacking higher than described in ComfortStance™ Floor system, remove the
“Jacking Safety” on page 2-9. Keep strut. Refer to “Strut Removal” on
hands and feet clear while jacking the page 7-24.
lift truck. After the lift truck is elevated 4. Take the steer chain off the steer plate.
to the required height, place blocks of a Remove the outer nut on the threaded end
solid material that will support the of the chain anchor. See Figure 7-4.
weight of the lift truck, or jack stands
that will support the weight of the lift Figure 7-4. Remove Steering Plate Chain Anchor Nut
truck, beneath the specified locations
shown in this maintenance manual, for Steer Plate
support. Lower the lift truck onto the
blocks or jack stands. Never rely on the
jack or jack stand alone to support the Steer
lift truck. Motor

3. Jack and block the lift truck so the

steerable wheel is off the floor.
Steer
4. Remove the axle nut.
Chain
5. Use a drift pin to drive the axle Chain Anchor Nut
approximately 0.5 in. (13 mm) toward the
battery compartment.
6. Rotate the steerable wheel so the opposite
end of the axle is visible. 5. Disengage the steer chain from the steer
motor assembly. Leave the chain attached
7. Remove the axle. Axle Puller to the other side of the steer plate.
P/N 950-350/AXLEPL is available from
the Parts Distribution Center. 6. Remove the two screws that hold the steer
position proximity sensor bracket in place,
8. With the axle removed, remove the wheels. then remove the bracket. See Figure 7-5.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Steer Caster Assembly Steering and Controls

Figure 7-5. Removing Steering Position Sensor Figure 7-7. Scribing a Mark from Hub to Steer Plate

Sensor Scribed Mark On Plate

Proximity
Ring Sensor

Scribed Mark On Hub

Steer
Plate

7. Remove the three flat head screws that

9. Remove the four bolts that hold the steer
hold the steer sensor ring to the top of the
plate in place, then remove the steer plate.
steer plate, then remove the ring. See
See Figure 7-8.
Figure 7-6.
Figure 7-8. Removing Steering Plate Bolts
Figure 7-6. Removing Steering Sensor Ring

Flat Head Screws

10. Remove the six mounting bolts holding the

8. Scribe a mark from the top of the steer steerable wheel assembly to the lift truck
hub onto the steer plate. (Realign these frame. See Figure 7-9.
marks later to make sure the steer plate is
installed in the correct position). See
Figure 7-7.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Steering and Controls Steer Caster Assembly

Figure 7-9. Steering Wheel Mounting Bolts

Use extreme care when the lift truck is

jacked up, elevated, or placed on blocks
or jack stands. Never block the lift truck
between the telescopic and the floor.
Attach an appropriately rated rigging
Mounting Bolts device to the top of the mast, and an
overhead hoist to stabilize the mast, if
jacking higher than described in
“Jacking Safety” on page 2-9. Keep
hands and feet clear while jacking the
lift truck. After the lift truck is elevated
to the required height, place blocks of a
solid material that will support the
weight of the lift truck, or jack stands
that will support the weight of the lift
11. Place chocks in front of the drive wheels. truck, beneath the specified locations
shown in this maintenance manual, for
12. Reinstall one of the steer plate bolts. Wrap support. Lower the lift truck onto the
a piece of heavy wire around this screw to blocks or jack stands. Never rely on the
use as a temporary support. Use this jack or jack stand alone to support the
temporary support to lower the steer lift truck.
assembly to the floor when the lift truck is
jacked up. See Figure 7-10. 13. Jack the rear of the lift truck. As the lift
truck is jacked, the steerable wheel
Figure 7-10. Temporary Support for Steerable Wheel
assembly separates from the tractor
Heavy Wire and
frame.
Steer Plate Bolt NOTE: Removing the steerable wheels from the
steer pivot yoke reduces the jacking
height.
14. Continue to jack the lift truck until the
pivot hub on the steerable wheel is flush
with the tractor frame. Block the lift truck
in this position. See Figure 7-11.

Jack
Block

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Steer Caster Assembly Steering and Controls

Figure 7-11. Wheel Hub Shown Flush with Lift Truck Frame Steer Caster Installation
Position the steerable wheel assembly within
the tractor frame.
1. While holding the steer wheel assembly
upright, lower the tractor until it is near
the mounting flange.
2. Remove the wire and bolt from the steer
plate. Position the stop correctly.
3. Install the mounting bolts. Refer to
“Component Specific Torque Chart” on
page A-4.
Wire and Bolt
4. Install the steer plate. Align the scribe
marks, made during disassembly, between
the hub and the steer plate.
5. Install the four mounting bolts and
tighten.
The steerable wheel assembly is heavy. 6. Install the steer sensing ring on top of the
Use a suitable lifting device if necessary. steer plate.
7. Install the steer position proximity sensor
15. While holding the wire, slowly move the bracket. The gap between the bottom face
steerable wheel assembly out from under of the sensor and the upper surface of the
the lift truck. steer plate should measure 0.060
16. As the wheels come out, lower the casting +0.04/–0.03 in. (1.5 +1.0/–0.7 mm).
to the floor. (Alignment Tool, P/N 939-350/ACT, is
available from the Parts Distribution
17. Move the steerable wheel assembly down
Center.)
and out from beneath the lift truck. See
Figure 7-12. 8. Reinstall and adjust the steer chain. The
chain should flex approx. 1/8 to 1/4 in.
Figure 7-12. Steerable Wheel Removed (1.6 to 3.2 mm).
9. On lift trucks equipped with the
ComfortStance™ Floor system, install the
strut. Perform Step 6 in “Installation” on
page 7-24.
10. Reconnect the battery connector and turn
the key switch ON.
11. Run “Test I89 - Steer Position Sensor” on
page 6-94. This verifies the steer position
proximity sensor is adjusted correctly.
12. Turn the key switch OFF and disconnect
the battery connector.
13. Remove any blocks supporting the lift
truck.
14. Lower the lift truck to the floor.
15. Install the steer compartment cover.
16. Reconnect the battery connector and turn
the key switch ON.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Steering and Controls Steer Caster Assembly

17. Test the steering function. If OK, return Figure 7-14. Steerable Wheel Shown Unassembled
the lift truck to service.
Pivot Hub

Steer Caster Disassembly

1. Remove the nut that holds the upper steer
hub to the steer pivot. See Figure 7-13.

Figure 7-13. Steerable Wheel Components

Lock Upper Steer Hub
Steer Pivot and Lock Nut
Nut Steer
and Wheel
Hub

Pivot
Key Hub

Grease
Service
Fitting 1. Clean the inside of the pivot hub.
Bearings
Steer 2. Clean and inspect the bearings. Replace
Pivot any worn components.
3. Remove, clean, and inspect the keys.
Clean and inspect the keyways.
4. Pack the bearings with grease. Refer to
“Lubrication Specification Chart” on
page A-2. Add additional grease to the
pivot spindle and hub so that when the
Bearings unit is assembled, it is 50-75% full of
grease.
5. Slide the steer pivot into the pivot hub.
6. Coat the keys and keyways with
thread-locking compound (P/N 990-536).

Reassembly
1. Install the upper steer hub.
2. Install the nut.

2. Use a three-arm puller to remove the 3. Tighten the nut while rotating the pivot
upper steer hub. hub that installs on the tractor frame.

3. Pull the steer pivot out of the pivot hub. 4. Continue to tighten the nut until the pivot
See Figure 7-14. hub just starts to resist rotation.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

ComfortStance Floor Steering and Controls

ComfortStance Floor NOTE: A tie rod and hardware may or may not
be present on the lift truck. It is not
necessary to replace the tie rod or any
The ComfortStance Floor system consists of a associated hardware if it is damaged or
two piece floor (floor plate and pivot plate), two missing.
pivot bearing blocks, and a strut. See
Figure 7-15.

Figure 7-15. ComfortStance Floor Components

Strut

3/4-10
(for lifting eye bolt)

8.5 in. (22 cm)

3 in. (7.6 cm)

Pivot Plate

Bearing
Floor Plate
Block

Bump Stop

Tie Rod

Bearings
Bearing
Block

Floor Plate 3. Remove the bolt that secures the deadman

switch cable. Unplug the deadman switch
Removal and remove the deadman pedal.
1. Turn the key switch OFF and disconnect 4. Remove the bolt that secures the tie rod, if
the battery connector. present, to the floor plate. It is located
under the lift truck at the right rear side.
2. Remove the steer compartment and
console covers. 5. Remove the floor pad and the pad over the
deadman pedal.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Steering and Controls ComfortStance Floor

6. Install a 4 in. lifting eye bolt into the NOTE: If removing the strut only, attach a 4 in.
threaded hole in the floor plate. lifting eye bolt to the floor plate and lift
slightly to relieve pressure on the strut.
NOTE: The bottom bolt that secures the strut to
The floor plate weighs approx. 320 lb. the lower mounting bracket is accessible
(145 kg). through a hole in the battery
compartment wall.
7. Use a suitable lift strap/chain and
overhead hoist to lift the floor plate. Pivot Plate Bearing
Slightly lift to remove slack in the Replacement
strap/chain.
8. Carefully remove the three bolts that 1. Remove the steerable wheel assembly.
secure the floor plate to the pivot plate. Refer to “Steer Caster Assembly” on
page 7-18.
9. Remove the floor plate.
2. Remove the four bearing block mounting
bolts. See Figure 7-15.
Installation
3. Remove the pivot plate.
1. Install the strut to the lower bracket.
4. Remove the bearing blocks and spacers
2. Apply thread-locking compound from the pivot plate.
(P/N 990-536) to the three bolts that
5. Remove the bearings from the pivot block
secure the floor plate to the pivot plate and
casting.
install the floor plate. Leave the eye bolt
attached to the floor plate and lower until 6. Install the new bearings.
approx. level. 7. Reinstall the bearing blocks and spacers.
3. Install the deadman pedal and cable. NOTE: Use a M12 x 1.75 tap to chase the
4. Attach the strut to the upper bracket. threads of the four bearing block
5. Lower the floor plate completely. When mounting holes.
settled, the floor plate height should NOTE: Position the bearing blocks with the
measure approx. 9 3/8 in. (238 mm) from counter-bore facing down.
the top of the floor pad to the warehouse
floor. If not, lift the floor plate slightly and 8. Reinstall the pivot plate with new
adjust the strut in the upper slotted mounting bolts. Apply thread-locking
bracket until the correct dimension is compound (P/N 990-536).
obtained. Torque the strut mounting bolts. 9. Reinstall the steerable wheel assembly.
Refer to “Component Specific Torque Refer to “Steer Caster Installation” on
Chart” on page A-4. Remove the hoist and page 7-21.
eye bolt.
6. Install the deadman pedal cover, floor pad,
and lift truck covers.
7. Test operation and return the lift truck to
service.

Strut Removal
Remove the bolts that secure the strut to the
upper and lower mounting brackets and remove
the strut.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Control Handle - Standard/Cold Storage Steering and Controls

Control Handle - 3. Position the thumb control return spring

onto the control handle. Make sure that
Standard/Cold Storage the ears of the spring are positioned
correctly. See Figure 7-16.

Removal Figure 7-16. Correct Positioning of Spring Ears

1. Turn the key switch OFF and disconnect

the battery connector.
2. Remove the console cover.

Use correct ESD precautions. See “Static

Precautions” on page 2-8.

3. Unplug the control handle wiring harness

from the VM at JPC12. Remove any cable
ties that secure the wiring harness.
4. Loosen the socket head screw that secures
the control handle assembly to its support NOTE: To avoid premature handle failure, do
bracket. not bend the ears on the spring.
5. Slide the control handle assembly to the 4. Align the lift knob with the potentiometer
left, out of its support bracket. shaft. Slide the lift knob onto the shaft
until fully seated.
Handle Disassembly 5. Move the lift knob to verify that it works
freely and returns to neutral.
1. Remove the two nylon screw inserts and
loosen the two set screws. Remove the lift 6. Tighten the two set screws securing the
knob. knob to the control handle and install the
nylon screw inserts.
2. Remove the return spring that goes over
the potentiometer shaft.
3. Remove the seven socket head screws
Lift Knob Values
located on the handle. Note the locations • The lift knob on solid state handles should
of the three different size screws for not require any adjustment.
reassembly.
• The lift potentiometer neutral for handles
4. Gently separate the two halves of the can range between 2V and 3V.
control handle. Do not lose any springs or
• The lift potentiometer voltage at fully
small parts.
clockwise (CW) should not exceed 4.6V.
5. Note the orientation of parts for correct
• The lift potentiometer voltage at fully
reassembly.
counterclockwise (CCW) should not
measure below 0.45V.
Handle Assembly • If the lift potentiometer voltages are
1. Make sure all internal assemblies are out-of-range, replace the pot or wiring.
positioned correctly. Piece the two halves
of the control handle back together. Lift Knob Assembly
2. Replace the seven screws on the control 1. Rotate the lift potentiometer shaft fully
handle. Make sure that they are located CCW.
correctly.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Steering and Controls Control Handle - Standard/Cold Storage

2. Install the lift knob on the potentiometer 3. Route the control handle wiring harness
shaft. Do not tighten the set screws yet. and plug into the VM at JPC12.
3. Rotate the lift knob fully CCW and tighten 4. Make sure that the cable extends out of
the set screws. the handle as straight as possible to avoid
4. Verify the lift potentiometer voltages. kinking.

5. Install the nylon screw inserts over the set 5. Reconnect the battery connector and turn
screws. the key switch ON.
6. Enter Maintenance Mode and perform
Learn. See “Maintenance Mode” on
page 3-20.
The solid state potentiometers used in
7. Reinstall the console cover.
this handle are ESD sensitive.

6. When installing the wire harness, a service Inspection

loop is required.
7. Install the handle and route the harness Whenever the control handle is disassembled,
last, after all the other wires are routed perform the checks defined in the following
through this area. Routing should occur table.
toward the left side of the lift truck, then
Part Check for:
forward and around the front of the VM.
Connect the handle from the right side of Horn button Cracks or deformation
the VM. assembly

Lift/lower pot Cracks, deformation, loose dowel

bracket pin, over-round or oversized
shaft hole
Make sure all other wires are tied back
and away from the handle harness Travel pot Cracks, loose spirol pin, stripped
service loop. Do not route through any enclosure threads, deformation or indents
components. on the external stops

Handle halves Cracks, damage or deformation

8. Test the motion of the service loop by or indents on the external stops
cycling the handle. The entire length of the
loop should absorb the twist. Make sure Lift/lower Cracks, deformation, stripped
that the loop does not hang up on adjacent knob threads, or loose dowel pin
wires, cable ties, or structures. Other Stripped threads. All screw
hardware threads must be cleaned.
Installation
1. Insert the shaft of the control handle Hand Soldering Procedures
assembly into the mounting bracket.
When hand soldering is performed on solid
NOTE: It is not necessary to clean all traces of
state potentiometers, the following is
precoat from the lift truck-side threads
recommended:
when installing the new set screw. The
set screw is not pre-coated. Do not apply • Flux - rosin base
thread-locking compound. • Solder - 60/40 rosin core or equivalent
2. Hold the control handle in place, aligning • Solder Iron - 55 watt max.
the hole in the shaft with the hole in the • Tip Size - 0.118 in. (3 mm) dia. x 1.182 in.
bracket. Torque the set screw to 14 ft. lb. (30 mm) long screwdriver
(19 Nm). • Tip Temperature - 500°F (260°C) max.
• Terminal Contact Time - 6 seconds max.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Control Handle - Standard/Cold Storage Steering and Controls

NOTE: Apply light soldering iron pressure on

the terminal. Make sure that the tip is
clean. A dirty tip does not transfer heat
well, therefore requiring longer dwell
time and greater tip pressure.

Contact contamination can occur if

cleaning solvent is allowed to enter the
switches or potentiometers.

After soldering, clean the terminals with a

brush dampened with an alcohol-based cleaner.
Make sure that the cleaner does not seep into
the electrical component.

Components damaged due to solvent saturation

are not covered under warranty.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Steering and Controls Control Handle - Optional Variable Flow

Control Handle - 2. Disconnect PCH2.

3. Install double-sided tape to the back of the
Optional Variable Flow new pot.
4. Slide the lift/lower potentiometer bracket
over the potentiometer shaft, Make sure to
Return Spring Replacement engage the metal tab of the potentiometer
in the slot in the side of the bracket. See
The lift/lower knob return spring can be
Figure 7-17.
replaced without control handle removal and
disassembly. Figure 7-17. Lift/Lower Pot Bracket Installation

When a return spring is replaced, coat the

Metal Tab
inside of the spring lightly with lithium grease
(P/N 990-635).

Bracket
Handle Removal
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the console cover.
3. Disconnect the cable from the control
handle.
4. Loosen the control handle set screw and
5. Insert the lift/lower pot assembly into the
remove the handle from the pivot.
right control handle shell.
6. Connect PCH2.
Disassembly
7. Adhere the heater pad section of the
NOTE: A fixture (P/N 828-009-213) is available flexible circuit to the back of the pot.
to hold the handle in position while
8. Reassemble and reinstall the control
disassembled. Note the orientation of
handle. See “Assembly” and “Installation”
switches, potentiometers, routing of the
on page 7-31.
cables and wires for reassembly.
9. Reconnect the battery connector and turn
1. Remove the nylon plug from the lift/lower the key switch ON.
knob to expose the set screw underneath.
Loosen the set screw and remove the 10. Enter Maintenance Mode and perform
lift/lower knob. Learn. See “Maintenance Mode” on
page 3-20.
2. Remove the six socket head screws
securing the handle shell halves together. 11. In Run Mode, test the lift/lower function
for correct operation.
3. Carefully remove the left half of the handle
shell.

Lift/Lower Potentiometer (VR2)

Replacement
1. Remove the lift/lower potentiometer
bracket and potentiometer from the
handle shell. Slide the bracket off the
potentiometer. See Figure 7-18 on
page 7-29.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Control Handle - Optional Variable Flow Steering and Controls

Figure 7-18. Optional Control Handle

Sideshift/Tilt Switch Rubber Boot

Lift/Lower Pot Bracket

PCH2

Lift/Lower Pot (VR2)

Flexible Circuit

Travel Pot Return Spring PCH1

Travel Pot (VR1) Positioner Pin Composite Bushings Pivot Shaft Assembly

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Steering and Controls Control Handle - Optional Variable Flow

Travel Potentiometer (VR1) 4. For ease of assembly, turn the

replacement boot inside out, install the
Replacement replacement boot and verify that the tabs
1. Lift up gently on the pivot shaft to free the are aligned and that the boot is seated
travel pot assembly from the handle. See correctly. Stretch the boot over the joystick
Figure 7-18 on page 7-29. housing. See Figure 7-19.
2. Slide the travel pot out of the pivot shaft
Figure 7-19. Boot Installation
assembly.
3. Disconnect PCH1.
4. Install double-sided tape to the back of the
new pot.
5. Install the pot in the pivot shaft assembly.
Align the flat on the pot shaft with the flat
inside the positioner.
6. Install the travel pot assembly in the
handle shell. The tab of the throttle pot
must engage the slot in the handle shell
(straight down). Align the composite Boot (turned inside out)
bushings with the molded holders in the
handle. 5. Reassemble and reinstall the control
7. Connect PCH1. handle.
8. Adhere the heater pad section of the
flexible circuit to the back of the pot. Assembly
9. Reassemble and reinstall the control
1. Check the flexible circuit and wires for
handle. See “Assembly” and “Installation”.
correct routing.
10. Reconnect the battery connector and turn
2. Orient the VR1 return spring ears straight
the key switch ON.
up in the right half of the handle.
11. Enter Maintenance Mode and perform
3. Install the left half of the handle shell. The
Learn. See “Maintenance Mode” on
pin in the left side handle shell must fit
page 3-20.
between the ears of the VR1 throttle pot
12. In Run Mode, test the travel function for return spring. The wires from the VR2
correct operation. lift/lower pot must fit between the tabs in
the handle shell. Make sure the tabs do
Sideshift/Tilt Switch Rubber not crush any of these wires.
Boot Replacement 4. If a fixture is used, loosen the thumb
screw and remove the handle from the
1. Move the lift/lower pot and bracket out of fixture.
the way to access the tilt and sideshift
5. Install the two socket head screws to hold
joystick boot.
the handle halves together.
2. While activating the switch in the tilt
6. Insert a screwdriver in the handle shaft
position, tilt back and rotate the assembly
mounting hole to hold the shaft in place.
out of the handle half.
7. Rotate the control handle from neutral to
3. Remove the boot assembly.
maximum forward, then maximum
NOTE: The joystick assembly has locating backward, then to neutral. The handle
indentations and the replacement boot should move freely with no binding.
has corresponding tabs. Correct any binding before proceeding
further.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Control Handle - Optional Variable Flow Steering and Controls

8. Install the five remaining socket head

screws in the handle and torque to 15 to
20 in. lb. (1.7 to 2.25 Nm).
9. Rotate the lift/lower potentiometer shaft
so the flat on the shaft is parallel to the
return spring pin on the potentiometer
bracket. If the potentiometer shaft has no
flat, rotate the shaft to the center of its
travel.
10. Install the lift/lower knob. The pin on the
knob must fit between the ears of the
potentiometer return spring.
11. Install and tighten the set screw and nylon
plug in the knob. Check the potentiometer
for correct rotation and spring return to
neutral. Correct any binding.

Installation
1. Install the control handle on to the pivot.
2. Apply thread-locking compound
(P/N 990-536) to the control handle set
screw.
3. Install the set screw and tighten.
4. Form a loop in the control handle cable
harness as it leaves the handle. Do not
route through or under any components.
Route the cable to the VM and connect
JPC12.
5. Make sure that all other wires are tied
back and away from the handle harness
service loop.
6. Test the motion of the service loop by
rotating the handle. The entire length of
the loop should absorb the twist. Make
sure the loop does not hang up on nearby
wires, cable ties, or structures.
7. Install the covers.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Steering and Controls Control Handle - Optional Variable Flow

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Drive and Brake

Drive and Brake

Section 7. Component Procedures

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Drive and Brake Drive Units

Drive Units
Removal Use extreme care when the lift truck is
jacked up, elevated, or placed on blocks
or jack stands. Never block the lift truck
between the telescopic and the floor.
The drive unit weighs approximately Attach an appropriately rated rigging
175 lb. (79 kg). Use a suitable lifting device to the top of the mast, and an
device if necessary. Have additional overhead hoist to stabilize the mast, if
help available when removing or jacking higher than described in
installing the drive unit. “Jacking Safety” on page 2-9. Keep
hands and feet clear while jacking the
1. Turn the key switch OFF and disconnect lift truck. After the lift truck is elevated
the battery connector. to the required height, place blocks of a
solid material that will support the
2. Remove the mast from the lift truck. See
weight of the lift truck, or jack stands
“Mast Removal and Installation” on
that will support the weight of the lift
page 7-98.
truck, beneath the specified locations
3. Drain all the gear oil out of the drive unit. shown in this maintenance manual, for
Use a drain pan that is approximately 1.5 support. Lower the lift truck onto the
gal. (5.7 liters). See Figure 7-20. blocks or jack stands. Never rely on the
jack or jack stand alone to support the
Figure 7-20. Draining Drive Unit lift truck.

8. Jack the side of the lift truck to remove the

drive unit. Place blocks beneath the lift
truck to support it. See Figure 7-21.

Figure 7-21. Drive Wheel Removal

4. Remove the brake assembly. 9. Remove the eight bolts that secure the
5. Remove the traction motor. wheel and tire assembly to the drive unit.
6. Install a lifting eye hook into one of the 10. Remove the six bolts that secure the drive
traction motor mounting holes. unit to the lift truck frame. See
Figure 7-22.
7. Loosen, but do not remove, the eight bolts
that secure the wheel and tire assembly to
the drive unit.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Drive Units Drive and Brake

Figure 7-22. Drive Unit Mounting Bolts Adding Oil
NOTE: The drive unit must be installed before
filling the drive unit with oil.
1. Remove the oil level check screw.
2. Remove the fill screw.
3. Refer to “Lubrication Specification Chart”
on page A-2 to determine the correct type
of gear lubricant (or oil for cold storage lift
trucks).
4. Slowly pour the lubricant in the fill hole.
Watch the oil level check screw hole. When
the lubricant is level with the bottom of the
screw hole, stop pouring. Allow all excess
oil to drain out.
Installation
5. Reinstall the oil level check screw and fill
1. Make sure that the drain plug is installed screw.
in the drive unit.
2. Apply thread-locking compound
(P/N 1013829) to the two locating pins.
Install the locating pins into the drive unit
casting.
3. Position the drive unit in place. Align the
bolt holes in the mounting flange with the
bolt holes in the tractor frame.
4. Apply thread-locking compound
(P/N 1013829) to the six mounting bolts
and install. Torque to 180 ft. lb. (244 Nm).
5. Install the drive wheel and tire assembly.
Install the wheel mounting bolts.
6. Lower the lift truck to the floor and torque
the drive wheel mounting bolts in a star
pattern to 110 ft. lb. (151 Nm).
7. Apply silicone sealant (P/N 990-659) to the
joint between the drive unit and traction
motor. Reinstall the traction motor. Torque
the mounting screws to 28 ft. lb. (38 Nm).
8. Reinstall the brake assembly. Make sure
to remove the brake release bolts from the
brakes.
9. Fill the drive unit with gear oil until the
fluid is even with the bottom of the fluid
check hole on the side of the drive unit.
10. Install the mast.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Drive and Brake Drive Units

Repair
Refer to Figure 7-23 for all bracketed [ ] item
number references in this procedure.

Figure 7-23. Drive Unit Exploded View

17 15
Legend:
1. Housing
2. Upper Pinion Bearing Cup and Cone Set
3. Helical Gear and Pinion Set
4. Spiral Pinion and Ring Gear Set
5. Axle Seal
6. Axle Shaft 16 13
7. Lower Pinion Bearing Cup and Cone Set
8. Outer Axle Bearing Cup and Cone Set
10
9. Inner Axle Bearing Cup and Cone Set
10. Thrust Washer
11. Shim Stack
12. Spacer 4
13. Axle Shaft Clamp Nut
14. Helical Gear Clamp Nut 10
15. Screw
16. Main Cover 11
17. Drain Plug
18. Filler Plug (Not Shown) 4
12
7

2 3
1
14

8
5

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Drive Units Drive and Brake

Disassembly Figure 7-26. Fill Level Plug Removal

Refer to Figure 7-23 on page 7-36 for all

bracketed [ ] item number references in this
procedure.

Clean the outside of the drive unit thoroughly

and drain any remaining oil from the drive unit.

Visually inspect the outside of the housing

[Item 1] for damage, wear, or cracks. Pay
particular attention to the area where hub wear
may be evident, the mast pivot area, motor 3. Remove the main cover screws [Item 15].
area, and around all bolts. 4. Pry the cover [Item 16] or tap with a mallet
to loosen the cover seal to the housing.
Figure 7-24. Hub Wear Inspection
5. Remove the cover from the housing.
6. Inspect inside the cover for damage or
wear.

Axle Shaft and Ring Gear Removal

1. Loosen the set screw locking the axle shaft
clamp nut [Item 13].

Figure 7-27. Axle Shaft Clamp Nut Set Screw

Main Cover Removal

1. Remove the drain plug [Item 17].

Figure 7-25. Drain Plug Removal

2. Use a screwdriver in the clamp nut slot to

turn the clamp nut off.

2. Remove the fill level plug.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Drive and Brake Drive Units

Figure 7-28. Clamp Nut Removal Figure 7-30. Remove Clamp Nut

3. Remove the thrust washer [Item 10]. 3. Use a rubber mallet to drive the spiral
4. Lift the ring gear from the housing. pinion [Item 4] from the housing.
5. Remove the thrust washer, shim, and NOTE: If the axle and pinion bearing seat
spacer [Items 10, 11, and 12]. dimensions are not recorded (stamped)
6. Use a rubber mallet to drive the axle from on the inside of the drive unit housing,
the housing. save the shims to use for reference at
reassembly.
Spiral Gear and Helical Gear Removal
Figure 7-31. Spiral Pinion Removal
1. Remove the set screw locking the helical
gear clamp nut [Item 14].

Figure 7-29. Clamp Nut Set Screw Removal

4. Lift the helical gear [Item 3], spacer, and

bearing [Item 2] from the housing.
5. Inspect the helical gear and the spiral gear
for damage or wear.
2. Use a screwdriver in the clamp nut slot to
turn the clamp nut off. (The gear may need NOTE: The spiral pinion and ring gear are a
to be wedged to keep it from turning.) matched set. Their alignment is
Inspect the clamp nut for damage. critical. Do not replace them
separately.

Bearing Cup, Shim, and Seal Removal

NOTE: The bearing cups and cones are usually
damaged during removal. They must be
replaced as sets.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Drive Units Drive and Brake

1. Use a mallet and a long punch to drive the Figure 7-34. Axle Shaft Bearing Cup Removal
lower pinion bearing cup [Item 7] from the
housing.
NOTE: If the axle and pinion bearing seat
dimensions are not recorded (stamped)
on the inside of the drive unit housing,
save the shims to use for reference at
reassembly.

Figure 7-32. Lower Pinion Bearing Cup Removal

4. Use a mallet and punch to drive the inner

axle bearing cup [Item 9] (toward the ring
gear) from the housing.
NOTE: If the axle and pinion bearing seat
dimensions are not recorded (stamped)
on the inside of the drive unit housing,
save the shims to use for reference at
reassembly.

2. Use a mallet and punch to drive the upper Figure 7-35. Inner Axle Bearing Cup Removal
pinion bearing cup [Item 2] from the
housing.

Figure 7-33. Upper Pinion Bearing Cup Removal

5. Visually inspect the housing bores and

sealing surfaces for damage or wear.
3. Use the punch and mallet to remove the Housing Cleaning and Inspection
outer axle bearing cup [Item 8] (toward the
axle) and axle seal [Item 5] from the Thoroughly degrease the housing. Visually
housing. inspect the entire housing again for damage,
cracks, or wear.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Drive and Brake Drive Units

Axle Shaft Disassembly Assembly

Always watch for pinch points when

using a press or pressing tools. Safety glasses are required.

1. Place a bearing puller clamp beneath the Prepare the housing for assembly. Run a tap
outer axle bearing cone [Item 8]. through all bolt and screw holes.

2. Press the bearing from the axle. Use a Shim Calculation

bearing press and a 6 in. tube
1. Determine the pinion shim starting
Figure 7-36. Press Bearing from Axle thickness.
a. Record the pinion bearing seat
dimension from the housing.
b. Record the mounting distance etched
on the pinion shaft.
c. Determine the shim thickness required
for the pinion.

Example Pinion Shim Calculation

Bearing seat dim. from housing 5.9020 in.
Mounting distance from pinion –4.9380 in.
3. Inspect the axle for damage or wear. Minimum bearing height –0.9375 in.
Shim Thickness Required 0.0265 in.
Pinion Gear Shaft Disassembly
1. Place a bearing puller clamp beneath the Actual Pinion Shim Calculation
bearing cone [Item 7] on the spiral gear. Bearing seat dim. from housing _______ in.
Mounting distance from pinion –_______ in.
Figure 7-37. Lower Pinion Bearing Removal
Minimum bearing height –0.9375 in.
Shim Thickness Required _______ in.

2. Determine the ring gear shim thickness.

a. Record the axle bearing seat dimension
from the housing.
b. Record the mounting distance etched
on the ring gear.
c. Determine the shim thickness required
for the ring gear.

2. Press the bearing from the pinion gear

shaft.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Drive Units Drive and Brake

Example Ring Gear Shim Calculation Figure 7-39. Lower Pinion Bearing Cup Installation
Bearing seat dim. from housing 3.7175 in.
Mounting distance from ring gear –1.8120 in.
Minimum bearing height –1.1875 in.
Minimum thickness of spacer –0.4630 in.
Minimum thickness of washer –0.2175 in.
Starting Shim Thickness Req’d 0.0375 in.

Actual Ring Gear Shim Calculation

Bearing seat dim. from housing _______ in.
4. Install the inner axle bearing cup [Item 9]
Mounting distance from ring gear –_______ in.
in the housing bore. Use a press or mallet.
Minimum bearing height –1.1875 in.
Minimum thickness of spacer –0.4630 in. Figure 7-40. Inner Axle Bearing Cup Installation
Minimum thickness of washer –0.2175 in.
Starting Shim Thickness Req’d ______ in.

Bearing Cup Installation

1. Press the upper pinion bearing cup
[Item 2] into the housing. Place the spiral
gear shims (0.015 in. [0.38 mm] thickness)
in the housing, then place the bearing cup
[Item 7] in the housing.

Figure 7-38. Upper Pinion Bearing Cup Installation

NOTE: Wipe away any chips or excess metal

pieces resulting from installation.
5. Install the outer axle bearing cup [Item 8]
in the housing. Use a mallet or press.

Figure 7-41. Outer Axle Bearing Cup Installation

2. Turn the drive unit housing over. Insert

the correct shim thickness (calculated -
refer to “Shim Calculation”) into the lower
pinion bearing seat.
3. Press the lower pinion bearing cup [Item 7]
in the housing.
NOTE: A setup bearing can be made by having
the outside of the cup turned down to Spiral Pinion and Ring Gear Installation
2.6130 in. so pressing and pulling it is
NOTE: The Spiral Pinion and Ring gears are a
not required during the setup process.
matched set [Item 4]. Their alignment is
critical. Do not replace them separately.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Drive and Brake Drive Units

Figure 7-43. Upper Pinion Bearing Cone Installation

The bearing can become extremely hot.

Use gloves to protect hands from burns.

1. Use a bearing heater to preheat the pinion

shaft bearing cones [Item 2 and 7] to
300ºF (150ºC) maximum.

Figure 7-42. Preheating Bearing Cone

5. Place the helical gear [Item 3] onto the top

pinion bearing cone [Item 2].
NOTE: Install the helical gear with the word
“UP” stamped on the gear facing up. The
gear hub face that is flush with the
outside surface of the gear should face
down and touch the bearing.
6. Insert the pinion gear up from the bottom
NOTE: Steps 2 through 5 must be completed of housing, through the pinion bearing
before the bearing cools. cone and helical gear.
7. Install the helical gear clamp nut onto the
2. Slide a preheated pinion shaft bearing
spiral pinion shaft. Rotate the helical gear
cone [Item 7] onto the spiral pinion gear
incrementally, bringing the clamp nut
shaft.
torque to 35 ft. lb. (47.5 Nm) to seat the
3. Gather the helical gear and pinion clamp pinion bearings and the helical gear.
nut.
Figure 7-44. Install Clamp Nut
NOTE: Handle the helical gear with care during
the entire assembly process. Do not
allow the gear teeth to be nicked or
damaged.
4. Place the second preheated pinion bearing
cone into the top bearing cup [Item 2] (the
traction motor flange on housing must be
facing up).

8. Check the rolling torque of the pinion gear.

The rolling torque must be 5 to 8 in. lb.
(0.6 to 0.9 Nm). Tighten or loosen the
clamp nut, as necessary, to attain the
correct rolling torque.
NOTE: If necessary, loosen the pinion nut and
strike the pinion gear with a punch in
the drill center to slide the bearing cone

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Drive Units Drive and Brake

on the pinion gear to loosen the rolling already pressed into the housing. Place the
torque. Retighten the pinion nut as spacer [Item 12] on the axle bearing, then
required. the shim stack [Item 11], and thrust
washer [Item 10], in that order. Insert the
9. Apply thread-locking compound
ring gear [Item 4] under the pinion gear.
(P/N 990-669) to the clamp nut and the
Make sure the tooth marked “X” on the
locking screw threads after the shimming
pinion gear is between the two teeth
is correct and final assembly is completed.
marked “X-X” on the ring gear.
10. Tighten the clamp nut to 23 ft. lb.
6. Insert the axle shaft [Item 6] up through
(31.2 Nm) and tighten the locking screw to
the bottom of the housing, through the
128 in. lb. (14.5 Nm). Make sure the open
spacer, shims, thrust washer, and ring
ends of the pinion clamp nut do not touch
gear. Install the second thrust washer
after the locking screw is torqued down.
[Item 10] and axle shaft clamp nut [Item
11. Check the rolling torque. The rolling 13] onto the axle.
torque must be 5 to 8 in. lb.
(0.6 to 0.9 Nm). NOTE: Do not use thread-locking compound on
the clamp nut until the shimming is
12. Tighten or loosen the pinion nut, as correct.
necessary, to attain the correct rolling
torque. 7. Clamp the helical gear to keep the gear
assembly from rotating. Torque the axle
NOTE: Less than 1/16 of a turn on the pinion shaft clamp nut [Item 13] to 125 ft. lb.
nut will have an affect on the rolling (170 Nm). Additional torque may be
torque. required to pull the axle up through the
heated bearing. Re-adjust to correct the
Axle Assembly/Installation torque setting. Remove the clamp, then
use the torque wrench on the axle shaft
clamp nut to rotate the gear assembly 11
times to re-align the “X” on pinion gear
The bearing can become extremely hot. with the “X-X” on the ring gear (to seat the
Use gloves to protect hands from burns. bearings). Replace the clamp and
re-torque the axle shaft clamp nut.
1. Use a bearing heater to preheat the axle 8. Make sure the “X” on the pinion gear is
bearing cones [Items 8 and 9] to 300ºF aligned to the “X-X” on the ring gear. Use a
(150ºC) maximum. dial indicator to check the backlash at the
2. Apply thread-locking compound large spiral bevel ring gear, by firmly
(P/N 990-543) to the OD of the axle seal rotating the large spiral bevel ring gear
[5] and install into the housing. back and forth, making certain that the
pinion gear is held motionless. Rotate the
NOTE: Steps 3 through 7 must be completed
gear to the tightest backlash location as
before the bearing cools.
determined by the assembler and check
3. Press the outer axle bearing cup [Item 8] the backlash again.
onto the axle shaft [Item 6].
NOTE: Clamp the helical gear to achieve a more
4. Gather the axle bearing cone [Item 9], accurate backlash reading.
spacer [Item 12], shim stack [Item 11]
(calculated - refer to “Shim Calculation” on 9. If the lowest backlash reading is within
page 7-40), thrust washer [Item 10], ring tolerance [0.004 to 0.010 in. (0.1 to
gear [Item 4], thrust washer [Item 10], and 0.25 mm)], proceed to Step 10. If the
axle shaft clamp nut [Item 13]. backlash is not within tolerance,
disassemble the axle ring gear assembly.
5. Rotate the unit so the ring gear cavity is Check for errors in the assembly of the
facing up. Lightly oil the axle bearing cone components or contamination. If the
[Item 9] and set into the cup that is backlash is still not within tolerance,

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Drive and Brake Drive Units

repeat Steps 8 through 11, adding or and locking screw threads. Install the
subtracting shims as necessary until the clamp nut onto the axle and torque to
backlash is within tolerance. 125 ft. lb. (170 Nm). Apply thread-locking
compound (P/N 1013829) to the locking
NOTE: Backlash may increase up to 0.003 in.
screw and torque to 128 in. lb. (14.5 Nm).
(0.076 mm) after the heated bearings
Make sure that the open ends of the axle
cool.
clamp nut do not touch after the locking
10. Apply marking compound to the ring gear screw is torqued. Check the axle gap
and check the contact pattern. See (distance between axle and housing). This
Figure 7-45. Add or remove shims as is an indication that the bearings are
required. After shimming is corrected, correctly seated. The gap should measure
verify the backlash is still within tolerance approx. 0.195 in. (4.95 mm).
per Step 9. 13. Check that the mounting surface of the
cover plate and housing are free of paint,
Figure 7-45. Ring Gear Contact Patterns
dirt, and debris. Clean both surfaces with
isopropyl alcohol and allow the surfaces to
dry. Apply RTV silicone gasket-forming
compound (P/N 990-659) to the housing
surface. Install the cover plate onto the
housing, making sure the drain hole in the
cover is on the opposite side of the pinion
gear. Install the screws (qty. 10) and
torque to 7 ft. lb. (9.4 Nm).
14. Install the magnetic drain plug into the
cover plate. Use gasket sealant compound
(P/N 990-556). Install the “Check Level”
plug into the housing finger tight and
without sealant.
Ideal
Contact 15. Install the dowel pins. Use thread-locking
Pattern compound (P/N 1013829).

11. Disassemble the components and return

to Step 2 of “Bearing Cup Installation” on
page 7-41. Follow the procedures for
reassembly.
12. Apply thread-locking compound
(P/N 990-669) to the axle shaft clamp nut

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Drive Tire Pressing Drive and Brake

Drive Tire Pressing same position the old tire was installed on
the hub. You can use a spacer (slightly
smaller in diameter than the inside
diameter of the tire insert and the same
thickness as the depth of the recess) to
Misalignment of the tire and hub while obtain the correct amount of recession.
the tire is being pressed onto the hub 4. Position the hub assembly with the old tire
can cause damage to the hub. For this on the top of the circular ram so the
reason, chamfers are provided on the outside of the wheel is positioned upward.
outside edge of the hub and on the end The outside edge of the hub has a chamfer
of the inside diameter of the tire’s metal to help guide the new tire onto the wheel.
insert. The chamfers help to center the The chamfered edge must always be the
hub and tire during the pressing leading edge when you press a tire onto
operation and reduce the possibility of the hub.
misalignment. To prevent damage,
install the hub on the circular ram with 5. Center the hub assembly on top of the ram
its chamfered side up. and make sure that they mate squarely.
6. Apply grease to the inside of the tire rim.
1. Check the inside surface of the metal 7. Position the new tire with its chamfered
insert on the new tire. Remove any scaling insert facing the hub. Align the new tire
or rust with sandpaper. Clean the inside of and the hub so that they are concentric.
the metal insert and lubricate it with a
soap solution. 8. Begin pressing the new tire onto the hub
and the old tire off. Run the press slowly
2. Place a circular ram on the press table. for the first few inches of travel. If the tire
The length of the ram must be longer than begins to cock to one side, stop the press
the width of the old tire to allow complete and realign the tire. A sharp jar with a
removal of the old tire. The outside soft-headed mallet will usually realign the
diameter of the ram must be small enough tire on hub.
to fit loosely in the insert of the tire, but
must be large enough to rest squarely on a NOTE: If the new tire does not press on with a
flat surface on the outer edge of the hub. minimum of 5 tons (68,947 kPa)
pressure, try pressing a different new
Outside of Hub tire. If the tire still does not press on,
and Tire Assembly replace the hub.
9. Release the press. Remove the wheel, tire
assembly, and the old tire from the press
New Tire table. Wipe off any grease. Inspect the
wheel and tire assembly.

Worn Tire

Circular Ram

Press Table
3. If the outside edge of the hub is not flush
with the edge of the metal insert in the old
tire, measure how far the hub is recessed
inside the tire. Place the new tire in the

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Drive and Brake Brakes

Brakes Figure 7-46. Brake Release Bolt Installation

Brake Assembly P/N 1043541

Inspection

Check the gap between the brake coil and

armature disc. The gap should measure 0.008
and 0.016 in. (0.2 and 0.4 mm). If the gap
exceeds 0.016 in. (0.4 mm), remove and
disassemble the brake assembly to check the
components.

A drive tire fender kit is available for lift trucks

that operate in dusty or dirty environments.
Refer to the Parts Manual.

Removal
1. Move the lift truck to a level surface and
block the tires.
2. Lower the forks all the way and tilt the
mast forward.
7. Remove the nut and washer from the
3. Turn the key switch OFF and disconnect motor shaft.
the battery connector.
8. Remove the three bolts that hold the brake
4. Remove the front covers. assembly to the motor. Lift the brake
NOTE: Note the location of the cable ties for assembly off the traction motor.
correct installation later.
Disassembly
5. Cut the cable ties joining the brake coil
harness and the speed feedback sensor 1. Remove the three bolts that hold the lower
harness and temperature sensors. friction plate to the brake coil.
Disconnect the brake coil assembly 2. Remove and inspect the brake friction
electrical connector JPB4 or JPB3 from disc.
the lift truck’s harness. 3. Clamp the brake assembly in a vise or use
6. Install the brake release bolts. Tighten to C-clamps.
release the brake. 4. Remove the brake release bolts and the
top friction plate from the brake coil.
NOTE: When removing the top friction plate
from the brake coil, hold the coil
inverted so the brake springs remain in
the coil assembly.
5. Check the thickness of the friction disc. If
the thickness is less than 0.235 in.
(6 mm), replace the friction disc.
6. Check the top and bottom friction plates.
Replace them if worn more than 0.003 in.
(0.08 mm).

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Brakes Drive and Brake

Assembly 7. Check the operation of the brake. Travel

forks-first at full speed with a rated load.
1. Place the springs evenly in the holes in the Press the EPO button. The lift truck
brake coil. (There may be fewer springs should stop within one and one half lift
used than there are holes.) truck lengths. This distance varies
2. Place the top friction plate over the depending on floor and tire conditions.
springs.
3. Carefully clamp the assembly together. Brake Assembly P/N 1094113
4. Install the two brake release bolts and
tighten. Inspection
5. Center the friction disc on the upper 1. Turn the key switch OFF and disconnect
friction plate. the battery connector.
6. Place the three bolts previously removed 2. Remove the front covers.
through the brake coil assembly.
3. Check the air gap between the armature
7. Secure the brake coil assembly to the and armature plate near all three spacers.
lower friction plate assembly. Torque to See Figure 7-47. If the air gap exceeds
70 in. lb. (7.9 Nm). 0.040 in. (1 mm), replace the brake pads.
Refer to “Pad Replacement” on page 7-48.
Installation
Figure 7-47. Checking Brake Air Gap
1. Install the brake assembly onto the
traction motor. Make sure the friction disc
fits over the splined hub. Refer to
Motor
“Component Specific Torque Chart” on Shaft
page A-4.
2. Install the nut and washer on the motor Brake
shaft and torque. Refer to “Component Mounting
Specific Torque Chart” on page A-4. Bolt (qty. 3)

3. Remove the brake release bolts and stow

in their correct location on the tractor
Armature
frame.

Armature
Plate

Make sure that all the brake release Adapter Spacer

bolts are removed before using the lift Plate
truck. The brake does not work if the
brake release bolts are not removed.
Removal
4. Plug the wiring harness connector from 1. Turn the key switch OFF and disconnect
the brake coil into the connector from the the battery connector.
VM (JPB4 for the right brake coil; JPB3 for
the left brake coil). Install cable ties as 2. Block the drive tires to prevent movement.
necessary. 3. Remove the front covers.
5. Install the front covers. 4. Disconnect the brake armature lead
6. Reconnect the battery connector and turn connection.
the key switch ON. 5. 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

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Drive and Brake Brakes

measured total air gap (non-energized). Figure 7-49. Pad Replacement

Insert the spacer between the armature
Small Flange Carrier
plate and the coil body. Tighten the
(large flange
locking bolt just enough to prevent opposite side)
rotation of the motor shaft.
6. Remove the retaining nut and washer from
the motor shaft. See Figure 7-47.
7. Remove the three brake mounting bolts.
8. Use a brake puller to remove the brake
assembly from the motor.

Pad Replacement
Pad (qty. 6)
1. Install the brake release bolts.
NOTE: Do not overtighten the brake release 5. Install the adapter plate. Torque the
bolts. adapter plate bolts to 6 ft. lb. (8.6 Nm).
2. Turn the brake assembly over and remove NOTE: Leave the brake release bolts installed
the three bolts securing the adapter plate. for reassembly to the motor.
See Figure 7-48.

Figure 7-48. Adapter Plate Removal Coil Replacement

1. If installed, carefully remove the brake
release bolts. Separate the coil from the
armature plate.
NOTE: The brake release bolts are under
tension from the springs inside the coil
body.
2. With the coil inverted, make sure all six
springs are inserted into the cavities.
NOTE: On coils with ten spring cavities, the two
empty cavities must be 180° apart.
3. Place the thin washer shaped spacer over
the springs.
4. Note the orientation and place the inverted
Adapter armature plate on the coil directly over the
Plate Bolts spacer.
5. Assemble the armature and coil:

3. Remove the adapter plate. Inspect the a. Use a clamp to mate the armature plate
spacers and replace if damaged. to the coil. Make sure the thin washer
is correctly aligned.
4. Remove the old pads from the carrier and
install the new pads. See Figure 7-49. b. Install the brake release bolts through
the coil and armature plate and tighten.
6. Install the carrier, pads, and adapter plate.
Torque the adapter plate bolts to 6 ft. lb.
(8.6 Nm).

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Brakes Drive and Brake

Installation bolt just enough to prevent rotation of the

motor shaft.
1. Correctly position the brake assembly on
6. Remove the nyloc flange nut from the
the motor. Make sure the keyways on the
motor shaft. See Figure 7-50.
motor shaft and carrier are correctly
aligned. 7. Remove the three brake mounting screws.
2. Gently tap the carrier flange onto the 8. Remove the brake assembly from the
motor shaft until seated. traction motor.
3. Apply thread-locking compound
(P/N 990-536) and install the three brake Installation
mounting bolts. Torque to 16 ft. lb.
1. Move the lift truck to a level surface and
(21.7 Nm).
block the drive tires.
4. Remove the brake release bolts and install
in their storage locations. NOTE: Both brakes must be replaced at the
same time.
5. Loosen one of the retainer bolts and insert
a 0.030 to 0.040 in. (0.76 to 1 mm) spacer 2. Remove the old brake assemblies. Refer to
between the armature plate and coil body. the applicable procedure in this section.
Tighten the retainer bolt just enough to NOTE: The traction motor or tilt cylinder may
prevent rotation of the motor shaft as the need to be removed on C50 models for
retaining nut is torqued. clearance to install the brakes.
6. Install the retaining nut and a new washer
3. Install the hub onto the traction motor
to the motor shaft. Torque the retaining
shaft. Reuse the existing key and spacer
nut to 150 ft. lb. (203 Nm).
unless they are damaged. See Figure 7-50.
7. Loosen the retainer bolt and remove the
spacer. Figure 7-50. Brake Assembly
8. Unblock the drive tires. Reconnect the Brake Release
battery connector and turn the key switch Bolts Brake
ON. Assembly:
Nyloc Flange
9. Make sure the brake operates correctly. Nut Stator

Brake Assembly P/N 1252130 Hub

Rotor
Removal Mounting
Screws Mounting
1. Move the lift truck to a level surface and
Plate
block the tires to prevent movement.
2. Turn the key switch OFF and disconnect Traction
the battery connector. Motor
3. Remove the front covers.
4. Disconnect the brake armature lead
connection.
5. Loosen one of the brake release bolts and
obtain a spacer approx. 0.005 to 0.015 in.
(0.12 to 0.38 mm) thicker than the 4. Install the mounting plate on the traction
measured total air gap (non-energized). motor (with the 45° chamfer towards the
Insert the spacer between the mounting motor) with three mounting screws, and
plate and the rotor. Tighten the locking torque to 18 ft. lb. (24 Nm).

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Drive and Brake Brakes

5. Install the rotor on the hub. The rotor NOTE: The brake must be de-energized and the
should slide onto the hub with minimal motor must NOT be running while
force. Lightly tap the rotor onto the hub checking the air gap.
with a rubber mallet if necessary. Make
1. Loosen (do not remove) the three mounting
sure that the rotor contacts the mounting
screws. See Figure 7-52.
plate.
2. Use an open-end wrench to screw the
sleeve bolts further into the stator. A 1/6
turn decreases the air gap by
Protect the rotor so the hammer does approximately 0.006 in. (0.15 mm).
not contact it directly.
3. Tighten the mounting screws and torque
6. Position the stator on the traction motor. to 18 ft. lb. (24 Nm).
See Figure 7-50. Install the stator onto the 4. Check the air gap near the screws with a
mounting plate with three mounting feeler gauge.
screws, and torque to 18 ft. lb. (24 Nm).
7. Remove and discard the three blue plastic Figure 7-52. Air Gap Adjustment
clips from the standoffs. See Figure 7-51.

Figure 7-51. Remove Blue Plastic Clips

8. Install the nyloc flange nut on the traction

motor shaft, and torque to 90 ft. lb.
(122 Nm). See Figure 7-50.

Brake Release Bolts

This brake assembly requires 60 mm long brake

release bolts. Replace the existing 50 mm brake
release bolts located on the dash with 60 mm
bolts.

Air Gap and Adjustment

The air gap of the brake in new condition,

measured between the stator and armature
plate, must be within the range of 0.006 to
0.014 in. (0.15 to 0.35 mm). Measure and
readjust if the air gap is not within this range.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Electrical Components

Electrical Components
Section 7. Component Procedures

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Battery Procedures

Battery Procedures touching and causing a short circuit.

Do not allow the metal cable end to
touch the battery. Use insulated tools
and avoid contact with the battery case
or cable ends.
Before working on the battery, review
1. To remove a cable from the connector,
“Battery Safety,” beginning on
push the retainer down while pulling the
page 2-5. Batteries for this lift truck
battery cable towards the rear and out of
weigh between 1700 and 3250 lb. (771
the connector. See Figure 7-53 and
to 1475 kg). Use extreme care during
Figure 7-54.
replacement. Use a suitable battery
moving device or hoist for lifting. Do not Figure 7-53. Battery Cable and Connector
extend a battery more than 1/3 of its
length outside the battery compartment
without being attached to a battery
moving device.

Battery Connector/Cables
Inspection
1. Turn the key switch OFF and disconnect
the battery connector.
2. Check the battery connector for damaged
cables.
3. Check to see if the battery cables are Figure 7-54. Battery Cable Removal from Connector
pulling out of the connector.
4. Check the cables at the battery terminals.
Connections should be tight, with no
corrosion.
5. Look inside the connector. Check all
internal contacts for damage, dirt, or
corrosion. Do not use a metal object to
clean the connector.
NOTE: Some degreasers and parts cleaners
cause the connector shell to
disintegrate. Avoid contacting the
battery connectors with solvents.
2. Do not attempt to repair the battery cables
Removal, Replacement, and by crimping new terminals. Replace the
Installation cable.

The cables to either half of the connector have a

lip on their forward end. This lip snaps over a
spring-loaded retainer that is part of the
connector.
NOTE: When replacing the battery cable ends,
remove only one end at a time from the
connector, to avoid the cable ends

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Battery Procedures Electrical Components

Battery Exterior Cleaning 7. Wash dirty batteries (or any that have had
electrolyte spilled on them) with a solution
1. Read, understand, and follow the of 1 lb. (0.45 kg) of baking soda added to
procedures, recommendations and 0.5 gal. (1.9 liters) of hot water.
specifications in the battery and battery
8. Use a brush with flexible bristles to clean
charger manufacturer’s manuals.
the entire top of the battery with the soda
solution. Wait until all foaming stops,
indicating that the battery exterior is
neutralized.
9. Rinse the battery with clean water.
10. Dry the battery completely before
reinstalling it.
11. Use a suitable battery moving device to
install the battery in the lift truck.
2. Wear personal protective equipment. See Reconnect the battery connector.
“Battery Safety” on page 2-5.
3. Turn the key switch OFF and disconnect Testing, Charging, and Maintenance
the battery connector. Remove the battery
from the lift truck. For information on testing, charging, and
maintaining your lift truck battery, consult the
4. Inspect the battery cables to make sure
battery manufacturer’s specifications and
they are not frayed or loose. Inspect the
instruction manual.
battery connector to make sure there is no
foreign material inside the connector. NOTE: Never plug the battery charger into the
5. Make sure the filler plugs are tight and the lift truck. This severely damages the lift
vent holes in the filler plugs are open. truck’s electrical system. Plug the
charger only into the connector from the
Figure 7-55. Battery Cable and Filler Plug battery.
Battery Cable

Filler Plug
Vent Hole Battery State-of-Charge

6. Keep the top of the battery clean and dry. Battery State-of-Charge (BSOC) is a feature that
Corrosion, dust, and moisture provide a monitors and remembers the charge level of the
conducting path to short-circuit cells or battery connected to the lift truck and prevents
create shorts to ground. excessive discharging of that battery. Operating
a lift truck with a discharged battery can
NOTE: Do not clean the top of the battery with damage both the battery and the electrical
the soda solution while it is installed in components of the lift truck. See page 5-4 for a
the lift truck. Water can seep into the detailed description of how BSOC works and
electrical components and cause serious the procedure for setting BSOC Cutout.
damage.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Power Cables

Power Cables Table 7-3. Cable Jacket Strip Length - Short Barrels
AWG Lug P/N Strip Length
Check the power cables for: 1/0 1002215/001-004 11/16 in. (17 mm)
• evidence of overheating 2/0 1002215/005-008 13/16 in. (21 mm)
• burned spots in the cable
3/0 1002215/009-012 1 in. (25 mm)
• nicks in the insulation
4/0 1002215/013-015 1-1/16 in. (27 mm)
• damaged or overheated terminal lugs
• damaged mounting hardware or brackets
Table 7-4. Cable Jacket Strip Length - Long Barrels

Replace damaged cables or mounting hardware AWG Lug P/N Strip Length
as necessary.
1/0 1002217/001-003

Power cables are marked on the terminal lug 2/0 1002217/004-006 1-9/16 in. (40 mm)
with the location where they belong. If the
3/0 1002217/007-009
marking is missing or is not readable, remark
the cable with the correct information. 4/0 1002217/010-011 1-11/16 in. (43 mm)
NOTE: Terminal lugs may be replaced in the
field with the appropriate crimping tools. 5. Insert the cable into the terminal.
Crimping tool, lugs, and heat-shrink are 6. Place the cable and terminal into the tool
available through the Parts Distribution die and crimp. Refer to Figures 7-56 and
Center. Failure to use the correct cables, 7-57.
terminal hardware, and torque values
can result in overheating and damage to Figure 7-56. Short Barrel Terminal
the components.

Power Cable Repair

Traditional lug crimping techniques for power
cables on DC motors may not meet the higher
current requirements of AC motors. Use
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. Cut an appropriate amount of replacement
cable of the same gauge. Use the removed
cable(s) for reference.
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 7-3 and
Table 7-4.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Power Cables Electrical Components

Figure 7-57. Long Barrel Terminals

7. Apply heat-shrink tubing (P/N 611-035) to

the terminal after crimping.
a. For short barrels, use 1.75 in. (45 mm)
of tubing. Apply 1 in. (25 mm) over the
jacket extending 0.75 in. (19 mm) over
the barrel.
b. For long barrels, use 2.5 in. (64 mm) of
tubing. Apply 1 in. (25 mm) over the
jacket extending 1.5 in. (38 mm) over
the barrel.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Motors

Motors DC Motor Service

Motor Brushes
General
Inspection
Power Cable Terminals
Figure 7-58. Motor Brush Location
Table 7-5. Power Cable Terminal Torques
Location/Stud
Torque
Size/Type

Traction Motors Top Nut: 12.5 to 18.4 ft. lb.

(23 to 25 Nm)
Lift Motor - AC Bottom Nut: 10.7 to 11 ft. lb.
(14.5 to 15 Nm)

Top Nut: 7.5 to 9.2 ft. lb.

(10.2 to 12.4 Nm)
Lift Motor - DC
Bottom Nut: 9.2 to 11.6 ft. lb.
(12.4 to 15.8 Nm)

Top Nut: 7.5 to 9.2 ft. lb.

(10.2 to 12.5 Nm)
Steer Motor
Bottom Nut: 9.2 to 11.7 ft. lb.
(12.5 to 15.9 Nm)

95 to 105 in. lb.

Power Amplifiers
(10.7 to 11.8 Nm)
Conduct a partial inspection of the motor
Contactor - M6 during scheduled maintenance. If the lift truck
50 in. lb. (5.6 Nm)
steel
is operated in a severe or caustic environment
Contactor - M8 or is used in an extended duty cycle
180 in. lb. (20.3 Nm) application, inspect the motor more frequently.
steel

Contactor - M8 Set up and rigidly adhere to a strict inspection

70 in. lb. (7.8 Nm)
brass/copper
schedule to obtain the maximum efficiency
from the electrical equipment.
DC Motor Troubleshooting Each partial inspection of the motor must
include:
See “DC Motors” on page 5-14.
1. Inspect the brushes for wear and for
correct contact with the commutator.
AC Motor Troubleshooting Record the level of wear on the brushes.
This history provides an indication of
See “AC Motors” on page 5-18.
whether a brush must be changed or if it
can wait until the next inspection. Refer to
Table 7-6 on page 7-58 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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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Motors Electrical Components

2. Check the brush spring tension. Refer to of the brushes are contoured to match the
“Motor Brush Spring Tension” on curve of the commutator.
page 7-58. 4. Remove the sandpaper.
3. Clean the brushes and holders. Wipe the 5. Blow any dust out of the motor with clean,
commutator with a dry, lint-free cloth. Do compressed air at a maximum of 30 psi
not use lubricants of any kind on or (207 kPa).
around the commutator.
4. Check the brush holders for a solid Aux Motor Brush Replacement
connection to the mounting support. 1. Remove the worn brushes. Inspect each
Tighten the mounting screws as brush holder and spring. The spring
necessary. should be tight and rest against the brush
5. Check the cap screws that hold the brush holder. If the spring is bent or damaged,
cross-connectors to the brush holder replace the spring set. Make sure the
body. rivets attaching the brush housing to the
brush board are not loose. Replace the
6. Make sure the motor terminals are
motor if there are loose rivets or damage to
secured tightly to the motor frame. Use
any part of the brush housing assembly.
care not to strip the threads or crush the
insulating parts. See “Power Cable 2. Slide the brush into the brush housing.
Terminals” on page 7-56. Make sure the brush wire is facing down
towards the motor. Verify the brushes
7. Check all the cap screws around the frame
move freely inside the brush holders. If a
for tightness.
brush hangs up or is tight, remove the
8. Keep the outside frame of the motor clean brush and inspect the brush holder for
and free from dirt. Maintain a free air damage. Verify the brushes being installed
passage around the motor to allow heat are the correct part number.
radiation.
3. Verify the brushes are in full contact with
Replacement the commutator and the brush springs are
correctly installed, applying pressure to
NOTE: If one brush needs replacement, always
the center of the brushes.
replace the entire set of brushes.
4. Check the brush spring tension. Refer to
Use only genuine Raymond brushes. Another Table 7-6, “Minimum Brush Length and
type of brush could cause damage to the Spring Tension,” on page 7-58.
commutator or cause excessive brush wear and 5. Attach the brush wire terminal to the
voids your warranty. brush holder assembly. The terminal on
the leads should point to the 3 o’clock
If the end of the brush is not already contoured position. Tighten the retaining screws
to fit the commutator, seat the brush to the until snug, do not over tighten and strip
commutator: the threads.
NOTE: If the motor commutator is not 6. Position the brush lead so that it is
accessible, use a brush seating stone to straight behind the brush. Pull excess wire
form the brush contour. up towards the screw terminal to allow
proper installation of the covers. Do not
1. Move the motor brush springs out of your tuck the leads to the side or inward toward
way. the commutator. Failure to correctly
2. Wrap a piece of 00 sandpaper around the position the leads results in the brushes
commutator. Do not use emery cloth to hanging up and losing contact with the
seat brushes. commutator.
3. Move the brushes back down into their 7. Reassemble the motor and test for correct
holders. Rotate the armature until the face operation.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Motors

Motor Brush Spring Tension 9. Refer to Table 7-6 for correct spring
tension.
Inspection
Table 7-6. Minimum Brush Length and Spring Tension
1. Turn the key switch OFF and disconnect
the battery connector. Min.
Motor Brush Spring Tension
2. Remove the operator compartment covers.
Length
3. Slide the brush up slightly in its holder.
Lift 0.62 in. 40 to 65 oz.
4. Insert a paper strip between the brush (4150 only) (15.7 mm) (1134 to 1842 grams)
face and the commutator. See Figure 7-59.
0.50 in. 12 to 30 oz.
Steer (Aux)
Figure 7-59. Motor Brush Spring Tension Inspection (13 mm) (340 to 850 grams)

Spring 10. Repeat Steps 3 through 9 for the

Scale
remaining brushes.

Polishing the Commutator

NOTE: Use a narrow masking tape (1/2 to
3/4 in. wide) and wrap a commutator
stone in a spiral configuration. Leave
only enough stone exposed to make
contact with the commutator. As the
Leather
Loop length of the stone becomes shorter with
use, peel back and remove portions of
the tape.

Paper Make sure loose clothing is tied back.

Do not wear jewelry. Wear insulated
gloves.

1. If the motor has 4 or more brushes,

Rotation remove an accessible brush from the
Pull paper in direction of rotation motor with the motor still installed in the
lift truck. If the motor only has 2 brushes
5. Place a small leather loop around the coil or the commutator is not accessible with
spring for the brush. If the brush spring the stone, the armature must be installed
has a loop at the brush, hook the spring in a lathe or replaced. If so, go to Step 4.
scale directly to the spring.
2. Activate the motor.
6. Attach a 5 lb. (2.27 kilogram) spring scale
3. With the motor turning, carefully insert
to the leather loop.
the commutator stone into the brush box
7. While gently pulling the scale outward, area.
slowly pull the paper strip in the direction
4. With minimal pressure, run the stone
that the commutator normally rotates.
back and forth across the commutator
8. When the paper strip begins to move until it is polished. Do not pass the stone
freely, the spring scale reads the brush over the ends of the commutator
spring tension. segments.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Motors Electrical Components

5. Thoroughly blow out the motor with 10. Install a new temperature sensor with the
compressed air. high temperature silicone (neutral curing)
6. Inspect the commutator. Reinstall the supplied with the temperature sensor.
brush or armature and cover. Mount the sensor close to the location of
the original. Secure the cable with a cable
7. Check operation. tie to one of the power leads for stress
relief.
AC Motor Service 11. Install the top end bell in the position that
was previously marked. Verify the correct
AC traction and lift motor service is limited to stator installation and install the snap
Speed and Temperature Sensor replacement. ring.
12. Use the four bolts previously removed to
AC Motor Temperature Sensor secure the top end bell to the bottom end
bell.
Temperature sensors in the AC traction and lift
13. Install the brake mounting motor flange
motors are integral to the motor. When a motor
with new mounting bolts.
temperature sensor fails, use the procedures
below to replace it. 14. Install the brake assembly including the
rotor hub mount and rotor hub.
Traction Motor Temp Sensor Replacement 15. Install the terminal board, reconnect
1. Turn the key switch OFF and disconnect JPTA3 and the power cables. Refer to
the battery connector. “Component Specific Torque Chart” on
page A-4.
2. Remove the brake assembly including the
rotor hub nut and rotor hub. Note the 16. Reconnect the battery connector and turn
number of spacers used. the key switch ON.
3. Disconnect the temperature sensor Lift Motor Temp Sensor Replacement
connector JPTA3.
1. Turn the key switch OFF and disconnect
4. Disconnect the power cables. Note the the battery connector.
locations for reassembly later.
2. Disconnect the temperature sensor
5. Remove the terminal board. connector JPLA3.
3. Disconnect the cables and motor harness
connections. Make sure that you note the
Use correct electrostatic discharge locations for reassembly later.
precautions. See “Static Precautions” on 4. Separate the pump assembly from the lift
page 2-8. pump motor and remove the lift pump
motor.
6. Mark the position of the top end bell and 5. Remove the four bolts that secure the top
bottom end bell relative to the stator, then end bell to the bottom end bell.
remove the snap ring. 6. Remove the top end bell. Use care that the
7. Remove the brake mounting motor flange. bearing remains in the bottom end bell to
reduce the chance of damaging the
NOTE: Use new flange mounting bolts when
bearing.
reassembling.
7. Install a new temperature sensor with the
8. Remove the four bolts that secure the top high temperature silicone (neutral curing)
end bell to the bottom end bell. supplied with the temperature sensor.
9. Use a puller to remove the top end bell. Mount the sensor close to the location of
Use care that the encoder bearing remains the original. Secure the cable with a cable
in the bottom end bell to reduce the tie to one of the power leads for stress
chance of damaging the bearing. relief.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Motors

8. Carefully press the top end bell to the NOTE: Use new flange mounting bolts when
stator. Do not pinch the cables or allow reassembling.
contact with the rotor. Verify the correct
12. Remove the four bolts that secure the top
stator installation.
end bell to the bottom end bell.
9. Use the four bolts previously removed to
13. Use a puller to remove the top end bell and
secure the top end bell to the bottom end
bottom end bell.
bell.
14. Remove the clamps that secure the
10. Install the lift motor to the pump
encoder bearing cable.
assembly.
15. Remove the encoder bearing from the rotor
11. Reconnect JPLA3 and the power cables.
with a suitable puller, pulling on the outer
12. Reconnect the battery connector and turn race only.
the key switch ON.
16. Remove the oil seal to allow pressing of the
bottom end bell to the stator for later
AC Motor Bearing Encoder reassembly.
17. Make sure that the O-ring and wave
Traction Motor Encoder Replacement
washer are correctly positioned in the
1. Turn the key switch OFF and disconnect bottom bell bearing pocket.
the battery connector.
18. Position the new encoder bearing in the
2. Remove the brake assembly including the bottom end bell with the cable oriented in
rotor hub nut and rotor hub. Note the the middle of the notch in the side of the
number of spacers used. bearing pocket.
3. Disconnect the temperature sensor 19. Use an assembly bushing on the outer
connector JPTA3. race and press the bearing into place. Do
4. Disconnect the bearing encoder connector not press on the encoder part of the
JPTA2. bearing.
5. Disconnect the power cables. Note the 20. Install the encoder bearing cable clamps.
locations for reassembly later. 21. Install the top end bell in the position that
6. Remove the terminal board. was previously marked. Verify the correct
stator installation and install the snap
ring.
22. Carefully press the bottom end bell to the
Use correct electrostatic discharge stator.
precautions. See “Static Precautions” on
page 2-8. 23. Secure the top end bell to the bottom end
bell with the four bolts previously
7. Remove the steering position reference removed. Install the oil seal.
bracket. 24. Install the key, pinion gear, and nut to the
8. Remove the traction motor. See “Removal” bottom of the traction motor. Install the
on page 7-62. traction motor. See “Installation” on
page 7-62.
9. Remove the nut that secures the pinion
gear. Use a suitable puller to remove the 25. Install the brake mounting motor flange
gear and key. with new mounting bolts.
10. Mark the position of the top end bell and 26. Install the brake assembly including the
bottom end bell relative to the stator, then rotor hub mount and rotor hub. See
remove the snap ring. “Brakes” on page 7-46.
11. Remove the brake mounting motor flange.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Motors Electrical Components

27. Install the terminal board. Reconnect

JPTA2, JPTA3, and the power cables. Refer
to “Component Specific Torque Chart” on
page A-4.
28. Install the steering position reference
bracket and filler tube if previously
removed.
29. Reconnect the battery connector and turn
the key switch ON.

Lift Motor Encoder Replacement

1. Turn the key switch OFF and disconnect
the battery connector.

Use correct electrostatic discharge

precautions. See “Static Precautions” on
page 2-8.

2. Disconnect the connectors JPLA2, JPLA3,

cables, and motor harness connections.
Make sure that you note the locations for
reassembly later.
3. Separate the pump assembly from the lift
pump motor and remove the lift pump
motor.
4. Remove the four bolts that secure the top
end bell to the bottom end bell.
5. Remove the top end bell with a suitable
puller.
6. Remove the encoder bearing from the
rotor, pulling on the outer race only.
7. Apply steady pressure to the inner ring to
install the new encoder bearing.
8. Carefully press the top end bell to the
stator. Do not pinch the cables or allow
contact with the rotor. Verify the correct
stator installation.
9. Secure the top end bell to the bottom end
bell with the four bolts previously
removed.
10. Install the lift motor and reconnect the lift
pump assembly. See “Lift Motor” on
page 7-64.
11. Reconnect JPLA2, JPLA3, and the power
cables.
12. Reconnect the battery connector and turn
the key switch ON.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Traction Motors

Traction Motors c. As you turn the bolts, the traction

motor pushes upward, breaking its seal
to the drive unit. See Figure 7-61.
Removal Figure 7-61. Traction Motor Removal, Breaking Seal
1. Turn the key switch OFF and disconnect
the battery connector. Traction Motor

2. Remove the three front covers.

3. Remove the mast.
4. Remove the brake assembly.
5. Remove the friction plate retaining nut.
6. Remove the friction plate.
7. Disconnect the three power cables from
the terminals on the traction motor and Bolt in “Blind” Hole
label for later installation. Use two Drive Unit
wrenches to avoid twisting the terminal
studs.
8. Disconnect JPTL2 (left) or JPTR2 (right)
and JPTL3 (left) or JPTR3 (right). The traction motor is heavy. Use a
suitable lifting device to move it if
9. Place a drain pan beneath the drive unit.
necessary.
Remove the drain plug and drain approx.
two pints (one liter) of drive unit oil. This
12. Lift the traction motor off the drive unit.
prevents oil from spilling when the traction
motor is removed. See Figure 7-60. 13. If you are not reinstalling a traction motor,
use plastic film and masking tape to seal
Figure 7-60. Drive Unit Drain Plug the opening for the traction motor so that
no debris can fall into the drive unit.
14. Remove the pinion gear from the traction
motor shaft.

Installation
1. Thoroughly clean the mating areas on the
traction motor shaft and pinion gear.
2. Correctly install the pinion gear on the
traction motor shaft (taper correctly
oriented). Apply thread-locking compound
(P/N 1013829) and install the nut. Torque
10. Remove the four bolts that attach the to 45 ft. lb. (61 Nm).
traction motor to the top of the drive unit. 3. Thoroughly clean the mating areas on the
11. To break the seal between the traction top of the drive unit and the bottom of the
motor and the drive unit: traction motor mounting flange.

a. Install two of the bolts you removed in 4. Apply a coat of gasket cement
Step 10 into the two “blind” holes on (P/N 990-556) to the mating surface on
the traction motor mounting flange. the top of the drive unit. A gasket
(P/N 828-013-978) may be used instead of
b. Evenly turn each bolt clockwise. the gasket cement.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Traction Motors Electrical Components

5. Position the traction motor on top of the

drive unit and align the mounting holes.
6. Refer to “Component Specific Torque
Chart” on page A-4 and install the bolts.
7. Install the brake assembly.
8. Reconnect the cables to the terminals on
the traction motor. Use two wrenches to
avoid twisting the terminal studs. Refer to
“Component Specific Torque Chart” on
page A-4.
9. Reconnect the harnesses to the traction
speed feedback sensors and temperature
sensors.
10. Add gear oil to the drive unit through the
filler plug hole.
11. Install the mast.
12. Install the front covers.
13. Reconnect the battery connector and turn
the key switch ON.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Lift Motor

Lift Motor Installation

1. Apply thread-locking compound
(P/N 1013829) to the lift motor mounting
studs.
Discharge the power amplifiers energy 2. Carefully place the lift motor on the
storage capacitors before removing any mounting bolts on the frame. Support the
large fuse or motor cable for service. To motor on the wood blocks used during
discharge, turn the key switch OFF, removal.
disconnect the battery, and manually
3. Install the washers and mounting nuts
push in the plungers on all three
and tighten.
contactors.
4. Fill the motor cavity (including the space
below the splines) with lubricant
Removal (P/N 1223184) to within 0.5 in. (12.7 mm)
1. Remove the mast. of the top of the cavity.
2. Turn the key switch OFF and disconnect 5. Mate the lift/aux pump to the lift motor.
the battery connector. Apply thread-locking compound
(P/N 1013829) to the mounting bolts and
3. Remove the three front covers. install. Reconnect the hoses.
4. Remove the power cables, labeling if 6. Reconnect the power cables to the motor.
necessary for reinstallation. Use two Use two wrenches to avoid twisting the
wrenches to avoid twisting the terminal terminal studs. Refer to “Component
studs. Specific Torque Chart” on page A-4.
5. Model 4250 only: Disconnect the speed 7. Model 4250 only: Reconnect the speed
sensor (JPL2) and temperature sensor sensor (JPL2) and temperature sensor
(JPL3). (JPL3).
6. Remove the two bolts securing the front 8. Remove the wood block from beneath the
cover mounting bracket to the reservoir. motor.
7. Use caution not to get oil in the motor. 9. Reinstall the front cover mounting
Remove the lift pump from the lift motor. It bracket.
may be necessary to disconnect the lift
pump hoses. 10. Install the mast.
8. Place wood blocks beneath the lift motor to 11. Reconnect the battery connector and turn
help support it during removal. Leave no the key switch ON.
more than a 1/2 in. (13 mm) gap between 12. Test the lift/lower functions. Check for
the top of the wood blocks and the bottom hydraulic leaks where the mast hoses were
bell of the lift motor. disconnected.
13. Turn the key switch OFF and disconnect
the battery connector.
The lift motor is heavy. Use a suitable 14. Install the front covers.
lifting device if necessary.

9. Remove the mounting nuts that hold the

lift motor to the frame.
10. Carefully slide the lift motor off the
mounting studs.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Power Amplifiers Electrical Components

Power Amplifiers NOTE: When correctly torqued, the cable and

terminal can rotate up to 5° in either
direction.
Removal 5. Reconnect JTL1, JTR1 or JL1 (AC Lift
only).
6. Reconnect the battery connector and turn
the key switch ON.
Before removing a power amplifier,
discharge the amplifier’s internal
capacitor by jumpering the + and –
terminals with a 100 ohm 25W resistor.

1. Turn the key switch OFF and disconnect

the battery connector.
2. Disconnect JTL1, JTR1 or JL1 (AC Lift
only) from the power amplifier.
3. Disconnect the power cables and the B–
bus bar from the power amplifier.
4. Remove the four mounting screws.
5. Lift the power amplifier off the mounting
plate.

Installation
1. Install the new thermal conductive
material between the base of the power
amplifier and the heatsink.
2. Position the power amplifier and install the
four mounting screws.
3. Tighten the mounting screws to 7.4 ft. lb.
(10 Nm).

Do not attempt to repair the power

cable terminal lugs without approved
tools. If a power cable has worn or
damaged lugs, either replace the cable
or replace the lugs. Refer to “Power
Cable Repair” on page 7-54. Failure to
use the correct cables, flanged nuts, and
torque values can result in overheating
and damage to the components.

4. Reinstall the bus bar and reconnect the

power cables to the correct terminals.
Torque to 95 to 105 in. lb. (10.7 to
11.8 Nm).

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Deadman Pedal

Deadman Pedal
If the switch does not activate when the
deadman pedal is fully pressed or if the switch
has failed, perform the following procedure.
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the pad over the deadman pedal.
3. Remove the bolt securing the deadman
switch cable clamp to the floor. Leave the
deadman switch plugged in and remove
the deadman pedal.
4. Measure the gap between the proximity
sensor and the indicator flag.
a. Fully press 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 7-62.

Figure 7-62. Deadman Pedal Adjustment

PEDAL DEPRESSED
Indicator Flag

0.05 to 0.07 in. Proximity Sensor

(1.2 to 1.7 mm) gap

b. If the gap is OK or the sensor does not

activate after adjustment, replace the
proximity sensor.
5. Run “Test I00 - Deadman (S2)”
(Page 6-78).
6. Reinstall the deadman pedal in the floor.
Refer to “Component Specific Torque
Chart” on page A-4.
7. Reinstall the pad over the deadman pedal.
NOTE: If the pad was previously glued, apply
glue (P/N 990-569/102) in locations
originally glued.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Wiring and Harness Connectors Electrical Components

Wiring and Harness When replacing wires, follow these guidelines:

• Use the appropriate tools to remove and
Connectors insert terminations at each connector.
• Remove damaged terminations and
discard. Never reuse a termination from a
General Connector Repair wire.
Procedures
• Do not cut away a terminal lug and reuse
the wire strands that were crimped into
Inspection the original lug.
• When stripping wire, use new wire strands
Whenever working on the lift truck, use care
for new terminations. Make sure to use a
around wiring harnesses.
new wire with extra length to allow for
• Carefully connect and disconnect all cutting and stripping of the ends to install
connections. new terminations.
• Do not pry connectors apart with • Use a new wire that is the same gauge
unspecified tools. (typically gauge 18 AWG), size, type, and
color as the wire it is replacing.
There should be a wire marker at each
• Use a hand stripper capable of stripping
termination. If the marker is missing or
by wire gauge number. Use care not to
unreadable, remark the wire to allow easier
nick or cut any of the wire strands.
identification.
Discard and replace a wire with damaged
NOTE: It is normal to find unused connectors strands. Insert the wire strands the
for uninstalled options that have heat correct length into termination before
shrink applied over them and are crimping.
strapped to the harness.
Soldering Procedures
Repair
To prevent damage from excessive heat when
soldering small components in assemblies,
follow these guidelines:
Use correct electrostatic discharge
• Make sure the soldering tip is clean. A
precautions. See “Static Precautions” on
dirty tip does not transfer heat well and
page 2-8.
encourages long dwell time and greater
pressure. Apply light pressure on the
When pulling a wire out through a bundle, cut
terminal.
off the pin or socket so it does not snag. When
replacing wires, in some cases you can tape or • Flux: rosin base
solder one end of a new wire to one end of the • Solder: 60/40 rosin core or equivalent
failed wire. Then you can pull the old wire out of
• Solder Iron: 15-25 watt “pencil-type”
the bundle and pull the new wire into the
maximum
bundle, all at the same time. Make sure to
disconnect the old wire from the new wire. • Tip Size: 3 mm (0.118 in.) diameter x
30 mm (1.182 in.) long screwdriver tip.
In other cases, it is easier to secure a new wire Make sure the tip is clean.
to the outside of the existing wire bundle with • After soldering, clean the terminals with a
cable ties of an appropriate size. The failed wire brush dampened with an alcohol-based
can be left in the bundle, or can be pulled by cleaner (P/N 990-600/FOF). Do not allow
one end to remove it from the bundle. any cleaner to seep into the switches or
potentiometers, or contact contamination
may occur.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Wiring and Harness Connectors

Molex Connectors Pin Extraction

Molex connectors have pins with locking ears To remove a pin from a Molex connector, use
that engage ridges in the plastic connector pin extraction tool P/N 950-026. See
body. See Figure 7-63. Figure 7-64.
1. Insert the extraction tool over the pin and
Figure 7-63. Molex Connectors - End View
push all the way into the connector. This
Pin releases the locking ears on the pin.
2. Pull the wire and pin from the connector.

Socket Pin Insertion

1. To insert a pin into a Molex connector,
insert the pin into the back side of the
connector and push the wire all the way in
until it clicks.
Locking Ears
2. The locking ears have now engaged the
connector.
To remove a pin from a Molex connector, these
locking ears must be pressed far enough to
clear the ridge in the connector.

Figure 7-64. Pin Extraction Tool

Tool Inserted Over Pin

Top View

Locking Ears

Extraction Tool

Side View

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Wiring and Harness Connectors Electrical Components

AMP Water-Resistant
Connectors
AMP connectors provide water-resistant
connection by the use of seals between wires
and connectors and between the mating
connector halves. See Figure 7-65.

Figure 7-65. AMP Water-Resistant Connector

Wire Seal

Interface
Seal
Contact
Cavity

Wire Seal Jack

Housing

Pin Contact

Pin Housing

Sealing Plug

To maintain the integrity of water-resistant Figure 7-66. AMP Pin Extraction

seals, use the following procedures when Extraction Tool
working with AMP connectors.

Pin Extraction

To aid in separating AMP connectors, use

unlatching tool Raymond P/N 950-042. To
remove a pin from an AMP connector, use pin
extraction tool Raymond P/N 950-009.
1. While holding the wire seal, push the
selected wire forward, then insert the
extraction tool into the contact socket. See Locking
Lance
Figure 7-66.
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 7-67.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Wiring and Harness Connectors

Figure 7-67. Removing Wire Figure 7-69. Wire Insertion

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 7-68.
Figure 7-68. 2. Plug unused pin positions with sealing
plugs. See Figure 7-70.
Figure 7-68. Wire Seal
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 7-70. Sealing Plug
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 7-69.

5. Use an interface seal between the 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 7-71.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Wiring and Harness Connectors Electrical Components

Figure 7-71. Interface Seal

Interface
Seal

Pin Housing

6. When mating connectors, make sure that

the polarized silos are correctly oriented.
Push the pin and jack halves of the
connector together until the locking
latches engage. See Figure 7-72.

Figure 7-72. Latching AMP Connector

Locking
Latches

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Wiring and Harness Connectors

AMP Harness/Traction Power

Amplifier Connector
Connector Components

Figure 7-73. Power Amp Connector Components

(PT-1 on Traction Power

Amplifier)

(JT-1)

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
must fall into an area defined by a 2 mm
lock tabs. See Figure 7-73.
diameter cylinder whose center is the centerline
2. Pry the wedge lock to the open position. of the contact front end. See Figure 7-75.
3. While rotating the wire back and forth over
a half turn (1/4 turn in each direction), Assembly
gently pull the wire until the contact is
removed. See Figure 7-74. Make sure that the wedge lock is open.
1. To insert a contact, push it straight into
Figure 7-74. AMP JPT1 Connector
the appropriate circuit cavity as far as it
goes. See Figure 7-75. (a) and (b).
2. Pull back on the contact wire with a force
of 1 or 2 lbs. to make sure the retention
fingers are holding the contact. See
Figure 7-75. (c).

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Wiring and Harness Connectors Electrical Components

Figure 7-75. Contact Insertion

3. After all the contacts are inserted, close

the wedge lock to its locked position.
Release the locking latches by squeezing
Be very careful when putting the wedge
them inward. See Figure 7-76.
lock in the locked position. Forcing the
Figure 7-76. Wedge Lock Latches
wedge lock can cause damage to the
connector. Make sure that 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 7-77.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Wiring and Harness Connectors

Figure 7-77. Wedge Lock Flush With Housing

Testing

Do not pierce the wire insulation with a sharp

point while troubleshooting.

The wedge lock has slotted openings in the

forward (mating) end. These slots accommodate
circuit test tabs that are approximately 3.3 by
0.6 mm and prevent damage to the receptacle.
For circuit testing in the field, use a flat probe
such as a pocket knife blade. Do not use a
probe with a sharp point.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Cold Storage Electrical Components

Cold Storage • the connectors, fuses, terminal strips,

and relays where they plug into the
sockets
Cold Storage (CS) is an option that enables lift
• all terminals on the hydraulic solenoids
truck operation in temperatures of –20°F
(–28.86°C) to 40°F (4°C). • all terminals on the horn
• the terminals of the key switch and
On cold storage lift trucks, the electrical panel EPO switch
on the tractor is completely enclosed to contain
• the terminals on the lift motor
heat.
• the terminals on the steer motor
Cold Storage Conditioning • the terminals on both traction motors
4. Install the recommended hydraulic fluid
Perform Cold Storage conditioning with the and gear case oil. Refer to “Lubrication
items listed below: Specification Chart” on page A-2.

Description Part Number

Silicone Grease 990-445

Sealing Compound 990-542

LPS3 Spray 990-644

NOTE: The Optional Handle is Cold Storage

ready.
1. Spray LPS3 on the steering plate.
2. Fill the two small holes in the body and
shank of the key switch with sealing
compound.
3. Apply silicone grease to the following
electrical connections:
• the terminals of the switch mounted on
the underside of the deadman pedal
• all terminals and connectors on the
power amplifiers
• both connectors on the operator display
• the back side of the VM connectors
(including unused connectors)
• the back side of the communications
jacks (JPC3, JPC4, and JPC9) on the
VM
• the free hanging connectors in the
harnesses
• the contactor coil terminals
• the fuse bodies, cable terminals, and
terminal studs on the contactor panel

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Electrical Components Cold Storage

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Hydraulic Components

Hydraulic Components
Section 7. Component Procedures

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Hydraulic Components Manifold Solenoids, Fittings, and Attachments

Manifold Solenoids,
Fittings, and
Attachments
Table 7-7 provides torque specifications for the
manifold components.

Table 7-7. Main Manifold Torque Specifications

Valve/Fitting Torque Coil Nut Torque
Component Function
ft. lb. (Nm) ft. lb. (Nm)

SOL1 Load Hold 35 (48) 5 (6.8)

SOL2 Lift/Lower 100 (135)

Finger Tight
SOL3 Lift Relief
37 (50)
SOL4 Priority Bypass 12 (16)

SOL5 Aux Proportional Relief 25 (35) 5 (6.8)

SOL6 Aux Select 60 (80) 10 (14)

SOL7C/7R HSA (4250 Only)

SOL9L/9R L/R Sideshift 27 (37) 7 (9)

SOL10 Tilt

CV1 Check Valve 35 (47)

N/A Filter Plug N/A

30 (40)
CB1, CB2 Counterbalanced Check Valve

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Manifold Solenoids, Fittings, and Attachments Hydraulic Components

Figure 7-78. Hydraulic Manifold (1 of 3)

SOL7R SOL9L SOL9R SSR Hydraulic Filter and Plug

SOL6

G2

SOL10 SOL7C AC CB1 CB2 SOL2

Expansion
Plugs

Bottom
View
CV1

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Hydraulic Components Manifold Solenoids, Fittings, and Attachments

Figure 7-79. Hydraulic Manifold (2 of 3)

SOL9L SOL9R

SOL7R SOL10 SOL7C

P1 SSL SSR

AA

G1

CYL

AUX-P TC TR AR

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Manifold Solenoids, Fittings, and Attachments Hydraulic Components

Figure 7-80. Hydraulic Manifold (3 of 3)

SOL5

SOL4

SOL1

SOL3

TANK CYL-P

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Hydraulic Components Hydraulic Fluid

Hydraulic Fluid All except Model 4250 TT Masts

S/N 50501 Up

Fluid Level 1. Without a load, extend the free lift cylinder

and continue to extend the main lift
cylinders to 90% of full stroke. Retract all
To check the level of the hydraulic fluid in the
cylinders completely. Repeat three times.
system:
2. Extend the cylinders without a load at
1. Lower the forks to the floor.
50% lift speed, then build full system
2. Remove the fill cap from the hydraulic pressure at the end of the main lift
reservoir. The hydraulic fluid should be cylinder stroke. Retract the cylinders.
1/2 to 1 in. (13 to 25.4 mm) above the Repeat four times.
filler screen. See Figure 7-81.
3. Cycle the mast with a half load (50% mast
NOTE: The reservoir capacity is approx. 6 gal. rated capacity) through full cylinder
(22.7 liters) for a metal reservoir and 6.5 extension several times. The cylinders
gal. (24.6 liters) for a plastic reservoir. should extend smoothly. Repeat the steps
if the cylinder extension is not smooth.
Figure 7-81. Hydraulic Fluid Filler Screen
Model 4250 TT Masts S/N 50501 Up
1. Lift the forks 6 to 12 in. (150 to 300 mm)
off the floor.
2. Main Lift Cylinders - Loosen (do not
remove) the bleed screw on the lift cylinder
to let any air escape. Hold a shop rag close
to and beneath the bleed screw to keep
any hydraulic fluid from spraying out.
When all of the air has escaped and
hydraulic fluid starts coming out of the
bleed screw hole, securely tighten the
bleed screw.
NOTE: Free Lift Cylinders are self-bleeding. Lift
and lower the forks several times.
Selecting Hydraulic Fluid Type
3. Lower the forks all the way to the floor.
See “Lubrication Specification Chart” on NOTE: When bleeding the hydraulic system,
page A-2. bleed all the cylinders.
4. Bleed the auxiliary system:
Bleeding the Hydraulic System
a. Tilt the mast all the way forward and
You must bleed the hydraulic system to remove backward several times.
any trapped air whenever you: b. If the lift truck has sideshift and/or
• Change the hydraulic fluid and filter fork positioning, shift the carriage
and/or forks all the way to the left and
• Change a hydraulic hose right several times.
• Disconnect a hydraulic fitting
5. Check the hydraulic fluid level. Add
• Notice that the load is bouncing hydraulic fluid as needed.
• Remove a hydraulic cylinder
• Remove a hydraulic pump
• Remove the hydraulic reservoir

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Pressure Relief Valve Hydraulic Components

Pressure Relief Valve Figure 7-82. Uninstalled Circlip

Measuring System Pressure

NOTE: To measure the system pressure, you
need a calibrated pressure gauge
capable of measuring 3000 psi (20684
kPa) at mid-range and the coupler to
attach to the manifold.
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the front covers.
3. Connect the pressure gauge to the test
port (G1) on the main hydraulic manifold.
4. Reconnect the battery connector and turn
the key switch ON. 2. Elevate the forks until the upper limit is
reached.
5. Place a maximum rated load (or heaviest
load available) on the forks. 3. Continue to try to elevate. Using a 5/64
hex key, push in and turn the lift pressure
6. Elevate the forks. Record the pressure adjusting screw to obtain a pressure
required to lift the load. Make sure that reading 10% greater than that previously
the load is elevated near the maximum recorded, ±50 psi (344 kPa).
rated height for that load when taking the
pressure reading. NOTE: A 5K lift truck may need +50 psi
(344 kPa) over the 10% value.
7. Lower the forks and remove the load.
NOTE: Make sure to push the adjuster in when
turning.
Adjusting Pressure
NOTE: The adjuster is very sensitive, and
changes pressure very quickly with very
little movement.
Do not lose the retaining circlip on SOL3. 4. Turn the adjusting screw clockwise to
increase pressure; counterclockwise to
1. Use a jeweler’s screwdriver or other small decrease pressure.
tool to remove the retaining circlip on
SOL3. See Figure 7-82. Save the circlip to 5. Reinstall the circlip.
reinstall after the pressure is set. 6. Check the pressure again. If the value
changed, repeat this procedure until the
correct pressure reading is obtained.
7. Turn the key switch OFF and disconnect
the battery connector.
8. Remove the pressure gauge.
9. Reinstall the front covers.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Hydraulic Components Proportional Lowering Valve Adjustment

Proportional Lowering
Valve Adjustment
If the carriage hesitates when being lowered, or
cannot be feathered, adjust the proportional
valve with the following procedure.
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.
Refer to Figure 7-78 on page 7-79. 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.
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 to refine the
adjustment point. When the 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 while empty
and loaded with “Test A23 - Lift Request”
on page 6-46 in Active Maintenance Mode.
Carriage movement should start at
approx. 9 to 10% request.
12. Reinstall the top cover.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Carriage Service - Lift-Tek ® Hydraulic Components

Carriage Service - ISS Removal - Mast on Floor

Lift-Tek ® 1. Remove the mast from the lift truck. Refer
to “Complete Mast Removal” on page 7-99.
2. Remove the chain anchor nuts and
The following procedures apply to all carriages
discard. Remove the chain anchors from
except those installed on a Model 4250 above
the carriage with the chains attached.
S/N 50500 with a TT Mast.
3. Disconnect the internal reeving hoses from
The Integral Side Shifter (ISS) travels within the the ISS fittings (if equipped). Plug the hose
rails of the mast inner upright on six rollers. ends.
Only the bottom four rollers are shim 4. Roll the ISS to the bottom of the mast.
adjustable. The top rollers are not shim
5. Attach an overhead hoist to the ISS bars.
adjustable. They are held in place by a retainer
Remove the ISS through the bottom of the
plate. The upper and lower load rollers are
mast.
interchangeable. The middle rollers are slightly
smaller in diameter. 6. Note the number of shims behind each
load roller for reassembly.
On TF and Quad masts, there are four side
thrust rollers to transfer ISS side loading to the ISS Inspection
inner rails. These rollers are eccentrically
adjustable. 1. Inspect the rollers for excessive wear or
damage. Replace rollers with visible flat
spots or cracks.
ISS Removal - Mast on Lift Truck
2. Turn the rollers on their shafts. Replace
1. Remove the load backrest. rollers with roughness or noticeable
NOTE: If the carriage has a Quick Disconnect restrictions to turning.
assembly, remove/replace while the 3. Inspect all welds between the ISS side
carriage is on the mast. plates and the ISS fork bars. Replace the
ISS, if any welds are cracked.
2. Raise the mast high enough to place a 20
in. (50 cm) long, 4 x 4 in. (10 x 10 cm) 4. Inspect the roller stub shafts. Small burrs
wood block between the intermediate or scratches can be repaired with emery
lower cross member and the ground. cloth. Repair or replace the ISS if roller
Lower the ISS to be even with the bottom stub shafts are damaged or there are
of the inner upright (the Free Lift cylinder cracks at the base of the stub shafts.
is completely retracted).
3. Attach an overhead hoist to the ISS. Raise Cylinder Seal Replacement
the ISS to slacken the carriage chains.
1. Remove the forks from the carriage.
4. Remove the chain anchor nuts and
2. Raise the carriage to eye level and center
discard. Remove the chain anchors from
the sideshift. Turn the key switch OFF and
the carriage with the chains attached.
disconnect the battery connector.
5. Disconnect the internal reeving hoses from
the ISS fittings (if equipped). Plug the hose 3. Remove the six lower carriage claw bolts,
ends. claws, and shims (if used - note their
position for reassembly).
6. Using the overhead hoist, lower the ISS to
the bottom of the mast to remove. 4. Lower the carriage completely.
5. Remove the front sideshift frame and
7. Note the number of shims behind each
backrest assembly by lifting it out and
load roller for reassembly.
upward.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Hydraulic Components Carriage Service - Lift-Tek ®

6. Place clean rags on the lower bar directly sure that the raised portion of the wiper is
under the two sideshift cylinder hydraulic facing outward.
fittings. Loosen the fittings (1/2 to 1 full 16. Lightly lubricate the wiper with hydraulic
turn) to allow removal of the sideshift rods. oil.
7. Remove the two sideshift rods by grasping 17. Identify the tapered end with the cylinder
and pulling them straight out from their rod groove. This end is inserted into the
bores and gland nuts. cylinder assembly. Carefully clean any
8. Use a pick to remove the rod wiper (black dust or dirt from the rod with a lint free
rubber) and the energized poly pack seals cloth. Lubricate the outside of the rod
(cream colored) from both sides of the lightly but completely with hydraulic oil.
cylinder assembly. See Figure 7-83. Spinning the cylinder rod helps to
correctly engage the cylinder rod into the
Figure 7-83. Sideshift Cylinder Seal Replacement wiper. Carefully insert the rod into the
cylinder gland nut, through the wiper seal,
and further to engage the main seal.
Install by pressing the rod into the
cylinder in a slow and smooth manner;
using a hammer or other abrupt motion
damages the seals. Verify the wiper does
not become inverted when inserting the
cylinder rods. If any portion of the wiper is
9. Clean and verify the cleanliness of the inverted, carefully slide the cylinder rods
inside bore of the gland nut. Make in an outward direction to restore the seal
absolutely certain that the two grooves for to a correct, non-inverted position.
the seals do not contain any foreign
matter. 18. Tighten both hydraulic fittings to 21 ft. lb.
(28.5 Nm).
10. Apply hydraulic fluid to the main seal
groove (farthest from the open end) within 19. Verify that the wear pads are installed
the gland nut with a small brush. correctly.
11. Install the seal into the second slot from 20. Install the frame and backrest assembly
the unthreaded side of the cylinder head onto the spine. Slide the frame from side
with the groove in the seal facing the to side to disperse the grease. Clean excess
inside of the cylinder. grease from the ends of the spine bars.
Apply thread-locking compound (P/N
12. Use one thumb to guide the seal into the 1013829) to the six holes at the rear of the
groove and the other to apply force. Roll frame lower bar.
the seal around the groove with both
thumbs until the seal snaps into the 21. Install the claws to the rear of the frame
groove. Make sure that the O-ring in the lower bar. Install the hex screws and
seal does not come out of the seal groove torque to 44 ±5 ft. lb. (60 ±6.8 Nm). Install
during installation. the forks.
13. Inspect the seal inside diameter. Make 22. Reconnect the battery connector and turn
sure that the seal is seated correctly in the the key switch ON. Lift the forks off the
groove without distortion. floor. Cycle the side shifter from left to
right several times to purge any air from
14. Lubricate the wiper seal groove with the hydraulic system. After all the air is
hydraulic fluid with a small brush. purged, test for smooth operation of the
15. Install the wiper seal into the groove just side shifter.
inside the gland nut assemblies. Squeeze
and insert the wide edge of the seal into
the groove and work the remaining seal
into the groove with your fingers. Make

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Carriage Service - Lift-Tek ® Hydraulic Components

ISS Installation
For installation, reverse the removal procedure
and do the following:
• Inspect the carriage.
• Lubricate the upright inner rails.
• Assemble the shims and load rollers on
the stub shafts. The shims should be
installed (except on the top rollers) to
provide a total side to side clearance no
greater than 1/16 in. (1.5 mm) at the
tightest point throughout the travel of the
ISS. Use an equal amount of shims on
each side.
• Torque the upper bearing retainer plate
screws to 6.5 ft. lb. (9 Nm).
• On TF and Quad masts, adjust the side
thrust rollers for unrestricted clearance
along the travel of the ISS. The rollers have
eccentric mount bases. Turn the base of
the roller toward the upright rail to
decrease clearance. Tighten the cap
screws to 70 to 80 ft. lb. (95 to 110 Nm).
• Attach the chain anchors to the carriage
with a new self-locking nut.
• Check and adjust the free lift chains. Refer
to “Free Lift Chain Adjustment” on
page 7-104.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Hydraulic Components Carriage Service - Cascade™

Carriage Service -
Cascade ™
Make sure that the locking pins are
removed from the forks. The forks must
The following procedures apply to carriages on
slide freely on the sideshifter frame or
a Model 4250 above S/N 50500 with a TT Mast.
carriage bars.

Sideshift Cylinder Seal Figure 7-84. Fork Removal

Fork Carrier
Replacement Outer Section
Fork Carrier Fork Carrier
NOTE: Rod seal carriers are the only Inner Section Cap Screws
serviceable parts on the cylinder and are
supplied with the seals loaded. The
cylinder must be removed from the
carriage to replace the seals.
1. Remove the cylinder from the carriage.
2. Place the cylinder in a soft jawed vice.

Do not clamp on the cylinder shell.

Clamp on the ends of the cylinder only.

3. Unscrew the seal carrier from each end of

the cylinder and slide out the cylinder rod.
4. Remove any sharp edges on the cylinder
with 400 grit emery cloth and clean with
solvent. 2. If necessary, remove the backrest to
5. Make sure that the seals and O-rings are provide access to the Fork Positioner
in place. Apply a thick film of petroleum mounting cap screws.
jelly to the interior bore. Carefully slide the
seal carrier onto the cylinder rod and
screw into the cylinder retainer. Tighten to
240 ft. lb. (325 Nm). Before removing any hoses, relieve
6. Reinstall the cylinder in the carriage. pressure in the hydraulic system. With
the lift truck OFF, open the lift truck
auxiliary control valve(s) several times
Fork Positioner in both directions.

Removal/Replacement 3. Disconnect the supply hoses from the Fork

Positioner manifold and for reassembly.
1. Remove the cap screws fastening the inner See Figure 7-85.
fork carriers and remove the forks. See
Figure 7-84.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Carriage Service - Cascade™ Hydraulic Components

Figure 7-85. Hose Connections b. Fully open and close the forks. Look for
Fork Positioner CLOSE OPEN unequal fork movement.
Assembly Forks Forks
c. Adjust the flow restrictor for the faster
fork by screwing the flow restrictor
inward, CW, 1/2 turn and test again.
d. Repeat the procedure until the fork
movement is equal. Positioning speed
should be 3 in. (75 mm)/second.
Tighten the jam nuts.

FP0858.eps

Manifold
4. Remove the cap screws fastening the Fork
Positioner to the sideshifter frame and
remove the unit through the front. Keep
track of the shims. For reassembly, shim
as necessary, with a maximum of 4 shims
per side. Tighten the mounting cap screws
to 50 ft. lb. (65 Nm).

The maximum difference in number of

shims per side is 2 and the total
allowable gap before tightening the cap
screws is 0.020 in. (0.5 mm).

5. For installation, reverse the previous steps

with the following exceptions:
• Service the Fork Positioner as required.
• If necessary, adjust the flow restrictors
for equal fork movement as follows:
Figure 7-86. Flow Restrictor Adjustment

FP0760.eps

Flow Restrictor (each side)

a. Loosen the jam nuts and screw both
flow restrictors in until they bottom.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Hydraulic Components Carriage Service - Cascade™

Figure 7-87. Fork Positioner Removal/Install

Cap screws –
Use lock washers
and tighten to
Sideshifter 50 ft.lbs. (65 Nm).

Fork Positioner

Shims –
Maximum 4 per side to reduce
FRONT
total allowable gap is 0.020 in
(0.5 mm) maximum.
Recommended Torque Sequence
A LH side top
B RH side bottom A
C RH side top
D LH side bottom D
LH Side

Confirm fork carriers are

RH Side behind face of carriage
FRONT using a straight edge.
C
B Fork Carriers
FP1416.eps

Service
Disassembly
1. Use C-clamps to clamp the Fork Positioner
face down on a bench top as shown. Use 2
x 4 in. (5 x 10 cm) wood blocks for
clearance and to keep the parts in
alignment. See Figure 7-88.
2. Remove the cylinder rod anchor plug.
Move the fork carrier toward the manifold
and remove the half-ring keepers. Move
the cylinder rod to the fully retracted
position. See Figure 7-88.
3. Unscrew the cylinder retainer with
Cylinder Retainer Socket Tool P/N
1217957/71 to remove the cylinder
assembly from the manifold.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Carriage Service - Cascade™ Hydraulic Components

Figure 7-88. Fork Positioner Disassembly

Tool
Anchor 1217957/72
Plug

Cylinder
Rod Cylinder
Shell
Keepers
FP1189.eps

FP1190.eps

Tool Fork Carrier

1217957/71
Cylinder
Shell
Piston/ Rod
Assembly

Cylinder
Retainer

4. Disconnect the hydraulic tubes at the end in a vise and tighten the shell to 200
manifold. Remove the C-clamp and remove ft. lb. (270 Nm).
the cylinder/fork carrier assembly.
NOTE: Cap screw (M25 x 1.5 x 60 mm L) and
NOTE: If the tubes are removed from the Jam Nut (M25 x 1.5) may also be used.
cylinder head end, reinstall prior to
installation of the cylinder/fork carrier Inspection
assembly to the manifold. Do not bend
the tubes. NOTE: Replace the Fork Positioner/Sideshifter
assembly as a complete unit if bending
5. Slide the fork carrier from the cylinder
damage is found.
shell. Remove the piston/rod assembly
from the cylinder shell. • Inspect the rod, piston, and retainer for
6. Remove all seals, O-rings, wear rings, and nicks and burrs. Remove minor
bearings from the components. imperfections with 400 grit emery cloth.
• Inspect the cylinder bore for minor nicks
and burrs. Remove minor imperfections
with a hone (butterfly).
Do not scratch the seal grooves. Use
• Inspect the cylinder shells for deformities,
brass seal removal tools to pry the items
cracks that could impair performance or
from grooves.
cause leaks under pressure.
7. If required, unscrew the cylinder shell • Inspect the fork carrier bearings for wear
from the head end with Cylinder Head Cap and replace as necessary.
Tool P/N 1217957/72. For reassembly,
replace the cylinder head end O-ring and
apply thread-locking compound (P/N
1013829) to the threads. Clamp the head

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Hydraulic Components Carriage Service - Cascade™

Reassembly 3. Install the new seals, O-rings, wear rings,

and fork carrier bearings. See Figure 7-89.
1. Lubricate the new seals, O-rings, and wear Refer to Figure 7-90 for the retainer seal
rings with O-ring lube, hydraulic fluid, or loading technique.
petroleum jelly.
NOTE: The fork carrier bearings snap into their
2. If necessary, use 400-grit emery cloth to
respective grooves. Bronze bearings
break any sharp edges on the piston,
consist of three separate segments.
retainer and cylinder shell chamfer angles,
and threads to prevent seal damage.
Figure 7-89. Fork Positioner Reassembly
U-Cup Pressure Seal
Note Seal Direction
Two-Piece
O-rings Wiper seal Wear Ring Pressure Seal Wipers Composite or Bronze Bearings

Retainer Piston Fork Carrier

External
Spacer
(if required)

O-ring

Head End/
Retainer Manifold Cylinder Cylinder Inner Fork Outer Fork Internal Fork Carrier Mounting Foot
Shell Rod Carrier Carrier Spacer Cap Screws
(if required)
Back (Driver's) View – RH Side

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Carriage Service - Cascade™ Hydraulic Components

Figure 7-90. Retainer Seal Loading Technique 8. Tighten the retainer to 120 ft. lb. (165
Nm). Tighten the hydraulic tubes at the
Twist seal into 'figure 8' or manifold and cylinder head end.
'half-circle' shape to
Lubricate seal and force
insert into retainer.
partially into groove.
Note Seal Direction.
3/8 in. (10 mm)
pin punch –
no sharp edge

1/2 in. (12-15 mm)

diameter rod
located flush with
bottom of seal
groove.

Use flat brass

O-ring tool to seat
seals fully into groove. FP0829.eps

4. Install the piston/rod assembly into the

cylinder shell. Push the rod fully into the
cylinder.

Make sure that the piston seal is not

damaged by the cylinder shell threads
during reassembly.

5. Slide the fork carrier onto the cylinder

shell with the cap screw heads facing
outwards. See Figure 7-89.
6. Align the cylinder assembly to the
manifold and insert the opposite cylinder
rod into the fork carrier. See Figure 7-89.
NOTE: Install the external spacer on the
cylinder rod, if required. Install the
cylinder retainer through the opposite
side of the manifold and screw partially
into the cylinder shell.
7. Make sure that the cylinder is correctly
oriented with the restrictor fittings on the
backside. Insert the tubes and screw the
retainer fully into the shell. Reclamp the
assembly to the bench.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Hydraulic Components Lift Cylinder Service

Lift Cylinder Service 8. Install the plunger retainer on the plunger.

Install the plunger/piston assembly into
the cylinder housing.
All except Model 4250 TT Masts
9. Free Lift Cylinder only - Pour 1/2 cup
S/N 50501 Up (120 ml) hydraulic oil into the cylinder
1. Remove the cylinder from the mast. Refer cavity between the housing and rod.
to the applicable cylinder removal 10. Tighten the retainer with the claw spanner
procedure in “Mast” on page 7-97. wrench and a strap wrench. Torque per
2. Remove the retainer with a claw type the following table.
spanner wrench.
Mast Torque
3. Remove the plunger/piston assembly from
the housing. 2-Stage (TF) 225 to 250 ft. lb. (305 to 340 Nm)
4. TF and TT Masts only - Remove the 3 Stage (TT) 275 to 300 ft. lb. (375 to 405 Nm)
Hydraulic Fuse components.
Quad 95 to 125 ft. lb. (129 to 169 Nm)
5. Inspect all components for nicks or burrs.
Minor nicks or burrs can be removed with
400 grit emery cloth.
Model 4250 TT Masts
NOTE: Minor nicks are those that do not S/N 50501 Up
bypass oil when under pressure.
Replace the part if the nicks cannot be 1. Remove the cylinder from the mast. Refer
removed with emery cloth. to the applicable cylinder removal
procedure in “Mast” on page 7-97.
6. Replace the retainer and piston seals,
backup rings, O-rings, and bearing. 2. Place the cylinder in a soft jawed vice or
Lubricate the new seals with petroleum other fixturing method to hold the cylinder
jelly prior to installation. during disassembly.

NOTE: Note the orientation of the piston seals 3. Use a claw type spanner wrench to remove
the retainer. Pull the plunger/piston
when removing them. Install the seals in
assembly from the shell.
the correct direction. The cylinder does
not operate correctly if the seals are 4. Carefully remove the seals from the piston
installed backwards. and retainer. Use a screwdriver with
smooth edges. See Figures 7-92 and 7-93.
7. TF Mast Free Lift and TT Mast Lift
Cylinders only - When replacing the piston
check valve O-ring, make sure that the
check valve is reinstalled with the arrow Do not scratch the seal grooves.
pointing in the correct direction.

Figure 7-91. Check Valve Direction

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Lift Cylinder Service Hydraulic Components

Figure 7-92. Piston Seal Removal by the washer, retaining rings, and
cushioning sleeve (main lift cylinder only).
NOTE: Make sure the arrow on the check valve
is pointing in the correct direction.

Figure 7-94. Check Valve O-Ring Replacement

7pumpbolts.jpg

Figure 7-93. Retainer Seal Removal

Check Valve

O-Ring

Washer
Retaining Ring

Free Lift
Cushion Sleeve
5. Clean the plunger, piston, retainer, and
cylinder bore, then inspect for nicks and
burrs. Minor nicks and burrs can be Retaining Ring
removed with 400 grit emery cloth. Main Lift

NOTE: Replace the part if nicks are felt with a 8. Place the guide tool (supplied with the seal
fingernail after using emery cloth. kit) in the cylinder shell. The guide tool
must cover all the threads, but not contact
6. Replace the seals, backup rings, O-rings, the thread relief chamfer. See Figure 7-95.
and wear ring.
Figure 7-95. Guide Tool
NOTE: Note the orientation of the seals when 7pumpbolts.jpg

removing them. Install the seals in the

correct direction. The cylinder does not
operate properly if the seals are installed Guide Tool
backwards.
7. To replace the O-ring on the internal Shell
check valve, first remove the retaining
Do not allow lower
rings, cushioning sleeve (main lift cylinder
edge of guide tool
only), and washer. Use a hook or screw-
to contact thread
driver to remove the check valve from the relief chamfer.
piston. Replace the O-ring and insert the
check valve back into the piston, followed

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Hydraulic Components Lift Cylinder Service

9. Apply a film of clean hydraulic oil to the

cylinder bore, loader, and piston seals.
Insert the plunger/piston assembly
through the guide tool and into the
cylinder shell. If resistance is encountered,
tap the plunger with a rubber mallet.
Remove the guide tool and make sure that
the plunger is fully inserted.
10. Install the retainer. Torque to
160 to 180 ft. lb. (217 to 244 Nm).
11. Reinstall the cylinder in the mast. Bleed
the cylinder.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Mast

Mast
Section 7. Component Procedures

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Mast Removal and Installation

Mast Removal and

Installation Tilting the mast too far forward causes
the bottom of the mast upright to
damage the drive unit cover plate.
Partial Removal
NOTE: For this procedure, you need a hoist or 10. Use the hoist or lift truck to carefully tilt
lift truck with a capacity of at least five the mast forward until it is tilted no more
tons. than 45° from the vertical position. See
Figure 7-97.
1. Turn the key switch OFF and disconnect
the battery connector. Figure 7-97. Mast Partial Removal (Detail)
2. Remove the console and front covers. Drive Unit
3. Remove the forks.
4. Verify that the mast is in a vertical
position. Mast Drive
Wheel
5. Position the lift truck beneath the hoist or
lift truck.
6. Turn the key switch OFF and disconnect
the battery connector.
7. Wrap a chain or lifting strap around the
top of the mast. Attach the chains or
straps to a hoist or lift truck.
8. Lift the hoist just enough to take the slack
out of the chain or strap.
9. Remove the tilt pin assembly retaining Avoid Contact
bolts and tilt pin assemblies. Carefully Between Mast
remove the pivot blocks from each tilt and Drive Unit
cylinder clevis, allowing the tilt cylinder to Cover Plate
rest on the brake assemblies.

Figure 7-96. Tilt Cylinder Removal from Mast

Installation after Partial
Removal
Tilt Pin Assembly
NOTE: For this procedure, you need a hoist or
lift truck of suitable capacity.
1. With the mast securely held by a strap and
chain, carefully raise the mast until it is
vertical.
2. Reconnect the battery connector and turn
Tilt Cylinder
the key switch ON.
3. Slowly extend the tilt cylinders until you
Retaining Bolt are able to install the tilt cylinder pivot
blocks into each clevis. Tighten the jam
nuts snug against the pivot blocks.
4. Install the tilt pin assemblies to secure the
pivot blocks to the mast. Install the
retaining bolts.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Mast Removal and Installation Mast

5. Remove the lifting device and any 9. Verify that the mast is in a vertical
chains/straps used to lift the mast. position.
6. Install the forks. 10. Turn the key switch OFF and disconnect
7. Install the covers. the battery connector.
11. Wrap a chain or lifting strap around the
top of the mast. Attach the chains or
Complete Mast Removal straps to a hoist.
NOTE: See also “Partial Removal” on page 7-98 12. Lift the hoist just enough to take the slack
for an alternative means of gaining out the chain or strap.
access to the motors and pumps.
13. Remove the tilt pin assembly retaining
bolts and tilt pin assemblies. Carefully
For this procedure, you need a hoist or lift truck
remove the pivot blocks from each tilt
of suitable capacity.
cylinder clevis, allowing the tilt cylinder to
1. Position the lift truck beneath the hoist. rest on the brake assemblies.
2. Turn the key switch OFF and disconnect
the battery connector. Figure 7-99. Tilt Cylinder Removal from Mast

3. Remove the console and front covers. Tilt Pin Assembly

4. Remove the forks.
5. Reconnect the battery connector and turn
the key switch ON. Elevate the fork
carriage about 18 in. (450 mm). Place
blocks under the fork carriage. Lower the
fork carriage onto the blocks.
Tilt Cylinder
Figure 7-98. Mast Pivot Bearing Caps
Retaining Bolt

14. Disconnect the hose from the lift/lower

manifold. Be careful not to spill hydraulic
fluid. Plug/cap each fitting to prevent
contamination from entering the hydraulic
system.

Figure 7-100.Mast Hydraulic Hose Disconnection

Lower Mounting Bolts

6. Turn the key switch OFF and disconnect

the battery connector.
7. Remove the lower mounting bolt only from
each mast bearing cap. Do not remove
the upper bolt.
8. Reconnect the battery connector and turn
the key switch ON. Elevate the fork
carriage, remove the blocking, and lower
the fork carriage all the way to the floor.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Mast Removal and Installation

15. Remove the upper mounting bolt securing 6. Carefully engage the mast pivot bearings
the mast pivot bearing cap on each drive with the yokes on the drive unit.
unit. Remove the mast pivot bearing cap. 7. Place the mast pivot bearing caps over
both mast pivot bearings. Install the upper
Figure 7-101: Mast Pivot Bearing Parts
mounting bolt in both mast pivot bearing
Drive Unit caps.
Shims
8. Reconnect the hydraulic hose at the main
Drive Wheel manifold.
Mast 9. Reconnect the battery connector and turn
the key switch ON.
10. Slowly extend the tilt cylinders until you
are able to install the tilt cylinder pivot
blocks into each clevis. Tighten the jam
nuts snug against the pivot blocks.
Pivot
Oilite Bearing Cap 11. Install the tilt pin assemblies to secure the
Bearing pivot blocks to the mast. Install the
retaining bolts.
16. Use the hoist or other lift truck to lift the
12. Remove the lifting device and any
mast just enough to allow it to be moved
chains/straps used to lift the mast.
away from the tractor.
13. Elevate the fork carriage about 18 in.
17. Use cable ties to attach the hose to the lift
(450 mm). Place blocks under the fork
chain to keep it in place.
carriage. Lower the fork carriage onto the
18. Have wood blocks positioned to support blocks.
the mast off the floor.
14. Turn the key switch OFF and disconnect
19. Carefully lower the mast onto the support the battery connector.
blocks with the fork carriage facing down.
15. Apply thread-locking compound
20. Note the number of shims between the (P/N 1013829) to the lower mast pivot
Oilite bearings and the mast. bearing cap mounting bolts and torque to
43 ft. lb. (60 Nm).
Installation after Complete 16. Remove the upper mast pivot bearing cap
Removal mounting bolts. Apply thread-locking
compound (P/N 1013829) to the bolts and
NOTE: For this procedure, you need a hoist or torque to 43 ft. lb. (60 Nm).
lift truck of suitable capacity.
17. Reconnect the battery connector and turn
1. Make sure that the pivot bearings are the key switch ON.
shimmed as they were when the mast was 18. Elevate the fork carriage and remove any
removed. blocking.
2. Wrap a chain or lifting strap around the 19. Install the forks.
top of the mast. Attach the chains or
straps to the lifting device. 20. Bleed the hydraulic system. See “Bleeding
the Hydraulic System” on page 7-82.
3. Slowly lift the mast up and off the wooden
blocks. 21. Install the covers.

4. Slowly move the mast towards the lift

truck.
5. Position the lower pivot bearings on the
mast at the same height as the pivot yokes
on the drive units.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Lift Chains Mast

Lift Chains Model 4250 TT Masts S/N 50501 Up

1. Raise the inner upright 3 ft. (90 cm). Place
a 3 ft. (90 cm) block under the free lift
Main Lift Chain Adjustment cylinder support blocks. The main lift
chain anchors are now accessible.
Adjust the main lift chains so that when the
unloaded mast is fully lowered, the uprights are 2. Adjust one chain to achieve the correct
flush at the bottom. upright position when fully lowered.
3. Adjust the other chain to achieve equal
All TT Masts except Model 4250 chain tension.
S/N 50501 Up 4. Raise and lower the mast several times to
confirm the adjustments.
1. Adjust one chain to achieve the correct
upright position when fully lowered. Figure 7-103: Main Lift Chain Anchors - TT Masts
S/N 50501 Up
2. Adjust the other chain to achieve equal
chain tension. Tighten the nuts together to
a torque of 50 to 70 ft. lb. (68 to 95 Nm).
3. Raise and lower the mast several times to
confirm the adjustments.

Figure 7-102: Main Lift Chain Anchors - TT Masts

S/N 42000 through 50500

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Lift Chains

Quad Mast 6. Raise and lower the mast several times to

confirm the adjustments.
1. Locate the four main lift threaded chain
anchors on the back side top of the outer
and outer intermediate uprights, on each Main Lift Chain Service
side of the main lift cylinders.
TT Mast
Figure 7-104: Main Lift Chain Anchors - Quad Mast

Block the intermediate upright.

1. Raise the inner upright 3 ft. (90 cm). Place

Outer Main a 3 ft. (90 cm) block under the free lift
Inner Main Lift Chain
Lift Chain Adjusting Nuts cylinder support casting, then lower the
Adjusting cylinder support onto the block. The main
Nuts lift chains should be slack.

Figure 7-105: TT Mast Blocking (below S/N 50501)

Free Lift Chain

Adjusting Nuts

Important: The chain anchor

nuts must be installed as shown
for correct operation.
2. Adjust one anchor of the outer main lift
chain pair first to achieve a flush inner
intermediate upright position with the
mast outer uprights.
3. Adjust the other anchor of the pair to Block

achieve equal chain tension.

4. Repeat Steps 1 and 2 for the inner main
lift chain pair to achieve a flush inner
upright position with the mast
intermediate uprights.
5. Tighten the nuts together to a torque of 50
to 70 ft. lb. (68 to 95 Nm).

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Lift Chains Mast

Figure 7-106: TT Mast Blocking (above S/N 50500) Figure 7-107: Outer Main Lift Chain Replacement - Quad
Mast

Upper Chain
Anchor on
Outer Upright

Outer Main
Lift Chains (2) Lower Chain
Anchor on Inner
Intermediate
Upright

2. Remove the cotter pins and pins from the

chain anchors. Remove the chains.
3. Inspect the chain anchors for cracks. 2. Remove the cotter pins and pins from the
Replace as required. chain anchors. Remove the chains.
4. For reassembly, reverse the disassembly 3. Inspect the chain anchors for wear or
procedure. Adjust the chains. cracks. Replace as required.
4. For reassembly, reverse the disassembly
procedure. Adjust the chains.
If the chain anchor is secured with a
Inner Main Lift Chain Replacement
nylon lock nut, install a new lock nut
when it is necessary to loosen the chain
or remove the anchor.

Quad Mast Block the inner upright.

Outer Main Lift Chain Replacement 1. Raise the inner upright and place a 2 ft.
(60 cm) long block under the free lift
cylinder support casting. Lower the
upright onto the block. The inner main lift
chains should be slack.
Block the inner intermediate upright.

1. Raise the inner intermediate upright and

place a 2 ft. (60 cm) long block under each
of the upright’s rails. Lower the upright
onto the blocks. The outer main lift chains
should be slack.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Lift Chains

Figure 7-108: Inner Main Lift Chain Replacement - Quad
Mast
Free Lift Chain Adjustment
Adjust the free lift chains so that when the mast
is vertical and the carriage is fully lowered the
forks are positioned as specified in the table
below.

Fork Type Distance Above Floor

2 in. (5 cm) measured from the top of

Standard
fork at the heel

0.12 to 0.25 in. (3 to 6.4 mm)

Chisel measured from the bottom of the
fork at the heel
Upper Chain
Anchor on
Outer Intermediate
Upright
Inner
Main Lift
All except Model 4250 TT Masts
Chains (2)
Lower Chain
S/N 50501 Up
Anchor on Inner
Upright 1. Locate the threaded chain anchors on the
front side of the cylinder. Adjust one chain
to achieve the correct fork height.
2. Adjust the other chain to achieve equal
chain tension. Tighten the nuts together to
a torque of 50 to 70 ft. lb. (68 to 95 Nm).
3. Raise and lower the mast several times to
confirm the adjustments.

Model 4250 TT Masts S/N 50501 Up

2. Remove the cotter pins and pins from the 1. Locate the threaded chain anchors on the
chain anchors. Remove the chains. front side of the inner upright cross
member in front of both cylinders. Adjust
3. Inspect the chain anchors for wear or
one chain to achieve the correct carriage
cracks. Replace as required.
position when fully lowered.
4. For reassembly, reverse the disassembly
2. Adjust the other chain to achieve equal
procedure. Adjust the chains.
chain tension.
3. Raise and lower the mast several times to
confirm the adjustments.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Lift Chains Mast

Free Lift Chain Service

1. Raise the carriage enough to place a 12 in.
(30 cm) block under the carriage, then
lower the carriage onto the block. The free
lift chains should be slack.

Block the carriage.

Figure 7-109: Blocking the Carriage

2. Remove the cotter pins and pins from the

chain anchors. Remove the chains.
3. Inspect the chain anchors for cracks.
Replace as required.
4. For reassembly, reverse the disassembly
procedure. Adjust the chains.

If the chain anchor is secured with a

nylon lock nut, install a new lock nut
when it is necessary to loosen the chain
or remove the anchor.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Roller Bearing (Puck) Adjustment - TT Mast - S/N 50501 Up

Roller Bearing (Puck)

Adjustment - TT Mast
- S/N 50501 Up

Adjust the roller bearing wear pad spacing as

shown. See Figure 7-110.

Figure 7-110: Roller Bearing Adjustment

0.008 to 0.016 in.

(0.2 to 0.4 mm)
Clearance

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Mast Skewing Mast

Mast Skewing members. Lower the cross member onto

the block. See Figure 7-113.

Raise the mast to full height: Figure 7-112: Mast Cylinder Shim Installation
Snap Ring
• If the mast kicks to the right at full
extension, the right side main lift cylinder
rod must be shimmed.
Shim
• If the mast kicks to the left at full
extension, the left side main lift cylinder
rod must be shimmed.

Figure 7-111: Mast Skewing (2-Stage shown) Angle Iron

TF Mast

TT Mast
Quad Mast - Place a 4 x 4 x 20 in. (10 x 10 x 50 cm) wood block between the outer intermediate and outer upright cross members. Lower the cross member onto the block.

Figure 7-113: Quad Mast Cylinder Shim Installation

Inner uprights must be blocked or
supported as shown.

All except Model 4250 TT Masts Snap

S/N 50501 Up Ring

1. TF and TT Masts - Place a 6 in. (15 cm)

long, 2 x 2 in. (5 x 5 cm) angle iron
Shim
between the top of the main lift cylinder
and the cross member. Do not contact the
cylinder rod seal. Lower the cross member
onto the angle iron. See Figure 7-112.

Quad Mast - Place a 4 x 4 x 20 in. (10 x 10

x 50 cm) wood block between the outer
intermediate and outer upright cross

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Mast Skewing

2. Remove the snap ring from the cylinder to Reinstall the outer and inner sleeves,
be adjusted. Activate the lower control to screw, and cap.
allow the cylinder rod to retract and 5. Repeat Steps 1 through 4 until skewing is
disengage the cross member. removed.
3. Install shim(s) as necessary.
4. Slowly activate the lift control to allow the
cylinder rod to engage the cross member.
Reinstall the snap ring.
5. Repeat Steps 1 through 4 until skewing is
removed.

Model 4250 TT Masts S/N 50501 Up

1. Place a 4 x 4 x 12 in. (10 x 10 x 30 cm)
wood block between the intermediate
weldment and the outer weldment cross
members. Lower the cross member onto
the block. See Figure 7-114.

Figure 7-114: Model 4250 TT Mast (S/N 50501 Up)

Cylinder Shim Installation

2. Remove the cap, screw, inner and outer

sleeves from the cylinder to be adjusted.
Activate the lower control to allow the
cylinder rod to retract and disengage the
cross member.
3. Install shim(s) as necessary.
4. Slowly activate the lift control to allow the
cylinder rod to engage the cross member.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

2-Stage (TF) Mast Service Mast

2-Stage (TF) Mast Service 5. Remove the free lift cylinder from the
mast. Refer to “Free Lift Cylinder Removal
- Mast on Floor” on page 7-113.
Bubbled items in the figures correspond to
6. Remove the ISS from the mast. Refer to
steps in the associated procedure.
“ISS Removal - Mast on Floor” on page
7-85.
Disassembly 7. Remove the pins fastening the free lift
chains to the inner upright chain anchors.
Refer to Figure 7-115.
8. Attach an overhead hoist to the inner
1. Remove the mast assembly from the lift upright cross member as shown.
truck. Refer to “Complete Mast Removal”
on page 7-99. 9. Roll the inner upright downward to expose
the upper and lower load rollers. Remove
2. Remove the main lift cylinders from the the load rollers. Note the number of shims
mast. Refer to “Main Lift Cylinder Removal behind each load roller.
- Mast on Floor” on page 7-112.
10. Attach an overhead hoist to the inner
3. Using an overhead chain hoist, turn the upright and remove it through the top of
mast over (face up). the outer upright.
4. Remove the internal hose reeving sheave
and hoses.

Figure 7-115: 2-Stage Mast Disassembly

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast 2-Stage (TF) Mast Service

Inspection 9. Install the internal hose reeving hoses.

Refer to “Internal Reeving Installation” on
1. Inspect the load rollers for excessive wear page 7-115.
or damage. Replace rollers with visible flat
10. Install the mast on the lift truck. Refer to
spots or cracks.
“Installation after Complete Removal” on
2. Inspect the load roller bearings by turning page 7-100.
the rollers on their shafts. Replace rollers
11. Adjust the free lift chains. Refer to “Free
with roughness or noticeable restrictions
Lift Chain Adjustment” on page 7-104.
to turning.
12. Check for mast skewing. Refer to “Mast
3. Inspect the load roller stub shafts. Repair
Skewing” on page 7-107.
or replace the upright if it is damaged or
has cracks at the base.
4. Check the gap between the uprights and
thrust plugs. Add shims or replace the
thrust plug if the gap is greater than 0.060
in. (1.5 mm).
5. Inspect the lift chains.

Reassembly
Refer to Figure 7-116.
1. Lubricate the outer rails. See “Lubrication
Specification Chart” on page A-2.
2. Attach an overhead hoist to the inner
upright. Install the inner upright through
the top of the outer upright.
3. Install the load rollers on the stub shafts
with the correct number of shims. Install
the shims to provide a total side to side
clearance no greater than 1/16 in. (1.5
mm) at the tightest point throughout the
travel in the upright. Use an equal number
of shims on each side.
NOTE: Roll the inner upright past the wear
pads before checking the roller
clearances.
4. Install the free lift chains to the inner
upright cross member chain anchors.
5. Install the free lift cylinder. Refer to “Free
Lift Cylinder Installation - Mast on Floor”
on page 7-113.
6. Install the ISS. Refer to “ISS Installation”
on page 7-87.
7. Turn the mast over.
8. Install the main lift cylinders. Refer to
“Main Lift Cylinder Installation - Mast on
Floor” on page 7-112.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

2-Stage (TF) Mast Service Mast

Figure 7-116: 2-Stage Mast Reassembly
Upright
Rails

LUBRICATE ONLY WHERE INDICATED

BY THE HEAVY LINE FOR THE FULL
LENGTH OF EACH UPRIGHT

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast 2-Stage (TF) Mast Service

Cylinder Removal and 3. Disconnect the cylinder supply hoses from

the cylinder inlet ports. Remove the special
Installation long fittings from the cylinder ports and
install plugs.
Refer to page 7-94 for cylinder service.
4. Disconnect the hose and tube from the
cylinder plungers.
Main Lift Cylinder Removal - Mast on
Floor 5. Remove the snap rings fastening the
cylinder rods to the inner upright.
Refer to Figure 7-117. 6. Pull the inner upright outward 2 ft.
1. Remove the mast from the lift truck. See (60 cm).
“Complete Mast Removal” on page 7-99. 7. Lift the cylinder from the base mount and
2. Lay the mast face-down on wood blocks as angle it inward to remove through the gap
shown. Block under the outer upright so at the top of the uprights.
the inner upright is free to move. The ISS 8. Note the number of shims (if equipped) on
must be positioned between the blocks each cylinder rod.
and free to move.

Figure 7-117: 2-Stage Mast Main Lift Cylinder Removal

Main Lift Cylinder Installation - Mast

on Floor

For installation, reverse the Removal procedure.

Bleed the system. See “Bleeding the Hydraulic
System” on page 7-82.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

2-Stage (TF) Mast Service Mast

Free Lift Cylinder Removal - Mast on 4. Disconnect the tube from the cylinder
Floor fitting. Cap the fitting and plug the tube.
5. Remove the snap rings fastening the
Refer to Figure 7-118. crosshead to the cylinder rod.
1. Remove the mast from the lift truck. See 6. Pull the crosshead with chains and hoses
“Complete Mast Removal” on page 7-99. off the cylinder rod.
2. Lay the mast down as shown. 7. Remove the cylinder strap and nylon
3. Roll the carriage toward the center of the segments.
cylinder to slacken the chains and internal 8. Remove the cylinder from the mast.
reeving hoses.

Figure 7-118: 2-Stage Mast Free Lift Cylinder Removal - Mast on Floor

Free Lift Cylinder Installation - Mast

on Floor

For installation, reverse the Removal procedure.

Bleed the system. See “Bleeding the Hydraulic
System” on page 7-82.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast 2-Stage (TF) Mast Service

Free Lift Cylinder Removal - Mast on Figure 7-119: 2-Stage Mast Free Lift Cylinder Removal -
Mast on Lift Truck
Lift Truck

Refer to Figure 7-119.

1. Completely lower the carriage. Remove the
forks or attachment. Attach an overhead
hoist to the top carriage bar.

The carriage must be supported by a

block while removing the cylinder to
avoid possible injury.

2. Raise the carriage to the center of the

cylinder to slacken the chains and internal
reeving hoses. Block the carriage in place
with a 4 x 4 x 24 in. (10 x 10 x 60 cm)
wood block between the lower carriage bar
and the floor.
3. Disconnect the tube from the cylinder
fitting. Cap the fitting and plug the tube.
4. Remove the snap ring fastening the
crosshead to the cylinder rod.
5. Pull the crosshead with chains and hoses
off the cylinder rod.
6. Remove the cylinder strap and nylon
segments.
7. Remove the cylinder from the mast.

Free Lift Cylinder Installation - Mast

on Lift Truck

For installation, reverse the Removal procedure.

Bleed the system. See “Bleeding the Hydraulic
System” on page 7-82.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

2-Stage (TF) Mast Service Mast

Internal Reeving Installation 30 ft. lb. (35 to 40 Nm). Check and adjust
the hose clearances.
Refer to Figure 7-120. 12. Raise and lower the mast several times to
1. Install the fittings on the carriage bracket. make sure that the hoses are tracking
correctly in the guide brackets. Use the
2. Install the front hose guide bracket to the
white line on the hoses to detect twisting.
back side of the inner upright cross
Adjusting the hose ends with a slight
member. Tighten the cap screws to 48 to
amount of twist may improve hose
52 ft. lb. (65 to 70 Nm).
tracking in the guides.
3. Install the rear hose bracket to the outer
upright. Insert the round bar at the end of Figure 7-120: Hose Reeving Installation - 2-Stage Mast
the bracket into the hole in the upper
outer chain anchor mounting block.
4. Attach the lower end of the bracket to the
4
inside of the outer upright chain anchor
mounting. Leave a gap between the top of 3 Hoses must
not contact
the bracket and the chain anchor mount. bottom of chain
The bracket should be parallel with the anchor mount.
upright. Tighten the cap screw to 48 to 52
ft. lb. (65 to 70 Nm).
5. Remove the existing cap screw and guard
from one side of the cylinder crosshead.
9
Install the hose sheave and guard. Tighten
the cap screw to 48 to 52 ft. lb. (65 to
70 Nm). Rear Hose
Guide Bracket
6. Install the hoses to the carriage fittings
with the white line facing outward.
7. Feed the hoses between the crosshead
guard and sheave. Raise the carriage just
above free lift. Route the hoses under the
front hose guide bracket. Install the hose 7
clamp. Pull on the hoses to remove slack. 10
Tighten the cap screw to 25 to 30 ft. lb. (35
to 40 Nm). Completely lower the carriage. 4
5 2
8. Route the hoses to the rear guide bracket. 8
The loop in the hoses should be 4 in. 11
(101 mm) ±1 in. (25 mm) below the bottom
of the rear bracket.
9. Install the hose clamps at the top of the
rear guide bracket. Make sure that the
loop is the same for both hoses. Tighten
the cap screws to 25 to 30 ft. lb. (35 to 40
Nm). Check and adjust the hose
clearances.
10. Install the bulkhead fittings to the bracket
with the securing nuts located on the top
side. Install the hose ends to the fittings.
11. Move the lowering control valve and 6
1
bracket to the back side of the center cross
member. Tighten the cap screws to 25 to

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast 3-Stage (TT) Mast Service - below S/N 50501

3-Stage (TT) Mast Service rollers. Remove the load rollers. Note the
number of shims behind each load roller.
- below S/N 50501 12. Attach an overhead hoist to the inner
upright. Remove the inner upright through
Bubbled items in the figures correspond to the top of the intermediate upright.
steps in the associated procedure.
13. Remove the main lift chain anchors (long
anchors) and chains from the outer
Disassembly upright cross member. Save the anchors
for reassembly.
Refer to Figure 7-121.
14. Roll the intermediate upright downward to
1. Remove the mast assembly from the lift expose the intermediate and outer upright
truck. Refer to “Complete Mast Removal” load rollers. Remove the load rollers. Note
on page 7-99. the number of shims behind each load
2. Remove the main lift cylinders from the roller.
mast. Refer to “Main Lift Cylinder Removal 15. Attach an overhead hoist to the
- Mast on Floor” on page 7-120. intermediate upright and remove it
3. Using an overhead chain hoist, turn the through the top of the outer upright.
mast over (face up).
Figure 7-121: 3-Stage Mast Disassembly
4. Remove the free lift cylinder from the
mast. Refer to “Free Lift Cylinder Removal
- Mast on Floor” on page 7-120.
5. Remove the ISS from the mast. Refer to
“ISS Removal - Mast on Floor” on page
7-85.
6. Remove the internal hose reeving sheave
and hoses.
7. Remove the pins fastening the main lift
chains to the inner upright chain anchors.
Pull the main lift chains back through the
chain sheaves.

Discard the used chain anchor nuts.

Install new chain anchor nuts during
reassembly.

8. Remove the main lift chain anchors (long

anchors) from the inner upright lower
back side. Save the anchors for Inspection
reassembly.
1. Inspect the load rollers for excessive wear
9. Remove the pins fastening the free lift
or damage. Replace rollers with visible flat
chains to the inner upright chain anchors.
spots or cracks.
10. Remove the free lift cylinder supply hose
2. Inspect the load roller bearings by turning
and sheave. Remove the main lift chain
the rollers on their shafts. Replace rollers
sheaves.
with roughness or noticeable restrictions
11. Roll the inner upright downward to expose to turning.
the inner and intermediate upright load

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

3-Stage (TT) Mast Service - below S/N 50501 Mast

3. Inspect the load roller stub shafts. Repair

or replace the upright if it is damaged or
has cracks at the base.
4. Check the gap between the uprights and
thrust plugs. If the gap is greater than
0.060 in. (1.5 mm), add shims or replace
the thrust plug.
5. Inspect the lift chains.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast 3-Stage (TT) Mast Service - below S/N 50501

Reassembly 10. Install the free lift chain anchors (short

anchors) and chains to the inner upright
Refer to Figure 7-122. center cross member. Refer to Figure
7-122.
1. Lubricate the outer rails. See “Lubrication
Specification Chart” on page A-2. 11. Install the free lift cylinder supply hose
through the hole in the outer upright top
2. Attach an overhead hoist to the
cross member and over the sheave on the
intermediate upright. Install the
intermediate top upright.
intermediate upright through the top of
the outer upright. 12. Install the ISS. Refer to “ISS Installation”
on page 7-87.
3. Install the load rollers on the outer and
lower intermediate upright stub shafts. 13. Install the free lift cylinder. Refer to “Free
Use the correct number of shims. Install Lift Cylinder Installation - Mast on Floor”
the shims to provide a total side to side on page 7-120.
clearance no greater than 1/16 in. (1.5 14. Install the internal reeving sheaves and
mm) at the tightest point throughout the hoses. Refer to “Internal Reeving
travel in the upright. Use an equal number Installation” on page 7-122.
of shims on each side. 15. Turn the mast over.
NOTE: Roll the upright past the wear pads 16. Install the main lift cylinders. Refer to
before checking the roller clearances. “Main Lift Cylinder Installation - Mast on
4. Lubricate the intermediate upright rails. Floor” on page 7-127.
See “Lubrication Specification Chart” on 17. Install the mast on the lift truck. Refer to
page A-2. Attach an overhead hoist to the “Installation after Complete Removal” on
inner upright. Install the inner upright page 7-100.
through the top of the intermediate 18. Adjust the main and free lift chains. Refer
upright. to “Main Lift Chain Adjustment” on page
5. Install the load rollers on the intermediate 7-101 and “Free Lift Chain Adjustment” on
upright top and inner upright lower stub page 7-104.
shafts. Use the correct number of shims. 19. Check for mast skewing. Refer to “Mast
Install the shims to provide a total side to Skewing” on page 7-107.
side clearance no greater than 1/16 in.
(1.5 mm) at the tightest point throughout
the travel in the upright. Use an equal
number of shims on each side.
NOTE: Roll the upright past the wear pads
before checking the roller clearances.
6. Install the chain sheave and free lift hose
sheave to the intermediate upright.
Tighten the cap screw to 26 to 30 ft. lb. (35
to 40 Nm).
7. Install the main lift chain anchors (long
anchors) and chains.
8. Install the chain anchors (long anchors) to
the back side of the inner upright lower
cross member. Refer to Figure 7-122.
9. Pull the main lift chains over the chain
sheaves and attach to the lower inner
upright chain anchors.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

3-Stage (TT) Mast Service - below S/N 50501 Mast

Figure 7-122: 3-Stage Mast Reassembly

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast 3-Stage (TT) Mast Service - below S/N 50501

Cylinder Removal and 5. Remove the snap ring fastening the

crosshead to the cylinder rod.
Installation
6. Pull the crosshead with chains and hoses
Refer to page 7-94 for cylinder service. (if equipped) off the cylinder rod.
7. Remove the cylinder retainer cap screws.
Main Lift Cylinder Removal - Mast on 8. Remove the cylinder from the mast.
Floor
1. Remove the mast from the lift truck. See
Free Lift Cylinder Installation - Mast
“Complete Mast Removal” on page 7-99. on Floor
2. Lay the mast face-down on wood blocks.
For installation, reverse the Removal procedure.
Block under the outer upright so the inner
Bleed the system. See “Bleeding the Hydraulic
upright is free to move. The ISS must be
System” on page 7-82.
positioned between the blocks and free to
move.
3. Disconnect the cylinder supply hoses from
the cylinder inlet ports. Remove the special
long fittings from the cylinder ports and
install plugs.
NOTE: Each internal fuse piston holds a
compressed spring in place.
4. Remove the snap rings fastening the
cylinder rods to the intermediate upright.
5. Pull the inner and intermediate upright
outward 2 ft. (60 cm).
6. Lift the cylinder from the base mount and
angle it inward to remove through the gap
at the top of the uprights.
7. Note the number of shims (if equipped) on
each cylinder rod.

Main Lift Cylinder Installation - Mast

on Floor

For installation, reverse the Removal procedure.

Bleed the system. See “Bleeding the Hydraulic
System” on page 7-82.

Free Lift Cylinder Removal - Mast on

Floor
1. Remove the mast from the lift truck. See
“Complete Mast Removal” on page 7-99.
2. Lay the mast down.
3. Roll the carriage toward the center of the
cylinder to slacken the chains and internal
reeving hoses.
4. Disconnect the hose from the cylinder 45°
fitting. Cap the fitting and plug the hose.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

3-Stage (TT) Mast Service - below S/N 50501 Mast

Free Lift Cylinder Removal - Mast on Figure 7-123: 3-Stage Mast Free Lift Cylinder Removal -
Mast on Lift Truck
Lift Truck

Refer to Figure 7-123.

1. Completely lower the carriage. Remove the
forks or attachment. Make sure that the
free lift cylinder is completely retracted.
Attach an overhead hoist to the top
carriage bar.

The carriage must be supported by a

block while removing the cylinder to
avoid possible injury.

2. Raise the carriage to the center of the

cylinder to slacken the chains and internal
reeving hoses. Block the carriage in place.
Use a 4 x 4 x 24 in. (10 x 10 x 60 cm) wood
block between the lower carriage bar and
the floor.
3. Remove the cylinder retainer bolts.
4. Remove the snap ring fastening the
crosshead to the cylinder rod.
5. Pull the crosshead with chains and hoses
(if equipped) off the cylinder rod and lay
over the upper carriage bar.
6. Pry the cylinder up out of the support
casting to gain access to the cylinder hose
fitting. Remove the hose from the 45°
fitting. Cap the fitting and plug the hose.
7. Remove the cylinder from the mast.

Free Lift Cylinder Installation - Mast

on Lift Truck

For installation, reverse the Removal procedure.

Bleed the system. See “Bleeding the Hydraulic
System” on page 7-82.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast 3-Stage (TT) Mast Service - below S/N 50501

Internal Reeving Installation 10. Attach the hose ends to the center hose
bracket, aligning the hoses with their
Refer to Figure 7-124. natural curve. Tighten the clamp cap
screws to 8 ft. lb. (11 Nm).
1. Install the shafts, sheaves, and hose
guards to the crosshead center plate. 11. Attach the left cylinder supply hose and
Leave the cap screw and nut finger tight to clamp to the outer upright center cross
allow for the hose installation. member. Tighten the clamp cap screw to
8 ft. lb. (11 Nm).
2. Install the ISS bracket to the tabs between
the ISS side plates. Leave the cap screws 12. Tighten the crosshead cover plate cap
finger tight. screw to 51 ft. lb. (70 Nm).
3. Install the fittings to the left or right side of 13. Tighten the carriage bracket cap screws to
bracket. Tighten the fittings finger tight. 46 ft. lb. (63 Nm).
4. Install the brackets, hose clamps, and 14. Raise and lower the mast slowly through
sheaves to the uprights. Tighten the several cycles, checking for correct hose
bracket cap screws to 38 ft. lb. (51 Nm). alignment, clearances, and hose tracking.
5. Completely lower the ISS. Route the hoses
down behind the top carriage bar to the
carriage bracket fittings. Connect the hose
fittings to the carriage fittings and tighten.
6. Loosen the crosshead cover plate cap
screw. Route the hoses up over the
crosshead sheaves. Orient the hoses with
the natural curve over the sheaves.
7. Route the hoses down between the free lift
cylinder and middle inner cross member to
the bracket behind the free lift cylinder.
The hoses route through the wire loop,
then underneath the lower inner cross
member. Assemble the clamp and hoses,
then pull down on the hoses with 80 lbs.
(36 kg) of force to remove the slack.
Tighten the clamp cap screws to 8 ft. lb.
(11 Nm).
8. Route the hoses under the lower inner
cross member to loop up to the lower hose
bracket. Install the hose clamps, leaving
the cap screws finger tight. Align the hoses
under the cross member and into the
clamp. Tighten the clamp cap screws to
8 ft. lb. (11 Nm).
9. Route the hoses up to and over the upper
hose sheaves and then down to the upper
hose bracket. Assemble the clamp and
hoses to the upper bracket, leaving the cap
screws finger tight. Starting with the outer
hose, pull down on the hoses with 80 lbs.
(36 kg) of force to remove the slack, then
tighten the clamp cap screws to 8 ft. lb.
(11 Nm).

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

3-Stage (TT) Mast Service - below S/N 50501 Mast

Figure 7-124: Hose Reeving Installation - 3-Stage Mast

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast 3-Stage (TT) Mast Service - S/N 50501 Up

3-Stage (TT) Mast Service Figure 7-125: Mast Disassembly

Intermediate Upright
- S/N 50501 Up
Inner Upright
Bubbled items in the figures correspond to
steps in the associated procedure.

Disassembly
Refer to Figure 7-125.
1. Remove the mast assembly from the lift
truck. Refer to “Complete Mast Removal”
on page 7-99. Outer Upright

2. Reverse the “Internal Reeving Installation”

on page 7-130 from Step 13 to Step 2.
3. Remove the free lift cylinders. Refer to Inspection
“Free Lift Cylinder Removal - Mast on
Floor” on page 7-128. 1. Inspect the pucks for excessive wear or
4. Disconnect the free lift chains from the damage. Replace pucks with visible flat
carriage. spots or cracks.
5. Disconnect the auxiliary hoses from the 2. Inspect the roller bearings by turning
carriage bulkheads and plug all fittings. them on their shafts. Replace roller
bearings with roughness or noticeable
6. Remove the carriage by sliding it out of the restrictions to turning.
bottom of the inner upright.
3. Inspect the bearing roller stub shafts.
7. Remove the main lift chain. Refer to “Main Repair or replace the upright if it is
Lift Chain Service” on page 7-102. damaged or has cracks at the base.
8. Remove the main lift chain sheave. 4. Inspect the lift chains.
9. Remove the fittings and hoses between the 5. Inspect the outer upright chain anchors.
mast manifold and the main lift cylinders.
6. Inspect the inner upright chain anchors.
10. Remove the main lift cylinders. Refer to
“Main Lift Cylinder Removal - Mast on
Floor” on page 7-127. Reassembly
11. Remove the mast manifold.
Refer to Figure 7-126.
12. Using an overhead hoist, turn the mast
1. Install the small and large roller bearing
over (cross members facing down).
assemblies in the locations specified. Push
13. Attach an overhead hoist to the inner the pucks in as far as they can go. The set
upright. Remove the inner upright through screws should be started but should not
the top of the intermediate upright. be installed far enough to start forcing the
14. Attach an overhead hoist to the puck out of the roller stud.
intermediate upright and remove it 2. Lubricate the roller bearing surfaces on
through the top of the outer upright. the outer, intermediate, and inner
15. Remove the bearing assemblies (if uprights. See “Lubrication Specification
necessary). Chart” on page A-2.
3. Attach an overhead hoist to the
intermediate upright. Install the

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

3-Stage (TT) Mast Service - S/N 50501 Up Mast

intermediate upright through the top of 15. Connect the auxiliary hoses to the carriage
the outer upright. bulkheads in the correct orientation.
4. Adjust the puck spacing on the roller 16. Connect the free lift chains to the carriage.
bearings positioned on the top of the outer Refer to “Free Lift Chain Service” on page
upright and at the bottom of the 7-105.
intermediate upright. This adjustment is 17. Install the free lift cylinders. Refer to “Free
made by driving in the adjusting set screw. Lift Cylinder Installation - Mast on Floor”
Spacing between the pucks and the rails on page 7-128.
should be between 0.008 and 0.016 in.
(0.2 and 0.4 mm) on both sides. Center the 18. Adjust the chains by securing the carriage
intermediate upright within the outer at the specified dimension from the bottom
upright. of the inner upright with C-clamps
clamped on the upright flange. Adjust both
5. Attach an overhead hoist to the inner chain anchors until they have equal
upright. Install the inner upright through tension with the carriage in the correct
the top of the intermediate upright. position (make minor adjustments once
6. Adjust the puck spacing on the roller the mast is upright). Leave the carriage in
bearings positioned on the top of the this position with the C-clamps in place.
intermediate upright and at the bottom of 19. Route the auxiliary and lift hoses. Refer to
the inner upright. This adjustment is “Internal Reeving Installation” on page
made by driving in the adjusting set screw. 7-130.
Spacing between the pucks and the rails
should be between 0.008 and 0.016 in.
(0.2 and 0.4 mm) on both sides. Center the
inner upright within the intermediate
upright.
7. Using an overhead hoist, turn the mast
over (cross members facing up).
8. Install the mast manifold as shown.
9. Install the main lift cylinders. Refer to
“Main Lift Cylinder Installation - Mast on
Floor” on page 7-127.
10. Install the fittings and hoses between the
mast manifold and main lift cylinders as
shown.
11. Install the main lift chain sheave.
12. Install the main lift chain. Refer to “Main
Lift Chain Service” on page 7-102.
13. Install the carriage by sliding it into the
bottom of the inner upright.
14. Adjust the puck spacing on the roller
bearings positioned on either side of the
carriage. This adjustment is made by
driving in the adjusting set screw. Spacing
between the pucks and the rails should be
between 0.008 and 0.016 in. (0.2 and
0.4 mm) on both sides. Center the carriage
within the inner upright.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast 3-Stage (TT) Mast Service - S/N 50501 Up

Figure 7-126: Mast Reassembly

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

3-Stage (TT) Mast Service - S/N 50501 Up Mast

Cylinder Removal and 5. Remove the two screws securing the

cylinder retaining bracket.
Installation
6. Remove the cylinder retaining bolt at the
Refer to page 7-94 for cylinder service. bottom of the cylinder.
7. Remove the main lift cylinder.
Main Lift Cylinder Removal - Mast on
Floor Main Lift Cylinder Installation - Mast
1. Remove the mast from the lift truck. See
on Floor
“Complete Mast Removal” on page 7-99.
For installation, reverse the Removal procedure.
2. Lay the mast face-down on wood blocks. In addition:
Block under the outer upright so the inner
upright is free to move. The ISS must be • Torque the screw at the top of the cylinder
positioned between the blocks and free to to 55 ft. lb. (74.5 Nm).
move. • Bleed the system. See “Bleeding the
3. Disconnect the cylinder supply hoses from Hydraulic System” on page 7-82.
the cylinder inlet ports. Remove the special
long fittings from the cylinder ports and
install plugs.
NOTE: Each internal fuse piston holds a
compressed spring in place.
4. Remove the cap, screw, inner sleeve, outer
sleeve, and shims (if present). See Figure
7-127.

Figure 7-127: Main Lift Cylinder Removal

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast 3-Stage (TT) Mast Service - S/N 50501 Up

Free Lift Cylinder Removal - Mast on Free Lift Cylinder Installation - Mast
Floor on Floor
Refer to Figure 7-128. For installation, reverse the Removal procedure.
1. Remove the mast from the lift truck. See Bleed the system. See “Bleeding the Hydraulic
“Complete Mast Removal” on page 7-99. System” on page 7-82.
2. Lay the mast down.
3. Roll the carriage toward the center of the
cylinder to slacken the chains and internal
reeving hoses.
4. Disconnect the cross-over tube and
fittings from the cylinders. Cap the fittings
and plug the hose.
5. Remove the free lift hose assembly from
the free lift chain sheave assembly by
removing the two bolts.
6. Remove the chain and nut from the free lift
chain anchor.
7. Remove the free lift chain sheave assembly
from the cylinder.
8. Remove the bolts connecting the cylinder
to the lower mounting blocks.
9. Remove the chain anchor and remove the
cylinder from the mast.

Figure 7-128: Free Lift Cylinder Removal - Mast on Floor

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

3-Stage (TT) Mast Service - S/N 50501 Up Mast

Free Lift Cylinder Removal - Mast on Figure 7-129: Free Lift Cylinder Removal - Mast on Lift Truck
Lift Truck

Refer to Figure 7-129.

1. Completely lower the carriage. Remove the
forks or attachment. Make sure that the
free lift cylinder is completely retracted.
Attach an overhead hoist to the top
carriage bar.

The carriage must be supported by a

block while removing the cylinder to
avoid possible injury.

2. Raise the carriage to the center of the

cylinder to slacken the chains and internal
reeving hoses. Block the carriage in place.
Use a 4 x 4 x 24 in. (10 x 10 x 60 cm) wood
block between the lower carriage bar and
the floor. Free Lift Cylinder Installation - Mast
3. Remove the bolts connecting the cylinders on Lift Truck
to the lower mounting blocks.
4. Remove the free lift hose assembly. For installation, reverse the Removal procedure.
5. Remove the chain and nut from the free lift Bleed the system. See “Bleeding the Hydraulic
chain anchor. System” on page 7-82.

6. Remove the free lift chain sheave assembly

from the cylinder.
7. Disconnect the cross-over tube and
fittings from the cylinders. Cap the fittings
and plug the hose.
8. Remove the chain anchors.
9. Remove the cylinder from the mast.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast 3-Stage (TT) Mast Service - S/N 50501 Up

Internal Reeving Installation 12. Attach the lift hose to the mast manifold.
13. Secure the two auxiliary hoses to the
Refer to Figure 7-130. fitting on the mast manifold with a cable
1. Install the auxiliary hoses at the carriage tie.
fittings. 14. Raise and lower the mast several times.
2. Route the auxiliary hoses over the free lift Make sure that the hoses track over the
cylinder and through the hose pulley pulleys correctly. The hose pulley
assembly. Attach the hose pulley assembly assembly attached to the free lift cylinder
to the free lift chain sheave assembly. should be aligned front to back. If it looks
like it is twisting as the free lift cylinder is
3. Route the auxiliary hoses down the free lift raised, perform the following adjustment
cylinder to the hose clamp. Install the hose procedure:
clamp components around the auxiliary
hoses and bolt the clamps to the a. Slightly loosen the aux hose fittings at
cross-member. Do not tighten. the carriage, allowing the swivel fitting
to correct the twist in the hose.
4. With the carriage at its lowest position,
pull the slack out of the two aux hoses. b. Tighten the fittings and check the hose
Mark the hoses at the bottom of the clamp. pulley assembly for alignment. If
Pull the hoses until the distance between necessary, adjust the hose ends with a
the line and the clamp is 1.5 ±0.5 in. (38 slight amount of twist to improve the
±12 mm). Tighten the clamp. alignment of the hose pulley assembly.
5. Route the auxiliary hoses as shown.
Clamp them at the positions specified with
the hose clamps.
6. Attach the lift hose to the cross-over tube
between the free lift cylinders.
7. Clamp the lift hose and auxiliary hoses
into the hose clamp. Make sure that the
plastic clamps are arranged as shown.
Torque the screws to 50 in. lb. (6 Nm).
8. Route the lift and aux hoses up to the
upper hose pulley assembly. Install the
hoses on the pulleys, then push the
pulleys into position so the shaft can
engage both pulleys.
9. Assemble the upper hose clamp as shown
with the hoses in the clamps, do not
tighten.
10. With the mast fully collapsed, pull the
slack out of the lift hose and two aux
hoses. Mark the hoses at the bottom of the
clamp. Pull the hoses until the distance
between the line and the clamp is 1.5 ±0.5
in. (38 ±12 mm). Tighten the clamp to hold
the hoses. Torque the screws to 50 in. lb.
(6 Nm).
11. Route the hoses as shown over to the main
lift cylinder and clamp at equal distances
in 3 places on the main lift cylinder.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

3-Stage (TT) Mast Service - S/N 50501 Up Mast

Figure 7-130: Internal Reeving Installation

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Quad Mast Service

Quad Mast Service 11. Remove the inner main lift chains and set
aside for reassembly.
12. Remove the load rollers from the lower end
Bubbled items in the figures correspond to
of the inner upright. Remove the load
steps in the associated procedure.
rollers and thrust plugs from the upper
end of the inner intermediate upright. Note
Disassembly the number of shims behind each for
reassembly.
NOTE: Quad Mast uprights require complete
disassembly in order to service the load 13. Attach an overhead hoist to the inner
rollers, thrust plugs/blocks, and upright and remove it through the top end
chain/hose sheaves. of the inner intermediate upright.
NOTE: The stub shafts on the lower end of the
Refer to Figure 7-131. inner upright come out of the inner
1. Remove the internal hose reeving from the intermediate upright between the rail
mast while it is on the lift truck. cutout and the stub shaft.
2. Remove the mast assembly from the lift 14. Remove the outer main lift chain anchors
truck. Refer to “Complete Mast Removal” from the lower end of the inner
on page 7-99. intermediate upright and the top end of
3. Remove the main lift cylinders from the the outer upright. Set the chains aside for
mast. Refer to “Main Lift Cylinder Removal reassembly.
- Mast on Floor” on page 7-138. 15. Remove the lower stop from the outer
4. Using an overhead chain hoist, turn the intermediate upright.
mast over (face up). 16. Remove the chain sheaves from the outer
5. Remove the free lift cylinder from the intermediate upright.
mast. Refer to “Free Lift Cylinder Removal 17. Roll the inner intermediate upright
- Mast on Floor” on page 7-138. downward and remove the lower rollers.
6. Remove the ISS from the mast. Refer to Remove the upper rollers and thrust plugs
“ISS Removal - Mast on Floor” on page from the outer intermediate upright. Note
7-85. the number of shims behind each roller for
reassembly.
7. Remove the free lift chain anchors and
chains from the inner upright center cross 18. Attach an overhead hoist to the inner
member and for reassembly. intermediate upright and remove it
through the top end of the outer
8. Disconnect the free lift cylinder hose from
intermediate upright.
the tube and remove the stop/hose
bracket/tube assembly. 19. Roll the outer intermediate upright
downward and remove the lower rollers.
9. Disconnect the inner main chain anchors
Remove the upper rollers and thrust
from the lower end of the inner upright
blocks from the outer upright. Note the
and the upper end of the outer
number of shims behind each roller and
intermediate upright.
thrust block for reassembly.
10. Move the inner upright downward. Remove
20. Attach an overhead hoist to the outer
the free lift hose sheave, hose, and main
intermediate upright and remove it
chain sheaves at the top of the inner
through the top end of the outer upright.
intermediate upright.
NOTE: The lower end of the inner upright must
be raised slightly to clear the inner
intermediate upright lower cross
member.

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Quad Mast Service Mast

Figure 7-131: Quad Mast Disassembly

Inner 12 12
Intermediate
Upright

8 Thrust
Plug
9 10 Thrust
10 Plug
Shim

7
Inner
Main Lift
Chains
11 10

10
MA0244.eps

12 9

7 12
Free Lift
Chains

MA0078.eps

Inspection
1. Inspect the load rollers for excessive wear
or damage. Replace rollers with visible flat
spots or cracks.
2. Inspect the load roller bearings by turning
the rollers on their shafts. Replace rollers
with roughness or noticeable restrictions
to turning.
3. Inspect the load roller stub shafts. Repair
or replace the upright if it is damaged or
has cracks at the base.
4. Check the gap between the uprights and
thrust plugs. If the gap is greater than
0.060 in. (1.5 mm), add shims or replace
the thrust plug.
5. Inspect the lift chains.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Quad Mast Service

Reassembly NOTE: Roll the uprights past the installed

thrust plugs/blocks before checking the
Refer to Figure 7-133. load roller clearance.
1. Lubricate the full length of the outer • Thrust Plug/Block Replacement - Install
upright rails. See “Lubrication the thrust plugs/blocks to provide a
Specification Chart” on page A-2. clearance of 0.06 in. (1.5 mm) max.
2. Attach an overhead hoist to the outer between an upright and its corresponding
intermediate upright and install it through thrust plug/block. Pry between the
the top of the outer upright. Position it out upright upper cross members. Measure
the lower end of the outer upright approx. the clearance at the XXX shown to
6 in. (15 cm). determine the thickness of the thrust
3. Assemble the shims, load rollers, and plug/block to use. Thrust plugs/blocks
thrust blocks to the upper end of the outer may be shimmed as required.
upright. Assemble the shims and load 4. Lubricate the full length of the outer
rollers to the lower end of the outer intermediate upright rails. See
intermediate upright. “Lubrication Specification Chart” on
• Roller Shimming - Install shims to page A-2.
provide a total side-to-side clearance of 5. Attach an overhead hoist to the inner
0.06 in. (1.5 mm) max. at the tightest intermediate upright and install it through
point throughout the travel of the the top end of the outer intermediate upright.
upright. Pry between the upright and Position it out the lower end of the outer
the load roller so that the opposite load intermediate upright approx. 6 in. (15 cm).
roller is tight against the upright. 6. Install the shims and load rollers to the
Measure the clearance for the pair of lower end of the inner intermediate
rollers at the XXX shown in Figure upright. Install the shims, load rollers,
7-132. Use an equal number of shims and thrust plugs to the upper end of the
on each side. outer intermediate upright. Refer to Step 3
Figure 7-132: Load Roller Clearance/Channel Lubrication for roller shimming and thrust plug
clearance measurement.
1 4 Lube
7. Install the chain sheaves to the upper end
of the outer intermediate upright. Install
Upright the outer main lift chain anchors and
Rails
chains over the outer intermediate upright
chain sheaves.
8. Install the outer main lift chain anchors
(long anchors) to the lower end of the inner
intermediate upright.
9. Install the lower stop on the outer
intermediate upright. Torque the cap
screw to 81 to 88 ft. lb. (110 to 120 Nm).
Upright 10. Install the main chain sheaves, free lift
Rail sheaves, and hose in the inner
Shim intermediate upright. Torque the retainer
cap screws to 26 to 30 ft. lb. (35 to 40 Nm).
Load
Rollers 11. Install the upper inner main chain
anchors to the outer intermediate upright.
Install the free lift hose bracket and tube.
3 12. Lubricate the inner intermediate upright
.06 in. rails. See “Lubrication Specification Chart”
(1.5 mm) on page A-2.
Max. MA0259.eps

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Quad Mast Service Mast

Figure 7-133: Outer Intermediate Upright Installation

3
Thrust Thrust
Plugs Block

2
.06 in.
(1.5 mm)
Max.
2 Thrust
Block

Inside
of Rail

Outer
3 Upright

MA0246.eps

Outer
Intermediate
Upright

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Quad Mast Service

Refer to Figure 7-134. 16. Install the stop/hose bracket/tube

13. Attach an overhead hoist to the inner assembly on the lower end of the inner
upright and install through the top of the upright. Torque the cap screws to 81 to
inner intermediate upright. Position it out 88 ft. lb. (110 to 120 Nm).
the lower end of the inner intermediate 17. Install the free lift chain anchors (short
upright approx. 6 in. (25 cm). anchors) and chains to the inner upright
14. Assemble the shims and load roller to the center cross member.
lower end of the inner upright. Assemble 18. Install the free lift cylinder supply hose to
the shims, load rollers, and thrust plugs to the free lift cylinder tube. Leave the tubing
the upper end of the inner intermediate clamp loose.
upright. Refer to Step 3 for roller 19. Install the ISS. See “ISS Installation” on
shimming and thrust plug clearance page 7-87.
measurement.
20. Install the free lift cylinder. Connect the
15. Install the inner main lift chain anchors tube to the cylinder fitting and tighten the
(long anchors) on the back side, lower end tubing clamp.
of the inner upright. Connect the inner
main lift chains.

Figure 7-134: Inner Upright Installation

14
13
Thrust
Plug
15 Thrust
13 Plug
Shim

MA0269.eps

14

14

Inner
Upright

16
MA0251.eps

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Quad Mast Service Mast

21. Place a 2 x 4 in. (5 x 10 cm) wood block

between the outer and outer intermediate
lower cross members to prevent upright
movement.
22. Turn the mast over (face down), rotating it
on its lower end. Make sure the mast is
re-blocked in a level position.

Figure 7-135: Blocking Uprights Before Turning Mast Over

22 21

MA0254.eps

23. Install the main lift cylinders.

24. Install the mast. Refer to “Installation after
Complete Removal” on page 7-100.
25. Install the internal hose reeving. See
“Internal Reeving Installation” on
page 7-139.
26. Adjust the main and free lift chains.
27. Check the mast for skewing. See “Mast
Skewing” on page 7-107.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Quad Mast Service

Cylinder Removal and Check Valve Inspection

Installation
Some Quad masts may experience drift if the
Refer to page 7-94 for cylinder service. check valve(s) in the right side main lift cylinder
become loose.
Main Lift Cylinder Removal - Mast on 1. Remove the right side main lift cylinder.
Floor 2. Remove the piston.
3. Remove the check valve. See Figure 7-136.
1. Remove the mast from the lift truck. See
“Complete Mast Removal” on page 7-99. Figure 7-136: Quad Mast Check Valves
2. Insert a 2 x 4 in. (5 x 10 cm) wood block
between the lower cross members of the
outer upright and outer intermediate
upright to prevent uprights from moving
out the bottom of the mast.
3. Lay the mast face-down on wood blocks.
Block under each end of the outer upright
so the mast is level and the inner uprights
and carriage are free to move.
4. Using a 1 in. wrench, disconnect the
cylinder supply hoses from the cylinder
inlet ports. Using a 1 in. socket, remove
the special long fittings from the cylinder
ports and install plugs.
5. Remove the snap ring from the top of the 4. Inspect the check valve. Replace the check
left hand cylinder rod. Remove the tube valve if the O-ring is missing or damaged.
and fitting from the top of the right side Refer to the Parts Manual.
cylinder rod. Plug the cylinder port. 5. Clean the check valve and apply
6. Roll the uprights through the top of the thread-locking compound (P/N 990-403)
mast 1 to 2 ft. (30 to 60 cm) and disengage to the circumference of the check valve.
the cylinder rods from the outer 6. Install the check valve and torque to 50 in.
intermediate upright. lb. (5.65 Nm).
7. Lift the cylinder from its base mounting 7. Repeat Steps 3 through 6 for the
boss in the outer upright and angle it remaining two check valves.
inward. Remove the cylinders through the
sides of the uprights. 8. Reassemble the cylinder and install in the
mast.
8. Note the number of shims (if equipped) on
each cylinder rod.
Free Lift Cylinder Removal - Mast on
Floor
Main Lift Cylinder Installation - Mast
on Floor 1. Remove the mast from the lift truck. See
“Complete Mast Removal” on page 7-99.
For installation, reverse the Removal procedure. 2. Lay the mast face-up, blocking under the
Bleed the system. See “Bleeding the Hydraulic lower mounts so the mast is level.
System” on page 7-82.
3. Roll the carriage upward to allow slack in
the free lift chains and internal reeving.
4. Remove the snap ring fastening the
crosshead to the cylinder rod.

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Quad Mast Service Mast

5. Pull the crosshead with chains and hoses Figure 7-138: Carriage Hose Bracket Installation
off the cylinder rod.
6. Roll the carriage above the free lift
cylinder.
7. Use a 1 in. wrench to disconnect the tube
from the cylinder fitting. Cap the cylinder
fitting and plug the tube.
8. Use a 5 mm hex head wrench to remove
the cylinder strap.
9. Remove the cylinder from the mast.
3
Free Lift Cylinder Installation - Mast
on Floor 2

For installation, reverse the Removal procedure.

Bleed the system. See “Bleeding the Hydraulic
3. Install the fittings on the bracket.
System” on page 7-82.
• Single Function - Install the fittings to
the left or right side location. Tighten
Internal Reeving Installation the fittings finger tight.
1. Install the shaft, sheave, and hose guards • Double Function - Install the fittings to
to the crosshead center plate. Leave the the left and right side location. Tighten
cap screw and nut finger tight to allow for the fittings finger tight.
the hose installation.
Figure 7-139: Fitting Installation
Figure 7-137: Crosshead Center Assembly
OR
3
1

SINGLE DOUBLE
FUNCTION FUNCTION
MA0256.eps

2. Install the carriage hose bracket to the

center tab on the lower carriage bar.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Quad Mast Service

Refer to Figure 7-140. 8. Completely lower the carriage. Route the

4. Install the lower internal hose reeving short hoses down behind the carriage bar
bracket and plastic inserts to the block at to the carriage bracket fittings. Connect
the bottom of the inner upright weldment. the hose ends to the fittings, leaving the
Torque the cap screw to 52 ft. lb. (71 Nm). hose ends finger tight.

5. Install the shaft and hardware to the inner NOTE: For Double Function, the No. 4 hoses
intermediate upright chain sheave shaft. connect to the two right fittings (viewed
Torque the cap screw to 52 ft. lb. (71 Nm). from the operator’s compartment).
6. Install the lower hose guide to the outer 9. Route the hoses over the crosshead
intermediate upright. Torque the cap sheaves.
screw to 30 ft. lb. (41 Nm). 10. Route the hoses down between the free lift
7. Install the hose clamps to the lower guide. cylinder and cross member. Position the
Leave the cap screws finger tight. hoses in their natural curve over the
crosshead sheaves. Tighten the hose ends
at the carriage bracket.

Figure 7-140: Hose Reeving Hardware Installation on Uprights

Outer
19 Upper Hose Guide Upright

Outer
Intermediate
Upright
5
16 Inner
Intermediate
Upright

19
17 7
Inner
Upright

Crosshead
MA3188.eps Components

Lower Guides
6

Lower Inner
4
Components Carriage
Components

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Quad Mast Service Mast

11. Connect the long hoses to the short hoses upright cross member. Torque the cap
behind the free lift cylinder. The outside screws to 7 to 11 ft. lb. (10 to 15 Nm).
hose(s) is approx. 4 in. (102 mm) shorter 13. Position the hoses with the tabs on the
than the inside hose(s). See Figure 7-141. inner upright bracket as shown in Figure
12. Pull down on the hoses with approx. 7-141.
30 lbs. (14 kg) of force. Clamp the hoses to 14. Install the lower internal hose reeving
the lower bracket attached to the inner cover plate and hardware. Tighten the cap
screws to 30 ft. lb. (41 Nm).

Figure 7-141: Hose Reeving Installation

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Quad Mast Service

Figure 7-142: Hose Reeving Installation - continued clamp at the top of the lower hose guide.
19 25 Pull downward on the hoses with 20 lbs. (9
kg) of force. Tighten the clamp cap screws
enough to stop hose movement.
17. Install the upper hose guide to the outer
upright. Tighten the cap screw to 30 ft. lb.
(41 Nm).
18. Loop the hoses approx. 5 in. (125 mm)
below the bottom of the lower hose clamp
and route upward into the upper hose
guide.
19. Install the hose clamps to the upper hose
guide. Leave the cap screws finger tight.
Upper
Hose 20. Route the hoses under the hose clamps at
Guide
the top of the upper hose guide. Tighten
22 19 21 the cap screws finger tight.
24 21. Route the hoses under the hose clamps at
the bottom of the upper hose guide. Do not
tighten the clamp cap screws.
22. Torque the crosshead cover plate cap
Crosshead
screw to 52 ft. lb. (71 Nm).
24
23. Align the hoses by twisting the hose ends
to travel centered in the crosshead on the
Lower
Hose
natural curve of the hose. The hoses
Guide should travel parallel to each other. Hold
the hoses while tightening the fittings to
keep the hoses from twisting.
24. Loosen the hose clamps at the top of the
lower hose guide. Pull down on the hoses
with 40 lbs. (18 kg) of force. Tighten the
hose clamp cap screws to 7 to 11 ft. lb. (10
to 15 Nm).
25. Loosen the hose clamps on the upper hose
23 guide. Adjust the hoses to the natural
hose bend and align evenly spaced in the
guide rails. Tighten the hose clamp cap
screws to 7 to 11 ft. lb. (10 to 15 Nm).
26. Raise and lower the mast slowly through
several cycles and check for the correct
15. Route the hoses up toward the top of the hose alignment, clearances, and hose
mast following the inner lift chains. Bend tracking in the guides.
the hoses over the inner intermediate
upright sheave and install the sheave on
the shaft bolted to the intermediate
upright. Install the washer and retaining
ring to the shaft.
16. Route the hoses down to the lower hose
guide. Place the hoses under the hose

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Models 4150/4250 Maintenance Manual Section 7. Component Procedures

Quad Mast Service Mast

Flow Control Valve

Replacement
1. Tilt the mast forward completely.
2. Lower the carriage completely.
3. Turn the key switch OFF and disconnect
the battery connector.
4. Place a small pan under the Flow Control
Valve.

Figure 7-143: Quad Mast Flow Control Valve

7MA0258.eps

5. Remove the hose attached to the Flow

Control Valve.
6. Remove the Flow Control Valve, noting the
direction of the arrow on the valve body.
7. Install the new valve with arrow on the
body in the same direction as the removed
valve. Torque to 44 to 48 ft. lb. (60 to 65
Nm).
8. Reattach the hose and torque to 44 to 48
ft. lb. (60 to 65 Nm).
9. Bleed the hydraulic system.
10. Test the lift function and check for leaks.

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Section 7. Component Procedures Models 4150/4250 Maintenance Manual

Mast Mast Tilt Adjustment

Mast Tilt Adjustment 2. Tilt the mast forward completely.

3. Place a square on the mast 39.4 in.
(1 meter) below where the plumb line is
Perform the following procedure to adjust the
attached and measure the distance
mast tilt.
between the face of the mast and the
1. Attach a plumb line to the mast. See plumb line.
Figure 7-144.
4. Repeat Steps 1 through 3. Use the back of
Figure 7-144: Measuring Mast Tilt the mast main frame for backward tilt.
5. Adjust the stroke of the tilt cylinders as
necessary to achieve the correct mast tilt.
Refer to Figure 7-144 and Table 7-8.

Table 7-8. Mast Tilt Parameters

Tilt Fwd Tilt Back Tilt
Type Angle Dim. A Angle Dim. A
39.4 in. Standard 3° 2.05 in. 5° 3.4 in.
(1 meter) (52 mm) (87 mm)
Optional 5° 3.4 in. 3° 2.05 in.
(87 mm) (52 mm)
Bottler’s 10° 6.8 in.
(173 mm)

Mast Tilt Position Switch

Adjustment
Lift trucks equipped with the Bottler’s Tilt
option require mast mounted switches (S11 and
S18) for the VM to determine the carriage and
mast position.

Adjust the Mast Tilt Position Switch (S18) so

that it opens when the mast is tilted beyond 3°
Mast forward.
Face
1. Attach a plumb line to the mast. See
39.4 in. (1 meter) Plumb Figure 7-144.
from plumb line
attach point Line 2. Place a square on the mast 39.4 in.
(1 meter) below where the plumb line is
attached and tilt the mast forward 3°
(2.05 in./52 mm at Dim. A in Figure
7-144).
3. Adjust the Mast Tilt Position Switch (S18)
bracket so that the switch opens when the
mast is tilted further forward.
Dim. A

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Models 4150/4250 Maintenance Manual Section 8. Theory of Operation

Section 8. Theory of Operation

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Section 8. Theory of Operation Models 4150/4250 Maintenance Manual

System Architecture

System Architecture
Table 8-1 identifies the electronic components
found on Model 4150/4250 lift trucks and their
function. Table 8-2 identifies where the memory
is stored.

Table 8-1. Electrical System Components

Component Function Ident

Vehicle Manager Controlling Manager for the lift truck. VM

Right Traction Power Amp Controls the right side traction motor. RTPA

Left Traction Power Amp Controls the left side traction motor. LTPA

Lift Power Amplifier Controls the pump motor. Used for 4250 hydraulic systems. LPA

Fuse/Relay Card Distributes B+/– to the lift truck. Houses the B+/– control fuses, FRC
and the relays.

Contactor/Fuse Panel Contactors and power fuses are on this panel.

Standard Handle Assembly Contains Solid State pots for Lift/Lower and Travel. Contains
mechanical type switches for the Horn, Sideshift, Tilt, and Aux
functions.

Optional Handle Assembly Contains Solid State pots for the Lift/Lower, Travel, Sideshift, Tilt,
and Aux functions. Contains the Hall Effect switch for the Horn.
Operator Display Card Shows information and fault codes to the operator. Contains the
vehicle identity (Primary Memory) and stores hour meter
information.
Steer Position Sensor Used by the VM to determine the steering position for correct control
of the traction motors.

Table 8-2. Stored Value Location

Value Location

Primary Memory Primary Memory is stored in the Operator Display. There is a backup copy in
the VM.
• If the Operator Display is blank or has corrupted memory, the VM sends a
copy to the Display if they can communicate.
• If both cards are valid, but different, the Operator Display overwrites the
VM.

Configure Mode Settings Configure Mode settings are stored in the VM.

Learn Mode Values Learn Mode values are stored in the VM.

Date and Time Date and Time are calculated and stored in the VM.

Hour Meters Hour Meters (Hours Deadman, Hours Lifting, Key Hours, and Traction Miles)
are stored in the Operator Display.

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Models 4150/4250 Maintenance Manual Section 8. Theory of Operation

Systems Overview

Systems Overview operator requests. The VM calculates the

steering position based on the three channels in
the steering position sensor. The VM reduces
The Model 4150/4250 control system uses up the travel speed (or changes the direction of
to four “intelligent” devices working together to rotation) of each individual motor if necessary
control the lift truck and respond to operator due to the steering position. It also may cause
requests. These devices pass information to speed reduction due to traction motor
each other via the Controller Area Network temperature. The VM contains a backup copy of
(CAN) Bus. The devices are: the Primary Memory (see Operator Display
• Vehicle Manager (VM) Card). The VM contains a power supply that
provides a regulated +12V and +5V. The VM
• Right Traction Power Amplifier (RTPA)
also determines that the correct battery is
• Left Traction Power Amplifier (LTPA) connected, and determines the Battery
• Lift Power Amplifier (LPA) (4250 only) State-of-Charge (BSOC) from the voltage
measured at BATTERY_SENSE_IN.
The system uses other “non-intelligent” devices.
• Operator Display Card Traction Power Amplifiers
• Fuse/Relay Card
The Traction Power Amplifiers (TPAs)
• Contactors communicate only with the VM, from where
• Steer Position Sensor they receive all requests regarding travel
direction and speed. The TPAs monitor the
traction motor encoders and temperature
Intelligent Devices sensors. They determine, based on the encoder
feedback and the travel request, if the lift truck
BUS+/– Communications should be traveling, plugging, or regenerative
braking, and determine if the performance has
BUS+/– are the communication lines that the achieved the travel request from the VM. If it
intelligent modules use to communicate with has not, the TPA adjusts the motor control
one another. BUS+ is a digital, serial voltage or sends a fault code to the VM, as
communication line. BUS– is a digital, serial appropriate. The TPAs are solely responsible for
communication line that is a mirror image of controlling traction motor current. The TPAs
BUS+. Using communication lines in this send the traction motor temperature status to
fashion limits noise problems associated with the VM. The VM then alters the travel request, if
long communication lines operating in a noisy necessary, depending on the traction motor
environment. temperature. The TPAs monitor their internal
temperature and limit current or travel speed as
Vehicle Manager required by their internal programming. The
TPAs also check the charging of the amplifiers
The Vehicle Manager (VM) controls the system. and different internal operating parameters.
It communicates with all other devices that are They also send fault codes to the VM if anything
on the communications BUS. It receives all is operating incorrectly. The right side TPA
requests for travel, auxiliary, and lift. The VM monitors and controls the TPC (Traction Power
receives information on the status of all Contactor).
switches such as the Deadman, Horn, Steer
Position Sensor, and EPO. It also receives Lift Power Amplifier (Model 4250)
traction motor speed, direction, and
temperature information from the Traction The Lift Power Amplifier (LPA) is used for all
Power Amplifiers, and lift motor speed and hydraulic functions except steering. The LPA
temperature information from the Lift Power only communicates with the VM, from where it
Amplifier (LPA). The VM determines allowable receives all requests regarding motor rotation
vehicle operation based on those inputs and speed. The LPA monitors both the lift motor

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Section 8. Theory of Operation Models 4150/4250 Maintenance Manual

Non-intelligent Devices

encoder and temperature sensor. Motor speed TPC Contactor

may be fixed or varied based on different types
of requests (such as tilt versus sideshift versus The TPC Contactor provides B+ to the power
high speed clamp). It determines if the motor side of both traction amplifiers. It is controlled
has achieved the requested speed (from the by the Right Traction Power Amplifier (RTPA).
encoder feedback). The LPA is solely responsible
for controlling lift motor current. It sends the
STR Contactor
lift motor temperature status to the VM. The
VM then determines if the motor must be
The STR Contactor provides B+ to the power
shut-down due to motor temperature. The LPA
side of the Steer Motor (SM). It is controlled by
monitors its internal temperature and limits
the VM.
current or lift speed as required by its internal
programming. The LPA also checks the
operation of the LPC, the charging of the Steer Position Sensor
amplifiers, and different internal operating
parameters. It also sends fault codes to the VM The Steer Position Sensor consists of three
if anything is operating incorrectly. independent Steer Feedback Proximity Sensors
located in one potted assembly. The steering
hub has a sensor plate mounted on it that
Non-intelligent Devices changes the activation sequence of the sensors
when the steering hub is rotated. The VM uses
Operator Display Card this to determine the steerable wheel position
for correct control of the traction motors.
The Operator Display Card is connected to the
VM. Messages and codes are shown on it. The
Display contains the Primary Memory, which
Hydraulic Devices
includes Model Number, Serial Number, Date of
The lift system consists of single acting
Manufacture, Hour Meters, and a list of enabled
hydraulic cylinders. During a lift from floor
Options. The keypad containing the data entry
level, the free lift cylinders elevate the carriage
push buttons connects to the Operator Display.
before the telescopic is extended by the lift
action of the main cylinders.
Fuse/Relay Card
Lift/Aux Pump (P1)
The Fuse/Relay Card is the control power
distribution board. It contains the B+ and B–
Pump P1 is a positive displacement gear pump
control fuses and the K1 through K4 relays. It
that rotates clockwise from the shaft end. P1 is
provides B+ and B– to the VM, TPC, LPC, and
used for all lift and aux functions.
STR. It also supplies B+ and B– to optional
equipment.
Sideshift Cylinders
LPC Contactor
The sideshift cylinder is a double-acting
hydraulic cylinder used to shift the load left and
In the Model 4250, this contactor is used to
right with respect to the mast. It is an integral
supply B+ to the power side of the Lift Power
part of the sideshift carriage.
Amplifier.

In the Model 4150, this contactor is used to Tilt Cylinders

supply B+ to the DC Lift Motor.
The tilt cylinders are double-acting hydraulic
cylinders used to tilt the mast forward and
back.

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Models 4150/4250 Maintenance Manual Section 8. Theory of Operation

Hydraulic Devices

Load Hold Valve (SOL1) Attachment Solenoids (SOL7C/R)

The load hold valve is a normally closed SOL7C/R are normally closed solenoid valves
solenoid valve used to hold the carriage in an used to block (de-energized) or allow (energized)
elevated position. fluid flow to and from the attachment cylinders.

Lift/Lower Valve (SOL2) Sideshift Solenoids (SOL9R/L)

The proportional lower valve is a pressure SOL9R/L are normally closed solenoid valves
compensated flow control solenoid valve used to used to block (de-energized) or allow (energized)
lower the carriage. As the voltage to the valve fluid flow to and from the sideshift cylinders.
increases, the flow through the valve increases,
regardless of the pressure. The Model 4150 Tilt Solenoid (SOL10)
uses SOL2 for feathering lift as well.
SOL10 is a normally closed solenoid valve used
Dump Valve (SOL3) to block (de-energized) or allow (energized) fluid
flow to and from the tilt cylinders.
SOL3 is a solenoid used as a lift system relief.
In addition, SOL3 is used to divert oil from P1 Steer Valve
back to the reservoir after a lift is stopped and
the pump is still spinning. It also acts as a valve The steer valve is an orbitrol type rotary flow
to port excess oil back to the reservoir when valve with an auxiliary port. When no steering
performing auxiliary functions. is requested, fluid flows through the auxiliary
port (E). When steering is requested, fluid flows
Priority Bypass (SOL4) first through the steer valve, hydraulic motor,
and the steer return port (T). Any excess flow
SOL4 is a normally open proportional pressure exits out the auxiliary port.
compensated priority flow valve. It regulates
flow to the auxiliary system by the voltage to the Counterbalance Check Valves (CB1,
coil, regardless of the system working pressure.
CB2)
Increasing the voltage decreases the flow to the
auxiliary system.
Counterbalanced check valves are used to hold
the tilt cylinders in place when a tilt request is
Prop Relief (SOL5) no longer present.

SOL5 is a proportional solenoid used as an

Check Valve (CV1)
auxiliary system relief. Voltage is used to adjust
the relief pressure [24V = 3000 psi (20684 kPa);
The check valve is used to make sure the fluid
0V = 100 psi (689 kPa)]. The voltage to this
exiting the lift cylinders during a lower
valve varies when different pressure settings for
command is routed through SOL2.
auxiliary attachments are chosen on the
Operator Display.
Hydraulic Filter
Aux Select (SOL6)
The hydraulic system has a filter in the main
manifold. Its purpose is to filter impurities from
SOL6 is a directional solenoid valve providing
the hydraulic system. It filters oil on the return
directional control to the tilt, sideshift, or
to the reservoir from the lift system. It has no
auxiliary functions. When SOL6 is energized,
internal bypass.
flow direction is reversed for tilt, sideshift, or
auxiliary functions.

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Section 8. Theory of Operation Models 4150/4250 Maintenance Manual

Traction System Theory

Traction System Theory memory. See “Maintenance Mode” on

page 3-20. During normal use, the VM learns
the extreme values for full forward/reverse and
Key ON full lift/lower. These values are also stored in
memory in the VM. See “Configure Mode” on
When the key is turned ON, the Vehicle page 3-11. For Travel or Lift/Lower, the VM
Manager powers up and proceeds with SelfTest. compares the pot position information to the
If the BATTERY_SENSE_IN (JPC24-24) voltage values that it stored when it learned the pots.
is between 28 and 45V, a circuit is turned ON in
the VM that provides B– to the RELAY_ENABLE When the control handle is moved from neutral,
(JPC14-6) to energize the relays. After this, the the VM detects a different voltage at JPC12-3
BATTERY_SENSE_IN voltage is used to from VR1. To release the brake, the VM must
determine BSOC. When K1, K2, K3, and K4 are know the deadman switch is operational and
energized, K2 or K3 provides B+ to the control that the control handle was moved. The VM
side of the power amplifiers. The TPC and LPC then provides B– to JPC20-14 (Brake) that
contactors provide the precharge. energizes the brake coils and releases the
brakes. The lift truck is equipped with two
NOTE: B+ power for the amplifiers may come traction motors, each with its own brake. Both
from K2 (JPF1-6) or K3 (JPF1-3). brakes are controlled by the same circuit from
the VM.
The VM establishes communication to the
amplifiers. After successful communication is When the VM receives a request to travel by
established, the VM requests the RTPA to seeing the VR1 voltage change (control handle
activate the TPC contactor and check its status. moved), it compares that voltage to the learned
For the 4250, the VM requests the LPA to value for VR1 to determine the direction and
activate the LPC contactor and check its status. magnitude of the travel request. The VM then
For the 4150, the VM activates the LPC looks at all speed limiting inputs such as motor
contactor via pin LPC_CTRL (JPC18-9) and temperature, height, weight, steering angle, and
verifies by LPC_SENSE (JPC22-20). The LPC fault codes to determine if the requested speed
and TPC are de-energized after approximately is allowable. The VM then initiates a request for
2.5 minutes of inactivity. the appropriate direction and speed to the TPAs
over the communications BUS. The VM
Deadman Pedal Pressed constantly updates the travel request to the
TPAs.
When the Deadman Pedal is pressed, S2
(Deadman Switch) is closed. The switch is an When the TPA receives a travel request from the
input at JPC22-8 to the VM. When S2 closes, it VM, it produces an output to the traction motor.
switches Deadman Switch voltage from a high All operational parameters that affect traction
state (greater than 4.5VDC) to a low state (less motor torque and speed are controlled
than 0.7VDC). exclusively by the TPA. It monitors motor
current, voltage, and RPM, and from them, can
When the VM receives that voltage, it activates determine motor performance. The TPA alters
a circuit in the VM that provides B– to its output to the traction motor to match the
JPC18-11 to energize the STR contactor coil motor performance to the travel request from
and the steer motor is powered up. the VM. As the travel request from the control
handle changes, so does the travel request from
the VM to the TPA. That in turn, alters motor
Travel Theory operation. To track the travel request from the
operator, the TPA monitors the speed sensor.
During Learn, the VM learns the neutral The TPA also monitors traction motor
position for the travel (VR1) and lift (VR2) temperature and the internal temperature of
potentiometers and stores those values in the amplifier and can alter travel based on the

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Models 4150/4250 Maintenance Manual Section 8. Theory of Operation

Travel Theory

TPA temperature. The TPA sends motor The TPA calculates both direction and speed,
temperature to the VM, and the VM alters the then determines whether the travel request
travel request based on the traction motor from the VM must be met with a travel, a plug,
temperature. or a regeneration control output to the traction
motor.
When the lift truck is moving and the travel
control handle is moved to request the opposite The VM constantly monitors the steering
direction, the same sequence of events takes position sensor for reduction in speed to a
place. particular traction motor, cut power to a
particular traction motor, or cause the motor to
The VM does not request plugging or reverse the direction of travel even if the travel
regeneration; it just requests travel in the control direction request did not change.
opposite direction.
This allows the lift truck to corner correctly with
the dual drive system.

Table 8-3. Steering Parameters

Operator
Steer Tiller
Steer Tire Position Effect On System Display
Position
Message

90° (full CW) to 67° Reverse direction in 1 motor Left 101

67° to 41° One motor power cut Left 100

41° to 18° Reduced throttle percentage Left 000

18° to –18° (wheels centered) Full Speed Centered 001

–18° to –41° Reduced throttle percentage Right 011

–41° to –67° One motor power cut Right 010

–90° (full CCW) to –67° Reverse direction in 1 motor Right 110

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Section 8. Theory of Operation Models 4150/4250 Maintenance Manual

Steering System Theory

Steering System Theory

With the key switch ON, the deadman pedal
pressed, and the EPO switch closed, Relay K2 is
energized, sending B+K2 from the Fuse/Relay
Card at JPF2-1 to SPL9.

From SPL9, the voltage goes to the STR

contactor X terminal. The VM supplies the
negative component (JPC18-11) to energize the
steering contactor coil. When the coil is
energized, the steer contactor tips close,
supplying battery voltage to the steer motor.

With the steer motor running, oil is sent

through the steering orbitrol and back to the
hydraulic reservoir. When steering is requested,
oil is sent through the orbitrol to the hydraulic
steer motor to rotate (steer) the drive unit.

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Models 4150/4250 Maintenance Manual Section 8. Theory of Operation

Lift/Lower System Theory

Lift/Lower System determine that the lift motor stopped spinning.

As long as the VM senses voltage on the P Sense
Theory line, it provides voltage to the Priority Bypass
(SOL4) and lift/lower proportional (SOL2) coil,
keeping the valve(s) open to allow the fluid from
Model 4150 the pump to return to the tank. This makes
sure that the cylinders do not continue lifting
after the request ends. Once the lift motor
Lift System
completely stops spinning, the VM removes
voltage to the Priority Bypass (SOL4) and the
The VM constantly monitors the output voltage
lift/lower proportional (SOL2) coil, closing the
of VR2. The VM compares this voltage to the
Priority Bypass (SOL4) and the lift/lower
voltages stored during the Learn process. The
proportional valve.
VM checks the battery voltage (for lift cutout),
and all enabled options and switches that could
prevent the activation of the lift system. When Lower System
satisfied that no criteria are present to prevent
lift, it then determines the requested percentage The following description is based on a lower
of full speed lift. It then activates Priority request from a full speed lift situation.
Bypass (SOL4). The lift/lower proportional valve
(SOL2) fully opens and closes the lift pump VR2 passes through neutral to a full speed
contactor (LPC) by taking the coils to B–. lower request. The VM recognizes the change
and realizes full speed lower is required. All
Opening the lift/lower valve fully prevents enabled options and switches that can prohibit
sudden movement when the lift pump is first lower are checked.
activated by allowing the fluid to return to the
tank. As soon as the command to close the P Once the VM is satisfied that lower is allowed, it
contactor is activated, the VM looks at the monitors the LPC_Sense line to determine the
LPC_Sense input, verifying the contactor closed condition of the P contactor (open or closed) and
as commanded. It then slowly reduces the PWM verifies the lift motor is not still spinning by
(Pulse Width Modulation) output to the coil for checking for back ElectroMotive Force (EMF).
the lift/lower proportional valve to match the As long as the VM senses voltage on the
percentage of lift speed requested. As the LPC_Sense line, it provides voltage to the
lift/lower proportional valve closes, hydraulic Priority Bypass (SOL4) and lift/lower
fluid passes through the CV1 check valve, the proportional coil, keeping the valve(s) open to
normally closed check valve in the load holding allow the fluid from the pump to return to the
valve, to the flow limiter on the crosstie, to the tank. This makes sure that the cylinders do not
flow limiters at the bottom of the lift cylinders. continue lifting after the request ends.
The flow limiter in the cylinder allows
unrestricted fluid flow to the center lift ram. The Once the lift motor completely stops spinning,
free lift cylinder elevates first because less the VM removes voltage to the lift/lower coil,
pressure is required. Once the carriage hits the closing the lift/lower proportional valve. The
stops on the inner telescopic, the pressure Load Holding solenoid (SOL1) is activated by
increases enough to start elevating the main lift the VM, opening the valve. The VM then
cylinder(s). gradually opens the lift/lower solenoid (SOL2)
to the percentage of requested lower. This
The VM monitors the LPC_Sense line to allows the oil to flow from the cylinders, the
determine the condition of the LPC contactor load holding valve, the lift/lower proportional
and verify the lift motor is spinning. When a lift valve, the filter, and back to the reservoir. The
request has finished (VR2 either returns to telescopics lower first due to the greater weight
neutral or through neutral to a lower request), of the telescopics. Once the telescopics are fully
the VM monitors the LPC_Sense line for back lowered, the center cylinder begins to lower.
ElectroMotive Force (EMF) from the motor to

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Section 8. Theory of Operation Models 4150/4250 Maintenance Manual

Model 4250

Model 4250 Lower System

Lift System With the key switch ON and the deadman

pressed, rotating the lift/lower control VR2 to
the lower position sends a change in voltage to
All inputs and outputs related to the lift/lower
the VM on JPC12-2 (the voltage is an increasing
system are controlled by the Vehicle Manager
voltage).
(VM). The VM determines what actions are
required based on inputs from the operator and
The VM senses the request for lower and sends
from system feedback.
the negative to the load holding solenoid (SOL1)
at JPC18-10 to energize its coil.
When VR2 is moved to request lift, a voltage is
sent to the VM at JPC12-2. The VM sees a
After the load holding solenoid opens, the
voltage different from the “learned” neutral
proportional lower solenoid (SOL2) opens to
voltage, and sends a request to the lift power
allow fluid to flow back to the reservoir by
amplifier via BUS+/– (JPC14-11 and JPC14-4
controlling the negative to the coil. This
on the VM to JPL1-23 and JPL1-35 on the Lift
negative comes from the VM at JPC20-16. SOL2
Power Amp). To lift, voltage from VR2 decreases;
opens proportionally to the amount that VR2 is
when it is moved to lower, the voltage from VR2
moved from neutral during lower.
increases.
Voltage across the proportional lower solenoid
Lift speed varies directly with lift motor RPM.
varies, depending on the position of the
The voltage supplied to the lift motor is
lift/lower control (VR2):
proportional to the amount of lift request from
VR2, faster lift = higher motor voltage. • Low voltage = slow lowering
Frequency is also manipulated to perform the • High voltage = fast lowering
operator’s request.

The lift power amplifier internally supplies B+ Auxiliary Functions

and B– to the lift contactor coil (LPC coil) at
JPL1-13 and JPL1-6 respectively. B– is Sideshift
controlled to close the normally open contactor
tips. When the lift contactor coil is energized, With the key switch ON and the deadman pedal
the contactor tips close, allowing B+ to the pressed, the following occurs to activate the
power side of the LPA. The LPA supplies voltage sideshift function.
to the lift motor.
Moving the sideshift control on the standard
Prior to requesting a lift, all valves are in the handle closes SS Left switch (S8), which
de-energized state. supplies DGND to the VM at JPC12-8, or SS
Right switch (S9), which supplies DGND to the
SOL4 receives oil flow at port 1 placing pressure VM at JPC12-9. Moving the sideshift control on
on the pilot line of the valve. This pressure the optional handle varies the output voltage of
moves the spool in the valve to allow flow out of the sideshift pot. SS Right decreases voltage
port 2 and down to CV-1. Then the oil flows and SS Left increases voltage. This voltage goes
through the de-energized load holding solenoid to the VM at JPC12-5. The VM sees a voltage
(SOL1), through the mast mounted flow limiter change at the respective connection and sends
to the flow limiters in the base of the lift a request to the LPA via BUS+/– (JPC14-11 and
cylinders, and into the lift cylinders producing JPC14-4 to JPL1-23 and JPL1-35).
lift.
The LPA internally supplies B– to the lift
When the lift knob is returned to neutral, the contactor coil (LPC) at JPL1-6, closing the
lift motor is ramped down. SOL3 is opened to normally open contactor tips.
relieve any pressure spikes in the system.

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Models 4150/4250 Maintenance Manual Section 8. Theory of Operation

Auxiliary Functions

When the lift contactor coil is energized, the to the power side of the lift power amplifier. This
contactor tips close, allowing B+ to the power supplies voltage to the lift motor to make it
side of the LPA. The LPA supplies voltage to the rotate. The motor turns at a speed
lift motor. The motor turns at a speed predetermined by software.
predetermined by software.
SOL4 receives oil flow at port 1, that flows
SOL4 receives oil flow at port 1 that flows through the valve and out port 3 to SOL6, the
through the valve and out port 3 to SOL6, the directional solenoid. When energized, SOL6
directional solenoid. When energized, SOL6 reverses the direction of the Aux functions.
reverses the direction of the Aux functions.
Oil flow then goes to SOL10. SOL10 must be
Oil flow then goes to solenoid 9R or 9L. Solenoid energized for Tilt to work in either direction.
9R and 9L must be energized for Sideshift to
work in either direction. From SOL9, the oil From SOL10, the oil flows through CB-1 or 2,
flows through the over-the-mast hoses to the depending on the requested tilt direction. The
Sideshift cylinders. oil then flows through the hoses to the Tilt
cylinders.
From the Maintenance Menu, the user can
establish sideshift speed. See Table 3-4, During a lift and aux function at the same time,
“Maintenance Mode Menu,” on page 3-20. SOL4 becomes energized to allow the correct oil
flow to the Aux functions.
This is used to adjust sideshift speed between 3
and 4.5 seconds. It is also used to set the Bottler’s Tilt (Optional)
correct speed of an attachment that has a
second AUX function. The VM varies the voltage Bottler’s Tilt allows additional forward mast tilt
to SOL4 to create the differing sideshift speeds. while in free lift, and may limit the lift height
depending on the tilt position.
Tilt
To accomplish this, there are modifications to
With the key switch ON and the deadman pedal the lift truck and the option must be enabled in
pressed, the following occurs to activate the Tilt FlashWare. See Table 3-1, “Configure Mode
function. Menu,” on page 3-11.

Moving the tilt control on the standard handle When the mast is fully lowered and vertical, the
closes Tilt Up switch (S6), which supplies High Speed Limit Switch (SW11) and Mast Tilt
DGND to the VM at JPC12-5, or Tilt Down Switch (SW18) are normally closed.
switch (S7), which supplies DGND to the VM at
JPC12-6. Moving the tilt control on the optional When tilt is requested, greater than 3° tilt
handle varies the output voltage of the tilt pot. forward is possible.
Tilt Down decreases voltage and Tilt Up
increases voltage. This voltage goes to the VM at When the lift truck is elevated above free lift,
JPC12-8. The VM sees a voltage change at the SW11 opens, causing a change in state to be
respective connection and sends a request to seen at the VM.
the LPA via BUS+/– (JPC14-11 and JPC14-4 to
JPL1-23 and JPL1-35). The VM does not allow tilt forward to go more
than 3° as seen by SW18.
The LPA internally supplies B– to the lift
contactor coil (LPC) at JPL1-6, closing the When the mast is tilted more than 3° while in
normally open contactor tips. free lift, and lift is requested, lift stops when
switch SW11 is deactivated.
When the lift contactor coil is energized, the
contactor tips close, allowing B+ to be supplied

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Section 8. Theory of Operation Models 4150/4250 Maintenance Manual

Auxiliary Functions

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Models 4150/4250 Maintenance Manual Section 8. Theory of Operation

Pinout Matrix

Pinout Matrix
Section 8. Theory of Operation

The pinout matrix chart lists functions and • Normal Level: the approximate voltage that
normal voltages of terminals and harness must be seen on that wire for the state
connector pins. The matrix columns have the indicated. Unless otherwise indicated,
following meanings: voltages are measured with respect to (wrt)
• Item: sequential number to aid in B– at TP4.
reference. • Signal Source: the device or connection
• Connector: the actual wire numbers or that supplies the signal directly to the
component abbreviations on the electrical wire.
schematic. • Signal User: the device or connection
• Function Description: brief definition of where the wire directly delivers the signal.
the signal carried on the wire.
• Theory of Operation: a detailed description
of the signal carried on the wire. If the
signal can be variable, the state of a
related component that will cause the
signal to differ is indicated. Identifies
possible causes for lack of the correct
signal.

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

1 JPC3-1 VBUS Voltage Supply for USB.

2 JPC3-2 D– Used for USB Communication.

3 JPC3-3 D+ Used for USB Communication.

4 JPC3-4 DGND B– for USB. <0.5V

5 JPC6-2 DATA_OUT No usable data can be obtained.

6 JPC6-4 DGND This is the negative path for the <0.5V VM OD

Operator Display circuits.

7 JPC6-5 SHIFT_CLOCK No usable data can be obtained.

8 JPC6-6 +12V This is the positive path for the 12V 10.8 to 13V VM OD
supply to the Operator Display.

9 JPC9-2 TXD Connector for FlashWare.

10 JPC9-3 RXD Connector for FlashWare.

11 JPC9-5 DGND Connector for FlashWare.

12 JPC10-1 +12VP 12V supply to Deadman Switch (S2). 10.8 to 13V VM S2

13 JPC10-3 ENABLE Connection for the VM to enable Key ON: 12V VM OCSS
Emitters for OCSS after the Deadman down: Emitters
Deadman pedal is pressed. <1V

14 JPC12-1 +5VP 5V supply from the VM used for VR1 5V VM VR1, VR2
std. handle (Travel) and VR2 (Lift/Lower) pots.

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Section 8. Theory of Operation Models 4150/4250 Maintenance Manual

Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

15 JPC12-1 +5VP 5V supply from the VM used for 5V VM Optional

opt. handle switches in the optional handle. handle
switches

16 JPC12-2 LIFT Input to the VM from VR2. Neutral: 1.17V VR2 VM

Full Lift: 0.62V
Full Lwr: 1.68V

17 JPC12-3 TRAVEL Input to the VM from VR1. Neutral: 1.0V VR1 VM

Full TF: 0.52V
Full FF: 1.60V

18 JPC12-4 FUNCTION 1 Input to the VM from SW3. De-activated: SW3 VM

opt. handle 4.32V
Variable down to
0.597V fully
activated

19 JPC12-4 FUNCTION 1 Input to the VM from S4. De-activated: 5V S4 VM

std. handle Activated: <1V

20 JPC12-5 SSHIFT Input to the VM from SW4. Neutral: 2.44V SW4 VM

opt. handle Full SS Right: 0.6V
Full SS Left: 4.36V

21 JPC12-5 TILT_UP Input to the VM from S6. De-activated: 5V S6 VM

std. handle Activated: <1V

22 JPC12-6 TILT_Down Input to the VM from S7. De-activated: 5V S7 VM

std. handle Activated: <1V

23 JPC12-7 H_HTR 8V to the heater in the optional Linear based on VM HTR6

opt. handle control handle. ambient temp.
0V @ 97°F,
8V @ 50°F

24 JPC12-8 TILT Input to the VM from SW4. Neutral: 2.44V SW4 VM

opt. handle Full Tilt Dn: 0.6V
Full Tilt Up: 4.36V

25 JPC12-8 SSHIFT_LEFT Input to the VM from S8. De-activated: 5V S8 VM

std. handle Activated: <1V

26 JPC12-9 SSHIFT_RIGHT Input to the VM from S9. De-activated: 5V S9 VM

std. handle Activated: <1V

27 JPC12-10 HORN Input to the VM from SW1. De-activated: 5V SW1 VM

opt. handle Activated: <1V

28 JPC12-10 HORN Input to the VM from S3. De-activated: 5V S3 VM

std. handle Activated: <1V

29 JPC12-11 FUNCTION 2 Input to the VM from SW2. De-activated: SW2 VM

opt. handle 4.32V
Variable down to
0.597V fully
activated

30 JPC12-11 FUNCTION 2 Input to the VM from S5. De-activated: 5V S5 VM

std. handle Activated: <1V

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Models 4150/4250 Maintenance Manual Section 8. Theory of Operation

Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

31 JPC12-12 DGND B– to the control handle. <0.5V VM Handle

switches

32 JPC14-1 B–F B–F for the VM. <0.5V TP4 VM

33 JPC14-2 DGND B–F for DGND on the VM. <0.5V TP4 VM

34 JPC14-3 DGND B–F for DGND on the VM. <0.5V TP4 VM

35 JPC14-4 BUS– The wire that carries the negative 2.185V VM VM,
component of the digital Power
communications between the VM Amps
and power amplifiers.

36 JPC14-6 RELAY_ENABLE Control path for K1, K2, K3, & K4 B+ w/Key Switch VM K1, K2,
on the Fuse/Relay Card. After S1 is ON and all relays K3, & K4
closed, all relays are energized de-energized;
simultaneously during SelfTest if the <0.5V w/Key
voltage at Battery_Sense_In is Switch OFF or ON
between 28 and 45V. If the lift truck and any relay
is equipped with optional heaters, energized
the VM may keep this circuit active
at B– even with the Key Switch OFF
(JPC14-7) to allow the heaters to run
based on the ambient temperature
sensor reading.

37 JPC14-7 B+K4 This is used for a circuit in the VM. If B+ w/Key Switch VM K4
the lift truck is equipped with the ON (B+ w/Key
optional heater assembly, the VM Switch OFF if lift
looks at the Ambient Temperature truck is equipped
Sensor (JPC24-23) input to with Cold Storage
determine if the Relay Enable circuit and ambient temp.
should remain activated to have requires heaters to
power remaining to the VM power remain ON)
supply.

38 JPC14-8 B–F B–F for the VM. <0.5V TP4 VM

39 JPC14-9 B–F B–F for the VM. <0.5V TP4 VM

40 JPC14-10 DGND B–F for DGND on the VM. <0.5V TP4 VM

41 JPC14-11 BUS+ The wire that carries the positive 2.8V VM VM,
component of the digital Power
communications between the VM Amps
and power amplifiers.

42 JPC14-12 B+KEY B+ that is switched by the Key Switch B+ S1 VM

(S1) to power functions on the VM
that are initiated after S1 is closed
and are not affected by the EPO.
This includes the VM power supplies,
the operation of the microprocessor,
and execution of the firmware.

43 JPC14-13 B+K2 B+ provided to the VM when the K2 B+ K2 VM

relay tips are closed. They are
de-energized when the EPO is open.

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Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

44 JPC14-14 B+K2 B+ provided to the VM when the K2 B+ K2 VM

relay tips are closed. They are
de-energized when the EPO is open.

45 JPC18-1 AUX SELECT Control path for SOL6. The voltage Neutral: B+ VM SOL6
varies with different functions and SS Left: 8.0V
also depends on the selection of SS Rt: 23V
sideshift percentage in Configure Tilt Up: 8.0V
Mode. Tilt Dn: 30V

46 JPC18-2 CUST OUT Customer Output 10.8 to 13V VM Customer

Output
Switch

47 JPC18-5 DGND DGND for the optional OCSS Lower <0.5V VM Lower Left
Left Detector. Detector

48 JPC18-6 DGND DGND for the optional OCSS Upper <0.5V VM Upper
Right Detector. Right
Detector

49 JPC18-9 LPC_CTRL Control path for the LPC Contactor. De-energized: B+ VM LPC Coil
(4150 only) Energized: 12.7V

50 JPC18-10 LOAD HOLD Control path for SOL1. De-energized: B+ VM SOL1

Energized: 13V

51 JPC18-11 STR_CONTACTOR Control path for the Steering De-energized: B+ VM Steering

Contactor. Energized: 11.3V Contactor
Coil

52 JPC18-12 HSA1 Control path for SOL7R and SOL7C. De-energized: B+ VM SOL7R,
Energized: 12.7V SOL7C

53 JPC18-14 SIDESHIFT Control path for SOL9R and SOL9L. De-energized: B+ VM SOL9R,
Energized: 11.9V SOL9L

54 JPC18-15 TILT Control path for SOL10. De-energized: B+ VM SOL10

Energized: 10.6V

55 JPC18-16 HORN Control path for the Horn. De-energized: B+ VM Horn

Energized: 0.1V

56 JPC18-18 TRAV/LIFT ALARM Control path for the Trav/Lift Alarm. De-energized: B+ VM Trav/Lift
Energized: 0.09V Alarm

57 JPC20-1 +12VP 12V supply to the optional OCSS 10.8 to 13V VM Upper Left
Upper Left Emitter. Emitter

58 JPC20-2 +12VP 12V supply to the optional OCSS 10.8 to 13V VM Lower Left
Lower Left Detector. Detector

59 JPC20-3 +12VP 12V supply to the optional Left 10.8 to 13V VM S22A
Battery Gate (S22A).

60 JPC20-4 +12VP 12V supply to the optional Right 10.8 to 13V VM S22B
Battery Gate (S22B).

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Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

61 JPC20-5 +12VP 12V supply to the optional Mast Tilt 10.8 to 13V VM S18 or
(Bottler’s Tilt) Switch (S18) or Mini Mini
Power Supply for the Tilt Centering Power
option. Supply

S/N <50501 with Quad Mast: 12V

supply to the Mast Tilt Speed
JPC20-6 Reduction Switch (S12).
62 +12VP 10.8 to 13V VM S12
(4250 only)
12V supply to the optional Lift Limit
Switch (S12).

S/N >50500 with TT or Quad Mast:

12V supply to the Mast Tilt Speed
JPC20-8 Reduction Switch (S11).
63 +12VP 10.8 to 13V VM S11
(4250 only)
12V supply to the optional Hi-Speed
Limit Switch (S11) (Bottler’s Tilt).

64 JPC20-9 +12VP 12V supply to the optional OCSS 10.8 to 13V VM Lower
Lower Right Emitter. Right
Emitter

65 JPC20-10 +12VP 12V supply to the optional OCSS 10.8 to 13V VM Upper
Upper Right Detector. Right
Detector

66 JPC20-12 DUMP Control path for SOL3. No request: B+ VM SOL3

Feather Lift: 9.0V
Full Lift: 8.1V
Full Lift & Aux
Request: 7.0V

67 JPC20-13 ISENSE5(K2) B+ from the K2 relay to the SOL6 B+ VM SOL6

coil. This is also used to sense the
current drawn by SOL6.

68 JPC20-14 BRAKES Control path for the Brake coils. The B+ without request VM Brakes
brakes are released after a throttle and Key Switch
command is initiated, and are ON; Initial brake
applied when travel stops or the EPO release: 0.4V, then
is pressed. 13V

69 JPC20-15 ISENSE2(K2) B+ Supply from the K2 relay to the B+ VM SOL2

SOL2 coil. This is also used to sense
the current drawn by SOL2.

70 JPC20-16 LIFT/LOWER Control path for the proportional De-energized: B+ VR2 VM

(4150 only) SOL2. The voltage should differ Lift: 21 to 34V
depending on the position of the Lift Lower: 35 to 19V
Pot (VR2).

71 JPC20-16 LIFT/LOWER Control path for the proportional De-energized: B+ VR2 VM

(4250 only) SOL2. The voltage should differ Lower: 35 to 19V
depending on the position of the Lift
Pot (VR2).

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Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

72 JPC20-17 ISENSE3(K2) B+ from the K2 relay to the SOL4 B+ VM SOL4

coil. This is also used to sense the
current drawn by SOL4.

73 JPC20-18 PRIORITY BYPASS Control path for SOL4. (Normal Key ON: B+ VM SOL4
std. handle voltages are approximate Sideshift: 22.75V
(4150 only) depending on the sideshift setting in Tilt: 23.9V
Maintenance Mode.)

74 JPC20-18 PRIORITY BYPASS Control path for SOL4. (Normal Key ON: B+ VM SOL4
opt. handle voltages are approximate Feather Lift: 12.4V
(4250 only) depending on the sideshift setting in Full Lift: 10V
Maintenance Mode.) Tilt: 20V
Tilt & Lift: 15V

75 JPC20-19 ISENSE4(K2) B+ from the K2 relay to the SOL5 B+ VM SOL5

coil. This is also used to sense the
current drawn by SOL5.

76 JPC20-20 PROP RELIEF Control path for SOL5. Lift: 32V VM SOL5
std. handle Aux: 18V

77 JPC20-20 PROP RELIEF Control path for SOL5. Lift: 32V VM SOL5
opt. handle Tilt & SS: 18V
Tilt & Lift: 12 to
18V

78 JPC22-3 GATE_L Input to the VM from the optional left Activated: approx. S22A VM
Battery Gate Switch (S22A). 0V
Not activated: 5V

79 JPC22-4 GATE_R Input to the VM from the optional Activated: approx. S22B VM
right Battery Gate Switch (S22B). 0V
Not activated: 5V

80 JPC22-5 TILT_DN Input to the VM from the optional Activated: approx. S18 VM
Mast Tilt Switch (S18) (Bottler’s Tilt). 0V
Not activated: 5V

S/N <50501 with Quad Mast: Input

to the VM from the Mast Tilt Speed Activated: approx.
JPC22-6 Reduction Switch (S12).
81 LIFT_LIM 0V S12 VM
(4250 only)
Input to the VM from the optional Lift Not activated: 5V
Limit Switch (S12).

82 JPC22-8 ON DEADMAN Input to the VM from the Deadman S2 open: approx. S2 VM

Switch (S2). 5V;
S2 closed: 0V

83 JPC22-9 POS C POS C input to the VM from the Activated: 1.36V Steer VM
Steer Position Sensor. Not activated: Position
8.12V Sensor

84 JPC22-10 DISP_MISO No usable data can be obtained.

85 JPC22-11 DGND DGND for the Deadman Switch <0.5V VM S2

(S2).

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Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

86 JPC22-13 BEAM_L Input to the VM from the optional Clear: <1V Lower Left VM
Lower Left OCSS Detector (Deadman Blocked: 5V Detector
pressed).

87 JPC22-14 BEAM_R Input to the VM from the optional Clear: <1V Upper VM
Upper Right OCSS Detector Blocked: 5V Right
(Deadman pressed). Detector

88 JPC22-19 STR_SENSE Sense wire used by the VM to Contactor STR VM

determine the state of the Steer De-energized: Contactor
Contactor and FU1. <0.5V
Energized: B+

89 JPC22-20 LPC_SENSE Sense wire used by the VM to Contactor LPC VM

(4150 only) determine the state of the LPC De-energized: Contactor
Contactor and FU3. <0.5V
Energized: B+

90 JPC22-21 EPO_SENSE Sense wire used by the VM to EPO Closed: B+ S21 VM

determine when the EPO (S21) is Open: <0.5V
open. This is used to initiate braking
and show a message.

S/N >50500 with TT or Quad Mast:

Input to the VM from the Mast Tilt
Speed Reduction Switch (S11). Activated: approx.
JPC22-22
91 HIGH_SPD 0V S11 VM
(4250 only) Input to the VM from the optional Not activated: 5V
Hi-Speed Limit Switch (S11) (Bottler’s
Tilt).

92 JPC24-1 +12VP 12V supply to the Steer Position 10.8 to 13V VM Steer
Sensor from the VM. Position
Sensor

93 JPC24-3 DGND DGND for the left Battery Gate <0.5V VM S22A
Switch (S22A).

94 JPC24-4 DGND DGND for the right Battery Gate <0.5V VM S22B
Switch (S22B).

95 JPC24-5 DGND DGND for the Mast Tilt Switch (S18) <0.5V VM S18 or
or Mini Power Supply for the Tilt Mini
Centering option. Power
Supply

S/N <50501 with Quad Mast:

DGND for the Mast Tilt Speed
JPC24-6 Reduction Switch (S12).
96 DGND <0.5V VM S12
(4250 only)
DGND for the optional Lift Limit
Switch (S12).

97 JPC24-7 DGND DGND for the Ambient Temperature <0.5V VM Ambient

Sensor. Temp
Sensor

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Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

S/N >50500 with TT or Quad Mast:

DGND for the Mast Tilt Speed
JPC24-8 Reduction Switch (S11).
98 DGND <0.5V VM S11
(4250 only)
DGND for the optional Hi-Speed
Limit Switch (S11) (Bottler’s Tilt).

99 JPC24-10 DGND DGND for the Pressure (Weight) <0.5V VM Pressure

Sensor. Sensor

100 JPC24-12 DATA_LATCH No usable data can be obtained.

101 JPC24-13 +12VP 12V supply to the optional Pressure 10.8 to 13V VM Pressure
Sensor from the VM. Sensor

102 JPC24-14 ADDR_LATCH No usable data can be obtained.

103 JPC24-17 POS A POS A input to the VM from the Activated: 1.36V Steer VM
Steer Position Sensor. Not activated: Position
8.12V Sensor

104 JPC24-18 PRESSURE_AIN Input to the VM from the optional 0 to 5V Based on Pressure VM
Pressure Sensor. weight on forks Sensor

105 JPC24-20 POS B POS B input to the VM from the Steer Activated: 1.36V Steer VM
Position Sensor. Not activated: Position
8.12V Sensor

106 JPC24-22 TILT_AIN Input to the VM from the Tilt Tilted Fwd: VR6 VM
Centering Pot (VR6). approx. 2V;
Centered:
approx 3V; Tilted
Back: approx. 4V

107 JPC24-23 AMBIENT Input to the VM from the optional 0 to 5V Based on Ambient VM
Ambient Temperature Sensor. ambient temp. Temp
Sensor

108 JPC24-24 BATTERY_SENSE_IN B+ present when the battery is B+ (there should TP1 VM
plugged in. It is supplied through a be no voltage
thermistor on the Fuse/Relay Panel. drop)
This is used by the VM to determine
that the correct battery is connected.
It accepts between 28 and 45V. If
the correct battery is sensed, Relay
Enable is energized during startup.
After startup, this voltage is used to
determine BSOC.

109 JPF1-1 B– B– for the FU8 (15A/5A) Fuse for <0.5V TP4 Accessory
the optional Accessory Power. Power

110 JPF1-2 B– B– for the FU8 (15A/5A) Fuse for <0.5V TP4 Accessory
the optional Accessory Power. Power

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Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

111 JPF1-3 B+F Provides B+F to B+K3 on the Power K3 Energized: B+ K3 Power
Amplifiers. B+K3 is used to power Amplifiers
the control circuits of the LPA, LTPA,
and RTPA.
Note: B+ power for the amplifiers
may come from K2 (JPF1-6) or K3
(JPF1-3). Refer to the schematic.

112 JPF1-4 B–F B– from the FU8 (15A/5A) Fuse for <0.5V TP4 TS1-1 & 2
the optional Accessory Power.

113 JPF1-5 ID0, ID1 Provides B+F to B+ID’s on the TPAs. K3 Energized: B+ K3 Power
At startup, the K3 coil is energized Amplifiers
and this is used to identify the
amplifiers.

114 JPF1-6 B+F Provides B+F to B+K2 on the Power K2 Energized: B+ K2 Power
Amplifiers. B+K2 is used to power Amplifiers
the control circuits of the LPA, LTPA,
and RTPA.
Note: B+ power for the amplifiers
may come from K2 (JPF1-6) or K3
(JPF1-3). Refer to the schematic.

115 JPF2-1 B+K2 B+ supplied to the Steer Contactor, K2 Energized: B+ K2 tips STR, LPC
LPC Contactor (4150), and the CNTR and
optional Power Amp Fan. optional
Power
Amp Fan

116 JPF2-2 B+K2 B+K2 to power the Horn, and the K2 Energized: B+ K2 tips Horn and
Travel/Lift Alarm. Travel/Lift
Alarm

117 JPF2-3 B+K2 B+ Supply from the K2 relay to the K2 Energized: B+ K2 tips Right
Right Brake Coil. Brake Coil

118 JPF2-4 B+K4 Supply input to the VM that allows K4 Energized: B+ K4 tips VM
the VM to remain powered up with
the Key Switch OFF. This is used in
cold storage applications to allow
the handle heater circuit to work
based on input from the Ambient
Temperature Sensor.

119 JPF2-5 B+K2 B+ from the K2 relay to the Left K2 Energized: B+ K2 tips Left Brake
Brake Coil. Coil

120 JPF2-6 B+K2 B+ from the K2 relay to the VM. K2 Energized: B+ K2 tips VM

121 JPF2-7 B+K2 B+ from the K2 relay to the VM. K2 Energized: B+ K2 tips VM

122 JPF2-8 B+K2 B+ Supply from the K2 relay to K2 Energized: B+ K2 tips SOL1, 3,
SOL1, 3, 7R, 7C, 9R, 9L, and the 7R, 7C,
optional SOL11. 9R, 9L, &
SOL11

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Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

123 JPF2-9 B+Key B+ from the K1 relay to be used for K1 Energized: B+ K1 tips TS1-5 & 6
Accessory Power after the Key
Switch is activated.

124 JPF3-1 B– B– for FU6 that provides B– to the <0.5V TP4 VM

VM.

125 JPF3-2 B– B– for FU6 that provides B– to the <0.5V TP4 VM

VM.

126 JPF3-3 DGND B–F for DGND on the VM. <0.5V FU6 VM

127 JPF3-4 DGND B–F for DGND on the VM. <0.5V FU6 VM

128 JPF3-5 B–F B–F for the VM. <0.5V FU6 VM

129 JPF3-6 B–F B–F for the VM. <0.5V FU6 VM

130 JPF3-7 B–F B–F for the VM. <0.5V FU6 VM

131 JPF4-1 B+ B+ from TP1 to FU5 to supply the K4 B+ TP1 K2, K4,
coil and the K2, K4 relay tips. Also VM
supplies BATTERY_SENSE_IN to the
VM.

132 JPF4-2 B+ B+ from TP1 to FU5 to supply the K4 B+ TP1 K2, K4,
coil and the K2, K4 relay tips. Also VM
supplies BATTERY_SENSE_IN to the
VM.

133 JPF4-3 B+ B+ from TP1 to FU7 and K1 tips to B+ TP1 FU7 &
supply the Accessory Power option. Accessory
Power
Option

134 JPF4-4 B+ B+ from TP1 to FU7 and K1 tips to B+ TP1 FU7 and
supply the Accessory Power option. Accessory
Power
Option

135 JPF4-5 B+EPO B+ supply from the EPO to K1, K2, EPO Closed: B+ EPO K1, K2,
and K3. All functions associated with Open: 0.05V K3
these relays are inoperable when the
EPO is open.

136 JPF4-7 BATTERY_SENSE_IN B+ present when the battery is B+ (there should TP1 VM
plugged in. It is supplied through a be no voltage
thermistor on the Fuse/Relay Panel. drop)
This is used by the VM to determine
that the correct battery is connected.
It accepts between 28 and 45V. If
the correct battery is sensed, Relay
Enable is energized during startup.
After startup, this voltage is used to
determine the BSOC.

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Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

137 JPF4-8 BRAKES Control path for the Brake Coils. B+ without request VM Brakes
Brakes are released after a throttle and Key Switch
command is initiated, and are ON;
applied when travel stops or the EPO Initial brake
is pressed. release: 0.4V, then
16V

138 JPF4-10 B+F B+ to the Key Switch. B+ FU5 S1

139 JPF4-11 BRAKES (Left) Control path for the Left Brake Coil. B+ without request VM Brakes
The brake is released after a throttle and Key Switch
command is initiated, and is applied ON;
when travel stops or the EPO is Initial brake
pressed. release: 0.4V, then
16V

140 JPF4-12 BRAKES (Right) Control path for the Right Brake Coil. B+ without request VM Brakes
The brake is released after a throttle and Key Switch
command is initiated, and is applied ON;
when travel stops or the EPO is Initial brake
pressed. release: 0.4V, then
16V

141 JPF4-13 RELAY_ENABLE Control path for K1, K2, K3, and K4 B+ w/Key Switch VM K1, K2,
on the Fuse/Relay Card. After S1 is ON and all relays K3, & K4
closed, all relays are energized de-energized;
simultaneously during SelfTest if the <0.5 w/Key
voltage at BATTERY_SENSE_IN is Switch OFF or ON
between 28 and 45V. If the vehicle and any relay
is equipped with optional heaters, energized
the VM may keep this circuit active
at B– even with the Key Switch OFF
(JPC14-7) to allow the heaters to run
based on the ambient temperature
sensor input.

142 JPL1-1 B+K2 (or K3) B+ to the LPA. Present when K2 (or K2 (or K3) K2 (or K3) LPA
K3) is energized. Energized: B+
Note: B+ power for the amplifiers
may come from K2 (JPF1-6) or K3
(JPF1-3). Refer to the schematic.

143 JPL1-6 LPC Control path for the LPC. The Lift LPC De-energized: LPA LPC
Power Amplifier supplies a path for B+
B– for the contactor by the way of Energized: 14.7V
the B– terminal.

144 JPL1-7 L VEL SENSOR– Return path for the encoder in the Lift <0.5V LPA Lift
Motor. Encoder

145 JPL1-8 T TEMP+ Temp Sensor input to the LPA. Approx. 1V @ Lift Motor LPA
(4250 only) Analog voltage that varies with the 75ºF (24ºC) Temp
Lift Motor temperature. Sensor

146 JPL1-11 ID0 B+ present at the amp with the K3 K3 Energized: K3 LPA
tips activated. It is used as an approx. B+
identifier.

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Section 8. Theory of Operation Models 4150/4250 Maintenance Manual

Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

147 JPL1-12 ID1 Not Used

148 JPL1-13 B+K2 (or K3) B+ for the LPC. The Lift Power Key Switch ON: LPA LPC Coil
(4250 only) Amplifier supplies B+ for the LPC. B+

149 JPL1-23 BUS+ Positive component of the digital 2.8V VM VM,

communications (CAN Bus) between Power
the VM and Power Amplifiers. Amps

150 JPL1-26 L VEL SENSOR+ 5V to the Encoder on the Lift Motor. 4.95V LPA Lift
Encoder

151 JPL1-31 L VEL PHASE A Input to the LPA from the Lift Motor Motor Stationary: Lift Motor LPA
Encoder. It is a square wave that is 4.06 or 0.03V Encoder
either high (>3V) or low (<1V). The Turning: 2.3V
frequency varies directly with the
motor speed. Identical to L VEL Phase
B except for the phase. The LPA uses
the relationship between the phases
to determine the lift speed.

152 JPL1-32 L VEL PHASE B Input to the LPA from the Lift Motor Motor Stationary: Lift Motor LPA
Encoder. It is a square wave that is 4.06 or 0.03V Encoder
either high (>3V) or low (<1V). The Turning: 2.3V
frequency varies directly with the
motor speed. Identical to L VEL Phase
A except for the phase. The LPA uses
the relationship between the phases
to determine the lift speed.

153 JPL1-33 BUS– Negative component of the digital 2.185V VM VM,

communications (CAN Bus) between Power
the VM and Power Amplifiers. Amps

154 JPTL1-1 B+K2 (or K3) B+ to the LTPA. Present when K2 (or K2 (or K3) K2 (or K3) LTPA
K3) is energized. Energized: B+
Note: B+ power for the amplifiers
may come from K2 (JPF1-6) or K3
(JPF1-3). Refer to the schematic.

155 JPTL1-7 T VEL SENSOR– Return path for the Encoder in the <0.5V LTPA TML
Left Traction Motor (TML). Encoder

156 JPTL1-8 T TEMP+ TML Temp Sensor input to the LTPA. Approx 1V @ 75ºF TML Temp LTPA
Analog voltage that varies with the (24ºC) Sensor
motor temperature.

157 JPTL1-11 NOT USED

158 JPTL1-12 ID1 B+ present at the amp with the K3 K3 Energized: B+ K3 LTPA
tips activated. It is used as an De-energized: –1V
identifier.

159 JPTL1-21 CAN TERM H Connection used to terminate the K2 Energized: LTPA LTPA
BUS+, BUS– communication. 2.96V

160 JPTL1-23 BUS+ Positive component of the digital 2.8V VM VM,

communications (CAN Bus) between Power
the VM and Power Amplifiers. Amps

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Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

161 JPTL1-26 T VEL SENSOR+ 5V supply to the TML Encoder. 4.95V LTPA TML
Encoder

162 JPTL1-31 T VEL PHASE A Input from the TML Encoder to the Motor Stationary: TML LTPA
LTPA. It is a square wave that is 4.06V or 0.03V Encoder
either high (>3V) or low (<1V). The Turning: 2.3V
frequency varies directly with the
motor speed. Identical to T VEL
Phase B except for the phase. The
LTPA uses the relationship between
phase A and B to determine travel
speed and direction.

163 JPTL1-32 T VEL PHASE B Input from the TML Encoder to the Motor Stationary: TML LTPA
LTPA. It is a square wave that is 4.06 or 0.03V Encoder
either high (>3V) or low (<1V). The Turning: 2.3V
frequency varies directly with the
motor speed. Identical to T VEL
Phase A except for the phase. The
LTPA uses the relationship between
phase A and B to determine travel
speed and direction.

164 JPTL1-33 BUS– Negative component of the digital 2.185V VM VM,

communications (CAN Bus) between Power
the VM and Power Amplifiers. Amps

165 JPTL1-34 CAN TERM L Connection used to terminate the K2 (or K3) LTPA LTPA
BUS+, BUS– communication. Energized: 2.96V

166 JPTR1-1 B+K2 (or K3) B+ to the RTPA. Present when K2 (or K2 (or K3) K2 (or K3) RTPA
K3) is energized. Energized: B+
Note: B+ power for the amplifiers
may come from K2 (JPF1-6) or K3
(JPF1-3). Refer to the schematic.

167 JPTR1-6 TPC Control path for the TPC. The RTPA TPC De-energized: RTPA TPC
supplies a path for B– for the B+
Contactor. Energized: 14.7V

168 JPTR1-7 T VEL SENSOR– Return path for the Encoder in the <0.5V RTPA TMR
Right Traction Motor (TMR). Encoder

169 JPTR1-8 T TEMP+ TMR Temp Sensor input to the RTPA. Approx 1V @ 75ºF TMR Temp RTPA
Analog voltage that varies with the (24ºC) Sensor
motor temperature.

170 JPTR1-11 ID0 B+ present at the amp with the K3 K3 Energized: K3 VM

tips activated. It is used as an approx. B+
identifier. De-energized: –1V

171 JPTR1-12 ID1 B+ present at the amp with the K3 K3 Energized: K3 VM

tips activated. It is used as an approx. B+
identifier. De-energized: –1V

172 JPTR1-13 B+K2 (or K3) B+ to the TPC from the RTPA. Key Switch ON: TPA TPC Coil
B+

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Section 8. Theory of Operation Models 4150/4250 Maintenance Manual

Pinout Matrix

Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User

173 JPTR1-23 BUS+ Positive component of the digital 2.8V VM VM,

communications (CAN Bus) between Power
the VM and Power Amps. Amps

174 JPTR1-26 T VEL SENSOR+ 5V supply to the TMR Encoder. 4.95V RTPA TMR
Encoder

175 JPTR1-31 T VEL PHASE A Input from the TMR Encoder to the Motor Stationary: TMR RTPA
RTPA. It is a square wave that is 4.06 or 0.03V Encoder
either high (>3V) or low (<1V). The Turning: 2.3V
frequency varies directly with the
motor speed. Identical to T VEL
Phase B except for the phase. The
RTPA uses the relationship between
phase A and B to determine travel
speed and direction.

176 JPTR1-32 T VEL PHASE B Input from the TMR Encoder to the Motor Stationary: TMR RTPA
RTPA. It is a square wave that is 4.06 or 0.03V Encoder
either high (>3V) or low (<1V). The Turning: 2.3V
frequency varies directly with the
motor speed. Identical to T VEL
Phase A except for the phase. The
RTPA uses the relationship between
phase A and B to determine travel
speed and direction.

177 JPTR1-33 BUS– Negative component of the digital 2.185V VM VM,

communications (CAN Bus) between Power
the VM and Power Amplifiers. Amps

8-26 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section A. Appendix

Section A. Appendix

Publication: 1193671C, Revised: 15 Aug 2022 A-1

Section A. Appendix Models 4150/4250 Maintenance Manual

Lubrication Specification Chart

Lubrication Specification Chart

Approved Raymond Lubricants

Where Used Type Specification Raymond Part Number

75W-90 Synthetic
Drive Unit Gear Case Gear 990-655/001 (1 qt./0.9 liters)
Gear Oil
(all applications) Lubricant 990-655/003 (1 gal./3.8 liters)
API Service GL-5

Hydraulic Reservoir 990-616/04 (1 qt./0.9 liter)

(Non-CS lift trucks) 990-616/01 (1 gal./3.8 liters)
Hydraulic Fluid ISO VG 46
+50° to +120°F 990-616/02 (2 gal./7.6 liters)
(+10° to +49°C) 990-616/03 (5 gal./18.9 liters)

Hydraulic Reservoir
1266010
(CS lift trucks - in and
Note: Do not add any additives.
out of cooler/freezer) Hydraulic Fluid ISO VG 32
Can be mixed with prior
0° to +80°F
hydraulic fluid (P/N 101723).
(–18° to +27°C)

Hydraulic Reservoir
(CS lift trucks - confined
990-618/TX1 (1 gal./3.8 liters)
to freezer) Hydraulic Fluid MIL-H-5606E
990-618/01 (1 gal./3.8 liters)
–20° to 0°F
(–29° to –18°C)

Mast Uprights, Bearings,

and so forth
(all-weather) Grease NLGI 2 1012992
–20° to +120°F
(–29° to +49°C)

High Performance/
1151877/001 (Rexoil)
Lift Chains High Load Chain Aerosol
1151877/002 (Rocol)
Spray

A-2 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section A. Appendix

Thread Adhesives, Sealants, and Lubricants

Thread Adhesives, Sealants, and Lubricants

Loctite (Supplier)
Description/Application Part Number
Number/Color

Adhesive (floor pad installation) 990-569/102

Cleaner - alcohol based 990-600/FOF

Contact cleaner 996-600/CC2

Corrosion inhibitor coating 990-644 LPS3 Spray

Gasket Sealant Compound 990-556

Lubricant (Spline Shaft) 1223184

Sealing compound (cold storage conditioning) 990-542

Silicone grease (cold storage conditioning) 990-445

Silicone sealant 990-659

Thread-locking compound primerless 990-669 2760

Thread-locking compound 1/4 in. and below 990-403 222/Purple

Thread-locking compound 1/4 to 3/4 in. dia. contamination

1013829 243/Blue
tolerant

*Loctite is a registered trademark of the Loctite Corporation. Brand endorsement is not implied here, but
listed only as a commonly identified product.

Publication: 1193671C, Revised: 15 Aug 2022 A-3

Section A. Appendix Models 4150/4250 Maintenance Manual

Component Specific Torque Chart

Component Specific Torque Chart

Thread-Locking Torque to: (use Dry value for pre-applied
Component Sub-Component(s) Compound thread-locking compound)
P/N 1013829 Lubricated Dry
gear (top of motor) 120 ft. lb. (162.7 Nm)
assembly to traction Yes N/A
Brake 15 ft. lb. (20.3 Nm)
motor
coil to lower friction plate No N/A 70 in. lb. (7.9 Nm)
mounting bracket to
20 ft. lb. (27.1 Nm) 27 ft. lb. (36.6 Nm)
tractor deck screws Yes
Control Handle shaft set screw 14 ft. lb. (19 Nm) N/A
15 to 20 in. lb.
assembly screws
No N/A (1.7 to 2.3 Nm)
cover screws 7 ft. lb. (9.4 Nm)
Drive Unit
tractor frame mtg. bolts Yes 180 ft. lb. (244 Nm) N/A
Drive Wheels mounting bolts No N/A 108 ft. lb. (146 Nm)
strut bracket bolts Yes 50 ft. lb. (67.8 Nm) 65 ft. lb. (88 Nm)
strut mounting bolts No N/A 100 ft. lb. (135.5 Nm)
floor plate to pivot plate
Floor 80 ft. lb. (108.5 Nm) 110 ft. lb. (149.1 Nm)
mounting bolts
(ComfortStance)
pivot plate bearing block
90 ft. lb. (122 Nm) 100 ft. lb. (135.5 Nm)
mounting bolts Yes
tie-rod mounting bolts 35 ft. lb. (47.5 Nm) 45 ft. lb. (61 Nm)
Hydraulic Steer sprocket set screws 13 ft. lb. (18.2 Nm) N/A
Motor mounting bolts 40 ft. lb. (54.2 Nm) 53 ft. lb. (71.8 Nm)
Top Nut:
203 to 221 in. lb.
(23 to 25 Nm)
Lift Motor - AC
Bottom Nut:
128 to 132 in. lb.
(14.5 to 15 Nm)
cable securing nut (top) No N/A
Top Nut:
90 to 110 in. lb.
(10.2 to 12.4 Nm)
Lift Motor - DC
Bottom Nut:
110 to 140 in. lb.
(12.4 to 15.8 Nm)
Manifold, Main mounting bolts 20 ft. lb. (27 Nm) 27 ft. lb. (36.6 Nm)
mounting (pivot bearing
Mast 43 ft. lb. (58.3 Nm) N/A
cap) bolts Yes
Overhead
mounting bolts 170 ft. lb. (230.5 Nm) 230 ft. lb. (312 Nm)
Guard

A-4 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section A. Appendix

Component Specific Torque Chart

Thread-Locking Torque to: (use Dry value for pre-applied

Component Sub-Component(s) Compound thread-locking compound)
P/N 1013829 Lubricated Dry
mounting bolts Yes 8 ft. lb. (10.8 Nm) 11 ft. lb. (14.9 Nm)
Power
Amplifiers 95 to 105 in. lb.
power cables
(10.7 to 11.8 Nm)
Top Nut:
40 to 50 in. lb.
(4.5 to 5.6 Nm)
power cables No N/A
Bottom Nut:
Steer Motor 50 to 60 in. lb.
(5.6 to 6.8 Nm)
mounting lock nuts 11 to 13 ft. lb.
(qty. 4) (15 to 17.5 Nm)
Steerable Wheel
mounting bolts (qty. 6)
Assembly 50 ft. lb. (67.8 Nm) N/A
Yes
brake sprocket nut
mounting bolts 21 ft. lb. (28 Nm) 28 ft. lb. (38 Nm)
Top Nut:
203 to 221 in. lb.
Traction Motors (23 to 25 Nm)
power cables No N/A
Bottom Nut:
128 to 132 in. lb.
(14.5 to 15 Nm)
pinion gear nut (drive end) Yes 45 ft. lb. (63 Nm) N/A

Publication: 1193671C, Revised: 15 Aug 2022 A-5

Section A. Appendix Models 4150/4250 Maintenance Manual

Torque Chart - Hydraulic Fittings

Torque Chart - Hydraulic Fittings

JIC SAE Straight Thread Steel Plugs
SAE
Thread (37° Flare Thread)
Dash Hollow Hex Head Plug HP50N Hex Head Plug P50N
Size
Size
ft. lb. Nm ft. lb. Nm ft. lb. Nm

-2 5/16-24 3 ±1 4 ±1 3 ±0.5 4 ±0.6 7.5 ±0.5 10 ±0.6

-3 3/8-24 6 ±1 8 ±1 5 ±0.5 7 ±0.6 14 ±1 19 ±1

-4 7/16-20 12 ±1 16 ±1 11 ±1 15 ±1 18 ±1 24 ±1

-5 1/2-20 15 ±1 20 ±1 15 ±1 20 ±1 22 ±1 30 ±1

-6 9/16-18 21 ±1 28 ±1 18 ±1 24 ±1 27 ±2 37 ±3

-8 3/4-16 45 ±2 61 ±3 46 ±2 62 ±3 48 ±2 65 ±3

-10 7/8-14 60 ±5 81 ±7 75 ±5 102 ±7 90 ±5 122 ±7

-12 1 1/16-12 85 ±5 115 ±7 85 ±5 115 ±7 110 ±5 149 ±7

-14 1 3/16-12 105 ±5 142 ±7 130 ±6 176 ±8 145 ±6 197 ±8

-16 1 5/16-12 120 ±5 163 ±7 135 ±6 183 ±8 160 ±6 217 ±8

-20 1 5/8-12 170 ±10 230 ±14 225 ±12 305 ±16 225 ±12 305 ±16

-24 1 7/8-12 200 ±15 271 ±20 250 ±12 339 ±16 250 ±12 339 ±16

-32 2 1/2-12 270 ±20 366 ±27 325 ±15 441 ±20 325 ±15 441 ±20

A-6 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section A. Appendix

Torque Chart - Straight Thread Face Seal O-Rings

Torque Chart - Straight Thread Face Seal O-Rings

SAE Dash Tube Size
ft. lb. Nm
Size Thread Size

-4 9/16-18 18 ±1 24 ±1

-6 11/16-18 27 ±2 37 ±3

-8 13/16-16 40 ±2 54 ±3

-10 1-14 63 ±3 85 ±4

-12 1 3/16-12 90 ±4 122 ±5

-14 1 5/16-32 95 ±6 129 ±8

-16 1 7/16-12 120 ±8 163 ±11

-20 1 11/16-12 140 ±8 190 ±11

-24 2-12 165 ±8 224 ±11

-32 2 1/2-12 360 ±10 488 ±14

Publication: 1193671C, Revised: 15 Aug 2022 A-7

Section A. Appendix Models 4150/4250 Maintenance Manual

Torque Chart - Standard (Ferrous)

Torque Chart - Standard (Ferrous)

Grade
None
Marking

SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 7 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque Tightening Torque
Size
Dry** Oiled* Dry** Oiled* Dry** Oiled* Dry** Oiled*
in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm
4-40 5 0.56 4 0.45 8 0.9 6 0.68 11 1.5 8 0.9 12 1.4 9 1.0
4-48 6 0.68 5 0.56 9 1.0 7 0.8 12 1.4 9 1.0 13 1.5 10 1.1
6-32 10 1.1 8 0.9 16 1.8 12 1.4 20 2.2 15 1.7 23 2.6 17 1.9
6-40 12 1.4 9 1.0 18 2.0 13 1.5 22 2.5 17 1.9 25 2.8 19 2.1
8-32 19 2.1 14 1.6 29 3.3 22 2.5 36 4.1 27 3.0 41 4.6 31 3.5
8-36 20 2.2 15 1.7 31 3.5 23 2.6 38 4.3 29 3.3 44 5.0 33 3.7
10-24 27 3.0 21 2.4 42 4.8 32 3.6 52 5.9 39 4.4 60 6.8 45 5.1
10-32 31 3.5 24 2.7 48 5.4 36 4.1 60 6.8 45 5.1 68 7.7 51 5.8
1/4-20 66 7.5 49 5.5 100 11.3 76 8.6 125 14.1 94 10.6 143 16.2 107 12.1
1/4-28 75 8.5 56 6.3 120 13.6 87 9.8 143 16.2 107 12.1 164 18.5 123 13.9
ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm
5/16-18 11 15.1 8 10.9 17 23.0 13 18 21 29 16 22 25 34 18 24
5/16-24 12 16.3 9 12.2 19 26 14 19 24 33 18 24 25 34 20 27
3/8-16 20 27 15 20 30 41 23 31 40 54 30 41 45 61 35 47
3/8-24 23 31 17 23 35 47 25 34 45 61 30 41 50 68 35 47
7/16-14 32 43 24 33 50 68 35 47 60 81 45 61 70 95 55 75
7/16-20 35 47 25 34 55 75 40 54 70 95 50 68 80 109 60 81
1/2-13 50 68 35 47 75 102 55 75 95 129 70 95 110 150 80 109
1/2-20 55 75 40 54 85 115 65 88 105 143 80 109 120 163 90 122
9/16-12 70 95 50 68 110 150 80 109 135 183 100 136 150 203 110 150
9/16-18 80 109 60 81 120 163 90 122 150 203 110 150 170 231 130 177
5/8-11 95 129 70 95 150 203 110 150 190 258 140 190 220 298 170 231
5/8-18 110 150 85 115 170 231 130 177 210 285 160 217 240 326 180 244
3/4-10 170 231 130 177 260 353 200 272 330 448 240 326 380 515 280 381
3/4-16 190 258 140 190 300 407 220 298 370 502 280 381 420 569 320 434
7/8-9 170 231 125 169 430 583 320 434 530 719 400 544 600 813 460 624
7/8-14 185 252 140 190 470 637 350 475 580 786 440 598 660 895 500 680
1-8 250 339 190 258 650 881 480 651 800 1085 600 813 900 1224 680 925
1-12 275 373 205 278 700 949 520 705 860 1166 660 895 1000 1360 740 1003
1 1/8-7 350 475 270 366 800 1085 600 813 1120 1519 840 1139 1280 1136 960 1302
1 1/8-12 400 544 300 407 880 1193 660 895 1260 1708 940 1274 1440 1952 1080 1464
1 1/4-7 500 680 375 509 1120 1523 840 1139 1580 2142 1200 1627 1820 2468 1360 1884
1 1/4-12 550 746 420 569 1240 1681 920 1247 1760 2386 1320 1790 2000 2720 1500 2034
1 3/8-6 650 881 490 664 1460 1980 1100 1491 2080 2820 1560 2115 2380 3227 1780 2413
1 3/8-12 750 1017 560 759 1680 2278 1260 1708 2380 3227 1780 2413 2720 3688 2040 2766
1 1/2-6 870 1180 650 881 1940 2630 1460 1980 2780 3769 2080 2820 3160 4298 2360 3200
1 1/2-12 980 1329 730 990 2200 2983 1640 2224 3100 4203 2340 3173 3560 4857 2660 3606
NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.
NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

A-8 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section A. Appendix

Torque Chart - Metric (Ferrous)

Torque Chart - Metric (Ferrous)

Ferrous Metric Bolts, Coarse Thread
(The grade rating is stamped on the head of the bolt.)
Grade 4.8 Grade 8.8 Grade 10.9 Grade 12.9
Size Dry** Oiled* Dry** Oiled* Dry** Oiled* Dry** Oiled*
in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm

M1.6-0.35 0.8 0.09 0.6 0.07 1.6 0.18 1.2 0.14 2.2 0.25 1.7 0.19 2.6 0.30 2.0 0.22
M2-0.40 1.7 0.19 1.3 0.14 3.3 0.37 2.5 0.28 4.6 0.52 3.4 0.39 5.3 0.60 4.0 0.45
M2.5-0.45 3.5 0.40 2.6 0.30 6.7 0.76 5.1 0.57 9.3 1.1 7.0 0.79 11 1.2 8.2 0.93
M3-0.5 6.2 0.70 4.7 0.53 12 1.4 9 1.0 17 1.9 12 1.4 19 2.2 15 1.7
M3.5-0.6 9.8 1.1 7.3 0.83 19 2.1 14 1.6 26 3.0 20 2.2 31 3.5 23 2.6
M4-0.7 14 1.6 11 1.5 28 3.2 21 2.4 39 4.4 29 3.3 45 5.1 34 3.8
M5-0.8 29 3.3 22 2.5 57 6.4 42 4.8 78 8.9 59 6.6 91 10.4 69 7.8
ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm

M6-1 – – – – 8 10.9 6 8.2 11 15.1 8 11.3 13 17.6 10 13.2

M8-1.25 – – – – 19 26 15 20 27 37 20 27 31 43 24 32
M8-1 – – – – 21 29 16 22 29 39 22 30 34 46 25 34
M10-1.5 – – – – 38 52 29 39 53 72 40 54 62 85 47 63
M10-1.25 – – – – 41 56 30 41 56 76 42 57 66 90 49 67
M12-1.75 – – – – 65 88 50 68 90 122 70 95 110 150 80 109
M12-1.25 – – – – 75 102 55 75 100 136 75 102 120 163 90 122
M14-2 – – – – 105 143 80 109 150 204 110 150 175 238 130 177
M14-1.5 – – – – 115 156 85 116 160 218 120 163 190 258 140 190
M16-2 – – – – 165 224 125 170 230 313 170 231 270 367 200 272
M16-1.5 – – – – 175 238 130 177 245 333 185 252 280 381 215 292
M20-2.5 – – – – 325 442 240 326 450 612 340 462 520 707 400 544
M20-1.5 – – – – 360 490 270 367 500 680 375 510 580 789 440 598
M24-3 – – – – 560 762 420 571 780 1061 580 789 900 1224 680 925
M24-2 – – – – 610 830 460 626 850 1156 640 870 1000 1360 740 1006
M30-3.5 – – – – 1120 1523 840 1142 1550 2108 1160 1578 1800 2448 1350 1836
M30-2 – – – – 1240 1686 920 1251 1700 2312 1280 1741 2000 2720 1500 2040
M36-4 – – – – 1950 2652 1460 1986 2700 3671 2000 2720 3160 4298 2350 3196
M36-2 – – – – 2200 2992 1640 2230 3000 4080 2250 3060 3500 4760 2650 3604
NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.
NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

Publication: 1193671C, Revised: 15 Aug 2022 A-9

Section A. Appendix Models 4150/4250 Maintenance Manual

Torque Chart - Standard (Brass)

Torque Chart - Standard (Brass)

Brass MS63 Standard Bolts, Coarse Thread
Torque (with bolts oiled*)
Size
in. lb. Nm
0-80 0.5 0.05
1-64 0.9 0.10
1-72 1.0 0.11
2-56 1.5 0.17
2-64 1.6 0.18
3-48 2.3 0.26
3-56 2.5 0.28
4-40 3.3 0.37
4-48 3.6 0.40
5-40 4.8 0.54
5-44 5.3 0.60
6-32 6.1 0.69
6-40 6.8 0.77
8-32 11 1.24
8-36 11 1.24
10-24 14 1.58
10-32 17 1.92
12-24 23 2.59
12-28 25 2.82
1/4-20 35 3.96
1/4-28 40 4.52
5/16-18 73 8.25
5/16-24 81 9.15
3/8-16 130 14.69
3/8-24 147 16.61
NOTE: *Use “oiled” values for bolts with
thread-locking compound.

A-10 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section A. Appendix

Torque Chart - Metric (Brass)

Torque Chart - Metric (Brass)

Brass MS63 Metric Bolts, Coarse Thread

Diameter Torque (bolts oiled)

(in millimeters) in. lb. Nm

2 1.2 0.14

2.5 2.5 0.29

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: 1193671C, Revised: 15 Aug 2022 A-11

Section A. Appendix Models 4150/4250 Maintenance Manual

Torque Chart - Thread-Forming Screws

Torque Chart - Thread-Forming Screws

Standard Thread-Forming Screws Metric Thread-Forming Screws
Nearest Plate Torque Nearest Plate Torque
Size
Thickness (in.) in. lb. Nm Size Thickness
0.0469 4 0.5 in. (mm) in. lb. Nm
2-56 0.0625 4 0.5 0.039 (1) 9 1.0
0.0938 5 0.6 M3 x 0.5 0.079 (2) 9 1.0
0.0625 6 0.7
0.118 (3) 14 1.6
3-48 0.0938 7 0.8
0.079 (2) 16 1.8
0.1250 7 0.8
0.0312 6 0.7 M4 x 0.7 0.118 (3) 29 3.3
4-40 0.0625 9 1.0 0.157 (4) 38 4.3
0.0938 11 1.2 0.098 (2.5) 25 2.8
0.0625 12 1.4 M5 x 0.8 0.138 (3.5) 53 6.0
5-40 0.0938 18 2.0 0.197 (5) 62 7.0
0.1250 20 2.3
0.118 (3) 44 5.0
0.0625 14 1.6
M6 x 1.0 0.177 (4.5) 89 10.0
6-32 0.0938 20 2.3
0.1250 22 2.5 0.236 (6) 89 10.0
0.0938 30 3.4 0.157 (4) 177 20.0
8-32 0.1250 45 5.1 M8 x 1.25 0.236 (6) 248 28.0
0.1875 45 5.1 0.315 (8) 266 30.0
0.0938 35 4.0
0.197 (5) 266 30.0
10-24 0.1250 45 5.1
M10 x 1.5 0.315 (8) 398 45.0
0.1875 55 6.2
0.0938 35 4.0 0.394 (10) 487 55.0
10-32 0.1250 50 5.6 0.236 (6) 531 60.0
0.1875 70 7.9 M12 x 1.75 0.354 (9) 575 65.0
0.1250 65 7.3 0.472 (12) 885 100.0
12-24 0.1875 75 8.5
0.2500 85 9.6
0.1250 85 9.6
1/4-20 0.1875 125 14.1
0.2500 125 14.1
0.1875 160 18.1
5/16-18 0.2500 225 25.4
0.3125 250 28.2
0.2500 350 39.5
3/8-16 0.3125 400 45.2
0.3750 450 50.8
0.3125 500 56.5
7/16-14 0.3750 600 67.8
0.5000 700 79.1
0.2500 500 56.5
1/2-13 0.3750 850 96.0
0.5000 1000 113.0

A-12 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section A. Appendix

Decimal Equivalent Chart

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 .397
1/32 .031 .03 .794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272

Publication: 1193671C, Revised: 15 Aug 2022 A-13

Section A. Appendix Models 4150/4250 Maintenance Manual

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400

A-14 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section A. Appendix

Standard/Metric Conversions

Standard/Metric Conversions
To Convert... Multiply, Add, or Subtract...
Area
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Distance
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Mass
Ounces to Grams Ounces x 28.35
Grams to Ounces Ounces x 0.035
Ounces to Kilograms Ounces x 0.028
Kilograms to Ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to Pounds Kilograms x 2.2
Pressure
Pounds per Square Inch (PSI) to kiloPascals PSI x 6.894
kiloPascals to Pounds per Square Inch (PSI) kiloPascals x 0.145
Speed
Miles per hour to Kilometers per hour Miles per hour x 1.609
Kilometers per hour to Miles per hour Kilometers per hour x 0.6214
Temperature
Fahrenheit to Celsius (°F minus 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) plus 32
Torque
Inch Pounds (in. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lb.) Newton Meters x 0.737
Volume
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26

Publication: 1193671C, Revised: 15 Aug 2022 A-15

Section A. Appendix Models 4150/4250 Maintenance Manual

Standard/Metric Conversions

A-16 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section I. Index

Section I. Index
Numerics Testing . . . . . . . . . . . . . . . . . . . . . 7-74
Attachment
2-Stage Mast Clamp . . . . . . . . . . . . . . . . . . . . . . 3-18
Disassembly . . . . . . . . . . . . . . . .7-109 Clamp (With Variable Pressure) . . . 3-18
Free Lift Cylinder High-Flow (One-Speed Operation) . 3-17
Installation . . . . . . . . 7-113, 7-114 Setup and Operation . . . . . . . . . . . 3-16
Removal . . . . . . . . . . . 7-113, 7-114 Unclamp . . . . . . . . . . . . . . . . . . . . 3-18
Inspection . . . . . . . . . . . . . . . . . .7-110 Attachment Control . . . . . . . . . . . . . . 3-16
Main Lift Cylinder Attachment Solenoids (SOL7C/R) . . . . . 8-5
Installation . . . . . . . . . . . . . .7-112 Aux Prop Valve SOL5 . . . . . . . . . . . . . 7-78
Removal . . . . . . . . . . . . . . . . .7-112 Aux Select (SOL6) . . . . . . . . . . . . . . . . . 8-5
Reassembly . . . . . . . . . . . . . . . . .7-110 Auxiliary Functions, Additional . . . . . . 3-17
Reeving . . . . . . . . . . . . . . . . . . . .7-115
3-Stage Mast below S/N 50501 B
Disassembly . . . . . . . . . . . . . . . .7-116
Free Lift Cylinder Battery
Installation . . . . . . . . 7-120, 7-121 Cables . . . . . . . . . . . . . . . . . . . . . 7-52
Removal . . . . . . . . . . . 7-120, 7-121 Charging . . . . . . . . . . . . . . . . . . . . 7-53
Inspection . . . . . . . . . . . . . . . . . .7-116 Cleaning Exterior . . . . . . . . . . . . . 7-53
Main Lift Cylinder Maintenance . . . . . . . . . . . . . . . . . 7-53
Installation . . . . . . . . . . . . . .7-120 Safety . . . . . . . . . . . . . . . . . . . . . . . 2-5
Removal . . . . . . . . . . . . . . . . .7-120 State-of-Charge (BSOC) . . . . . 5-4, 7-53
Reassembly . . . . . . . . . . . . . . . . .7-118 Testing . . . . . . . . . . . . . . . . . . . . . 7-53
Reeving . . . . . . . . . . . . . . . . . . . .7-122 Battery Specifications . . . . . . . . . . . . . . 3-4
3-Stage Mast S/N 50501 Up Bleeding Hydraulic System . . . . . . . . . 7-82
Disassembly . . . . . . . . . . . . . . . .7-124 Brakes . . . . . . . . . . . . . . . . . . 7-46 to 7-50
Free Lift Cylinder P/N 1043541
Installation . . . . . . . . 7-128, 7-129 Assembly . . . . . . . . . . . . . . . . 7-47
Removal . . . . . . . . . . . 7-128, 7-129 Disassembly . . . . . . . . . . . . . . 7-46
Inspection . . . . . . . . . . . . . . . . . .7-124 Inspection . . . . . . . . . . . . . . . . 7-46
Main Lift Cylinder Installation . . . . . . . . . . . . . . . 7-47
Installation . . . . . . . . . . . . . .7-127 Removal . . . . . . . . . . . . . . . . . 7-46
Removal . . . . . . . . . . . . . . . . .7-127 P/N 1094113
Reassembly . . . . . . . . . . . . . . . . .7-124 Coil Replacement . . . . . . . . . . 7-48
Reeving . . . . . . . . . . . . . . . . . . . .7-130 Inspection . . . . . . . . . . . . . . . . 7-47
Installation . . . . . . . . . . . . . . . 7-49
A Pad Replacement . . . . . . . . . . . 7-48
Removal . . . . . . . . . . . . . . . . . 7-47
AC Motors . . . . . . . . . . . . . . . . . . . . . 5-18 P/N 1252130
Additional Auxiliary Functions . . . . . 3-17 Air Gap and Adjustment . . . . . 7-50
Adjustment Brake Release Bolts . . . . . . . . . 7-50
Mast Tilt . . . . . . . . . . . . . . . . . . .7-144 Installation . . . . . . . . . . . . . . . 7-49
System Pressure . . . . . . . . . . . . . 7-83 Removal . . . . . . . . . . . . . . . . . 7-49
AMP Connectors . . . . . . . . . . . . . . . . 7-69 Brushes . . . . . . . . . . . . . . . . . . . . . . . 7-56
AMP Harness Brushes, Motor . . . . . . . . . . . . 7-56 to 7-59
Assembly . . . . . . . . . . . . . . . . . . . 7-72 BSOC
Connector Components . . . . . . . . 7-72 (Battery State-of-Charge) . . . . 5-4, 7-53
Contact Insertion . . . . . . . . . . . . . 7-72 Setting BSOC Cutout . . . . . . . . . . . 5-5
Disassembly . . . . . . . . . . . . . . . . 7-72

Publication: 1193671C, Revised: 15 Aug 2022 I-1

Section I. Index Models 4150/4250 Maintenance Manual

C Conditioning . . . . . . . . . . . . . . . . . 7-75
ComfortStance Floor . . . . . . . . . . . . . 7-23
Cable, Terminology . . . . . . . . . . . . . . . .5-7 Communication Error Code
Cables, Power . . . . . . . . . . . . . . . . . . . 7-54 Troubleshooting . . . . . . . . . . . . . . 5-19
CAN Bus Commutator
Test . . . . . . . . . . . . . . . . . . . . . . . . 6-86 Polishing . . . . . . . . . . . . . . . . . . . 7-58
Theory of Ops . . . . . . . . . . . . . . . . .8-3 Component Locator Photos . . . . . . . . . . 7-5
Card Configure Mode . . . . . . . . . . . . . . . . . 3-11
Fuse/Relay . . . . . . . . . . . . . . . . . . 5-11 Configure Mode Menu . . . . . . . . . . . . 3-11
Vehicle Manager . . . . . . . . . . . . . . 5-10 Connectors
Cascade Carriage AMP . . . . . . . . . . . . . . . . . . . . . . . 7-69
Service Battery . . . . . . . . . . . . . . . . . . . . . 7-52
Disassembly . . . . . . . . . . . . . . 7-90 Circuit Card . . . . . . . . . . . . . . . . . 5-10
Inspection . . . . . . . . . . . . . . . . 7-91 Fuse/Relay Card . . . . . . . . . . . . . 5-11
Reassembly . . . . . . . . . . . . . . . 7-92 General . . . . . . . . . . . . . . . . . . . . 7-67
Caster, Steer Molex . . . . . . . . . . . . . . . . . . . . . . 7-68
Disassembly . . . . . . . . . . . . . . . . . 7-22 Power Amp . . . . . . . . . . . . . . . . . . 7-72
Installation . . . . . . . . . . . . . . . . . . 7-21 Repair . . . . . . . . . . . . . . . . . . . . . 7-67
Reassembly . . . . . . . . . . . . . . . . . . 7-22 Vehicle Manager . . . . . . . . . . . . . . 5-10
Removal . . . . . . . . . . . . . . . . . . . . 7-18 Contactors . . . . . . . . . . . . . . . . . . . . . 4-10
Service . . . . . . . . . . . . . . . . . . . . . 7-22 LPC . . . . . . . . . . . . . . . . . . . . . . . . 8-4
CB1 - CB2 Counterbalanced STR . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Check Valve . . . . . . . . . . . . . . . . . 7-78 Tests
Chain LPC . . . . . . . . . . . . . . . . . . . 6-100
Inspection . . . . . . . . . . . . . . . . . . . 4-11 Steer . . . . . . . . . . . . . . . . . . . . 6-99
Main Lift . . . . . . . . . . . . . . . . . . . 7-101 TPC . . . . . . . . . . . . . . . . . . . . 6-98
Maintenance . . . . . . . . . . . . . . . . . 4-11 TPC . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Service . . . . . . . . . . . . . . . . . . . . . 4-11 Control Handle
Storage Preparation . . . . . . . . . . . . 3-22 Optional . . . . . . . . . . . . . . . . . . . . 7-28
Charts, Torque Soldering Procedures . . . . . . . . . . 7-26
Component Specific . . . . . . . . . . . . .A-4 Standard . . . . . . . . . . . . . . . . . . . 7-25
Face Seal O-Rings . . . . . . . . . . . . . .A-7 Conversion
Ferrous, Metric . . . . . . . . . . . . . . . .A-9 Decimal to Fraction . . . . . . . . . . . A-13
Ferrous, Standard . . . . . . . . . . . . . .A-8 Fraction to Decimal . . . . . . . . . . . A-13
Hydraulic Fittings . . . . . . . . . . . . . .A-6 Standard/Metric . . . . . . . . . . . . . . A-15
Metric, Brass . . . . . . . . . . . . . . . . .A-11 Counterbalance Check Valves
Standard, Brass . . . . . . . . . . . . . .A-10 (CB-1, CB-2) . . . . . . . . . . . . . . . . . . 8-5
Thread-Forming Screws . . . . . . . .A-12 Customer Output
Check Valve (CB1 - CB2) . . . . . . . . . . . 7-78 Test O47 . . . . . . . . . . . . . . . . . . 6-120
Check Valve (CV1) . . . . . . . . . . . . 7-78, 8-5 CV1 Check Valve . . . . . . . . . . . . . . . . 7-78
Checking Hydraulic Oil Level, Cylinder
see Oil . . . . . . . . . . . . . . . . . . . . . . 7-82 Free Lift
Circuit Card Connectors . . . . . . . . . . . 5-10 2-Stage Mast
Fuse/Relay Card . . . . . . . . . . . . . . 5-11 Installation . . . . . .7-113, 7-114
Vehicle Manager . . . . . . . . . . . . . . 5-10 Removal . . . . . . . .7-113, 7-114
Clamp Attachment . . . . . . . . . . . . . . . 3-18 3-Stage Mast below S/N 50501
Clamp Attachment Installation . . . . . .7-120, 7-121
(With Variable Pressure) . . . . . . . . 3-18 Removal . . . . . . . .7-120, 7-121
Cleaning 3-Stage Mast S/N 50501 Up
Lift Truck . . . . . . . . . . . . . . . . . . . .2-4 Installation . . . . . .7-128, 7-129
Codes . . . . . . . . . . . . . . . . . . . 6-12 to 6-32 Removal . . . . . . . .7-128, 7-129
Cold Storage . . . . . . . . . . . . . . . . . . . . 7-75

I-2 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section I. Index

Quad Mast E
Installation . . . . . . . . . . . .7-139
Removal . . . . . . . . . . . . . .7-138 Electrical
Main Lift Symptoms . . . . . . . . . . . . . . . . . . 5-30
2-Stage Mast Electrical Symptoms
Installation . . . . . . . . . . . .7-112 Troubleshooting . . . . . . . . . . . . . . 5-30
Removal . . . . . . . . . . . . . .7-112 Electrical Troubleshooting
3-Stage Mast below S/N 50501 Symptoms . . . . . . . . . . . . . . . . . . 5-30
Installation . . . . . . . . . . . .7-120 Electrostatic Discharge
Removal . . . . . . . . . . . . . .7-120 See Static Precautions
3-Stage Mast S/N 50501 Up ESD Ground Jack . . . . . . . . . . . . . . . . 2-8
Installation . . . . . . . . . . . .7-127
Removal . . . . . . . . . . . . . .7-127 F
Quad Mast
Installation . . . . . . . . . . . .7-138 Filter Plug, Hydraulic . . . . . . . . . . . . . 7-78
Removal . . . . . . . . . . . . . .7-138 FlashWare
Service (except TT Mast Program . . . . . . . . . . . . . . . . . . . . . 3-6
S/N 50501 Up) . . . . . . . . . . . 7-94 Starting . . . . . . . . . . . . . . . . . . . . . 3-6
Service (TT Mast Floor, ComfortStance . . . . . . . . . . . . . 7-23
S/N 50501 Up) . . . . . . . . . . . 7-94 Fluid Capacities . . . . . . . . . . . . . . . . . . 3-4
Sideshift Fluids
Seal Replacement (Cascade) . . 7-88 Bleeding Hydraulic System . . . . . . 7-82
Seal Replacement (Lift-Tek) . . 7-85 Fluids, see Oil . . . . . . . . . . . . . . . . . . 7-82
Storage Preparation . . . . . . . . . . . 3-22 Fork
Inspection . . . . . . . . . . . . . . . . . . . 4-12
D Positioner
Removal/Replacement
DC Motor (Cascade Carriage) . . . . . . . 7-88
Brushes . . . . . . . . . . . . . . . . . . . . 7-56 Fraction to Decimal Conversion . . . . . A-13
Troubleshooting . . . . . . . . . . . . . . 5-14 Free Lift
DC Motor Test . . . . . . . . . . . . . . . . . . 5-17 Chain
Deadman Pedal Adjustment . . . . . . . 7-66 Adjustment . . . . . . . . . . . . . . 7-104
Decals and Plates . . . . . . . . . . . . . . . 7-13 Service . . . . . . . . . . . . . . . . . 7-105
Decimal to Fraction Conversion . . . . . A-13 Free Lift Cylinder
Default Passwords, see Passwords . . . . 3-9 2-Stage Mast
Display Messages . . . . . . . . . . . . . . . . 3-8 Installation . . . . . . . . 7-113, 7-114
Drive Motor, see Motors . . . . . . . . . . . 7-62 Removal . . . . . . . . . . 7-113, 7-114
Drive Tire Pressing . . . . . . . . . . . . . . 7-45 3-Stage Mast below S/N 50501
Drive Unit Installation . . . . . . . . 7-120, 7-121
Adding Oil . . . . . . . . . . . . . . . . . . 7-35 Removal . . . . . . . . . . 7-120, 7-121
Assembly Procedures . . . . . . . . . . 7-40 3-Stage Mast S/N 50501 Up
Axle Shaft Assembly . . . . . . . . . . 7-43 Installation . . . . . . . . 7-128, 7-129
Bearing Installation Removal . . . . . . . . . . 7-128, 7-129
Shim Calculation . . . . . . . . . . 7-40 Quad Mast
Bearing Removal . . . . . . . . . . . . . 7-38 Installation . . . . . . . . . . . . . . 7-139
Disassembly Procedure . . . . . . . . 7-37 Removal . . . . . . . . . . . . . . . . 7-138
Exploded View . . . . . . . . . . . . . . . 7-36 Fuse/Relay Card
Housing Disassembly Theory of Ops . . . . . . . . . . . . . . . . . 8-4
Helical Gear . . . . . . . . . . . . . . 7-38 Troubleshooting . . . . . . . . . . . . . . 5-12
Spiral Gear . . . . . . . . . . . . . . 7-38 Fuse/Relay Card Connectors . . . . . . . 5-11
Drive Units . . . . . . . . . . . . . . . . . . . . 7-34 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Dump Valve (SOL3) . . . . . . . . . . . . . . . 8-5

Publication: 1193671C, Revised: 15 Aug 2022 I-3

Section I. Index Models 4150/4250 Maintenance Manual

G Power Amplifier, Theory of Ops . . . . 8-3

Lift Chain
Ground Jack, ESD . . . . . . . . . . . . . . . .2-8 Free Lift
Adjustment . . . . . . . . . . . . . . 7-104
H Service . . . . . . . . . . . . . . . . . 7-105
Main Lift
Harness Adjustment . . . . . . . . . . . . . . 7-101
Connectors . . . . . . . . . . . . . . . . . . 7-67 Service . . . . . . . . . . . . . . . . . 7-102
Soldering Procedures . . . . . . . . . . . 7-67 Lift/Aux Pump (P1) . . . . . . . . . . . . . . . 8-4
Terminology . . . . . . . . . . . . . . . . . .5-7 Lift/Lower
High-Flow Attachment . . . . . . . . . . . . 3-17 Potentiometer . . . . . . . . . . . . . . . . 7-28
Horn Theory of Ops . . . . . . . . . . . 8-9 to 8-11
Test . . . . . . . . . . . . . . . . . . . . . . . 6-107 Valve (SOL2) . . . . . . . . . . . . . . . . . . 8-5
Hydraulic Lights
Components . . . . . . . . . . . . . . . . . 7-78 Steering Indicator . . . . . . . . . . . . . . 3-8
Filter . . . . . . . . . . . . . . . . . . . . . . . .8-5 Load Holding Valve (SOL1) . . . . . .7-78, 8-5
Filter Plug . . . . . . . . . . . . . . . . . . . 7-78 Locator Photos, Components . . . . . . . . 7-5
Fluid Capacity . . . . . . . . . . . . . . . . .3-4 Loctite®
Fluid, see Oil . . . . . . . . . . . . . . . . . 7-82 See Thread Adhesives
Oil, Selecting, see Oil . . . . . . . . . . . 7-82 LPC Contactor . . . . . . . . . . . . . . . . . . . 8-4
System Theory of Ops . . . . . . . . . . . . . . . . . 8-4
Storage Preparation . . . . . . . . . 3-22 Lubrication Specification Chart . . . . . . A-2
Hydraulic Fluid Level . . . . . . . . . . . . . 7-82
M
I
Main Lift
IETM . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Chain
Inspection Adjustment . . . . . . . . . . . . . . 7-101
Battery Connector . . . . . .. . . . . . . 7-52 Service . . . . . . . . . . . . . . . . . 7-102
Contactors . . . . . . . . . . .. . . . . . . 4-10 Main Lift Cylinder
Control Handle . . . . . . . .. . . . . . . 7-26 2-Stage Mast
Forks . . . . . . . . . . . . . . .. . . . . . . 4-12 Installation . . . . . . . . . . . . . . 7-112
Fuses . . . . . . . . . . . . . . .. . . . . . . .5-6 Removal . . . . . . . . . . . . . . . . 7-112
Motor Brushes . . . . . . . .. . . . . . . 7-56 3-Stage Mast below S/N 50501
Quad Mast Check Valve .. . . . . . 7-138 Installation . . . . . . . . . . . . . . 7-120
Wiring/Harness . . . . . . .. . . . . . . 7-67 Removal . . . . . . . . . . . . . . . . 7-120
Installation, Truck . . . . . . . .. . . . . . . .3-5 3-Stage Mast S/N 50501 Up
Interactive Electronic Installation . . . . . . . . . . . . . . 7-127
Technical Manuals . . . . . . . . . . . . .1-3 Removal . . . . . . . . . . . . . . . . 7-127
Quad Mast
Installation . . . . . . . . . . . . . . 7-138
L
Removal . . . . . . . . . . . . . . . . 7-138
Maintenance
L/L Pot Test . . . . . . . . . . . . . . . . . . . . 6-35
180 Day/500 HD . . . . . . . . . . . . . . 4-6
Lift
360 Days/2000 HD . . . . . . . . . . . . 4-9
Chain
90 Days/250 HD . . . . . . . . . . . . . . 4-5
Maintenance . . . . . . . . . . . . . . 4-11
Maintenance Minder . . . . . . . . . . . . . . 4-3
Storage Preparation . . . . . . . . . 3-22
Disabling . . . . . . . . . . . . . . . . . . . . 4-4
Cylinder
Enabling . . . . . . . . . . . . . . . . . . . . . 4-3
Service (TT Mast
Maintenance Mode . . . . . . . . . . . . . . . 3-20
S/N 50501 Up) . . . . . . . . . 7-94
Maintenance Mode Menu . . . . . . . . . . 3-20
Motor, see Motors . . . . . . . . . . . . . 7-64
Maintenance, Scheduled . . . . . 4-2 to 4-14
Power Amplifier . . . . . . . . . . . . . . . 7-65

I-4 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section I. Index

Mast . . . . . . . . . . . . . . . . . . . . . . . . . 7-97 Removal

2-Stage Complete . . . . . . . . . . . . . . . . . 7-99
Disassembly . . . . . . . . . . . . .7-109 Partial . . . . . . . . . . . . . . . . . . . 7-98
Free Lift Cylinder Roller Bearing (Puck)
Installation . . . . . . . . . . . .7-113 Adjustment . . . . . . . . . . . . . . 7-106
Removal . . . . . . . . . . . . . .7-113 Skewing . . . . . . . . . . . . . . . . . . . 7-107
Inspection . . . . . . . . . . . . . . .7-110 Tilt Adjustment . . . . . . . . . . . . . . 7-144
Main Lift Cylinder Types . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installation . . . . . . . . . . . .7-112 Memory Location . . . . . . . . . . . . . . . . . 8-2
Removal . . . . . . . . . . . . . .7-112 Menu
Reassembly . . . . . . . . . . . . . .7-110 Configure Mode . . . . . . . . . . . . . . . 3-11
Reeving . . . . . . . . . . . . . . . . .7-115 Maintenance Mode . . . . . . . . . . . . 3-20
3-Stage below S/N 50501 Messages . . . . . . . . . . . . . . . . . 6-7 to 6-11
Disassembly . . . . . . . . . . . . .7-116 Model Designation . . . . . . . . . . . . . . . . 3-4
Free Lift Cylinder Modes of Operation . . . . . . . . . . . . . . 3-11
Installation . . . . . . . . . . . .7-120 Configure . . . . . . . . . . . . . . . . . . . 3-11
Removal . . . . . . . . . . . . . .7-120 Maintenance . . . . . . . . . . . . . . . . . 3-20
Inspection . . . . . . . . . . . . . . .7-116 Run . . . . . . . . . . . . . . . . . . . . . . . 3-11
Main Lift Cylinder See also Passwords . . . . . . . . . . . . 3-11
Installation . . . . . . . . . . . .7-120 Motors
Removal . . . . . . . . . . . . . .7-120 AC . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Reassembly . . . . . . . . . . . . . .7-118 Bearing Encoder . . . . . . . . . . . 7-60
3-Stage S/N 50501 Up Open Winding . . . . . . . . . . . . . 5-18
Disassembly . . . . . . . . . . . . .7-124 Service . . . . . . . . . . . . . . . . . . 7-59
Free Lift Cylinder Shorted Winding . . . . . . . . . . . 5-18
Installation . . . . . . 7-128, 7-129 Temperature Sensor . . . . . . . . 7-59
Removal . . . . . . . . 7-128, 7-129 Brush Spring Tension . . . . . . . . . . 7-58
Inspection . . . . . . . . . . . . . . .7-124 Brushes . . . . . . . . . . . . . . 7-56 to 7-59
Main Lift Cylinder DC . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Installation . . . . . . . . . . . .7-127 armature . . . . . . . . . . . . . . . . . 5-17
Removal . . . . . . . . . . . . . .7-127 Field Winding Test . . . . . . . . . . 5-17
Reassembly . . . . . . . . . . . . . .7-124 Grounded Motor Test . . . . . . . 5-17
Reeving . . . . . . . . . . . . . . . . .7-130 Open Circuit Test . . . . . . . . . . 5-17
Installation Short Circuited Armature . . . . 5-17
After Complete Removal . . . . .7-100 Short-Circuited Armature . . . . 5-17
After Partial Removal . . . . . . . 7-98 Lift . . . . . . . . . . . . . . . . . . . . . . . . 7-64
Quad Power Cable Terminals . . . . . . . . . 7-56
Check Valve . . . . . . . . . . . . . .7-138 Steer . . . . . . . . . . . . . . . . . . . . . . . 7-18
Disassembly . . . . . . . . . . . . .7-132 Storage Preparation . . . . . . . . . . . 3-22
Flow Control Valve Traction . . . . . . . . . . . . . . . . . . . . 7-62
Replacement . . . . . . . . . .7-143 Troubleshooting
Free Lift Cylinder AC . . . . . . . . . . . . . . . . . . . . . . 5-18
Installation . . . . . . . . . . . .7-139 DC . . . . . . . . . . . . . . . . . . . . . 5-14
Removal . . . . . . . . . . . . . .7-138
Inspection . . . . . . . . . . . . . . .7-133 O
Main Lift Cylinder
Installation . . . . . . . . . . . .7-138 Oil
Removal . . . . . . . . . . . . . .7-138 Hydraulic
Reassembly . . . . . . . . . . . . . .7-134 Selecting . . . . . . . . . . . . . . . . . 7-82
Reeving . . . . . . . . . . . . . . . . .7-139 Hydraulic, Checking Level . . . . . . . 7-82
Quantities . . . . . . . . . . . . . . . . . . . . 3-4
Open Circuit DC Motor Test . . . . . . . . 5-17

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Section I. Index Models 4150/4250 Maintenance Manual

Open Winding AC Motor . . . . . . . . . . . 5-18 Free Lift Cylinder

Operator Display . . . . . . . . . . . . . . . . . .3-8 Installation . . . . . . . . . . . . . . 7-139
Steering Indicator Lights . . . . . . . . .3-8 Removal . . . . . . . . . . . . . . . . 7-138
Operator Display Card Inspection . . . . . . . . . . . . . . . . . 7-133
Theory of Ops . . . . . . . . . . . . . . . . .8-4 Reassembly . . . . . . . . . . . . . . . . 7-134
Reeving . . . . . . . . . . . . . . . . . . . 7-139
P
R
Passwords . . . . . . . . . . . . . . . . . . . . . .3-9
Changing a Password . . . . . . . . . . 3-10 Raymond Service Information . . . . . . . . . iv
Config Mode . . . . . . . . . . . . . . . . . .3-9 Reeving
Default . . . . . . . . . . . . . . . . . . . . . .3-9 2-Stage Mast . . . . . . . . . . . . . . . 7-115
Entering a Password . . . . . . . . . . . .3-9 3-Stage Mast below S/N 50501 . . 7-122
Maintenance Mode . . . . . . . . . . . . .3-9 3-Stage Mast S/N 50501 Up . . . . 7-130
Pin Extraction Quad Mast . . . . . . . . . . . . . . . . . 7-139
AMP Connectors . . . . . . . . . . . . . . 7-69 Roller Bearing Adjustment . . . . . . . . 7-106
Molex Connectors . . . . . . . . . . . . . 7-68 Run Mode . . . . . . . . . . . . . . . . . . . . . 3-11
Pin Insertion
AMP Connectors . . . . . . . . . . . . . . 7-70 S
Molex Connectors . . . . . . . . . . . . . 7-68
Pinout Matrix . . . . . . . . . . . . . 8-13 to 8-26 Safety
Potentiometer Battery . . . . . . . . . . . . . . . . . . . . . . 2-5
Lift/Lower (VR2) . . . . . . . . . . . . . . 7-28 Decals . . . . . . . . . . . . . . . . . . . . . 7-13
Travel (VR1) . . . . . . . . . . . . . . . . . 7-30 Definitions . . . . . . . . . . . . . . . . . . . 2-2
Power Amplifier ESD . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Connectors . . . . . . . . . . . . . . . . . . 7-72 General . . . . . . . . . . . . . . . . . . . . . 2-3
Discharging Internal Capacitor . . . .5-2 Static Precautions . . . . . . . . . . . . . 2-8
Replacement . . . . . . . . . . . . . . . . . 7-65 Towing . . . . . . . . . . . . . . . . . . . . . 2-11
Power Cables . . . . . . . . . . . . . . . . . . . 7-54 Welding . . . . . . . . . . . . . . . . . . . . 2-12
Power Cables, Motor . . . . . . . . . . . . . . 7-56 Scheduled Maintenance . . . . . . 4-2 to 4-14
Power Source Limit Faults 180 Day/500 HD . . . . . . . . . . . . . . 4-6
Troubleshooting . . . . . . . . . . . . . . 5-20 360 Day/2000 HD . . . . . . . . . . . . . 4-9
Pressure 90 Day/250 HD . . . . . . . . . . . . . . . 4-5
Relief Valve . . . . . . . . . . . . . . . . . . 7-83 Chains . . . . . . . . . . . . . . . . . . . . . 4-11
System, Adjustment . . . . . . . . . . . 7-83 Guidelines . . . . . . . . . . . . . . . . . . . 4-2
System, Measuring . . . . . . . . . . . . 7-83 Sealants, Specifications . . . . . . . . . . . . A-3
Priority Bypass (SOL4) . . . . . . . . . . . . .8-5 Serial Number
Prop Relief (SOL5) . . . . . . . . . . . . . . . . .8-5 Location on Specification Tag . . . . . 3-3
Proportional Lowering Valve Service (Cascade Carriage)
Adjustment . . . . . . . . . . . . . . . . . . 7-84 Disassembly . . . . . . . . . . . . . . . . . 7-90
Public Standard Interface Inspection . . . . . . . . . . . . . . . . . . 7-91
Troubleshooting . . . . . . . . . . . . . . 5-21 Reassembly . . . . . . . . . . . . . . . . . 7-92
Puck (Roller Bearing) Adjustment . . . 7-106 Service Information, Raymond . . . . . . . . iv
Shorted Winding on AC Motor . . . . . . 5-18
Q Shorts to Frame Test . . . . . . . . . . . . . . 5-2
Side Shifter
Quad Mast Inspection . . . . . . . . . . . . . . . . . . 7-85
Check Valve . . . . . . . . . . . . . . . . 7-138 Installation . . . . . . . . . . . . . . . . . . 7-87
Inspection . . . . . . . . . . . . . . . 7-138 Removal - Mast on Floor . . . . . . . . 7-85
Disassembly . . . . . . . . . . . . . . . . 7-132 Removal - Mast on Lift Truck . . . . 7-85
Flow Control Valve Sideshift Cylinder
Replacement . . . . . . . . . . . . . 7-143 Seal Replacement (Cascade) . . . . . 7-88

I-6 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section I. Index

Seal Replacement (Lift-Tek) . . . . . 7-85 Specifications, Vehicle . . . . . . . . . . . . . 3-3

Sideshift Cylinders, Theory of Ops . . . . 8-4 Standard/Metric Conversions . . . . . . . A-15
Sideshift Solenoids (SOL9L/R) . . . . . . . 8-5 Static
SOL1 Precautions . . . . . . . . . . . . . . . . . . . 2-8
Test . . . . . . . . . . . . . . . . . . . . . . .6-105 Steer Caster
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 Disassembly . . . . . . . . . . . . . . . . . 7-22
Torque Specs . . . . . . . . . . . . . . . . 7-78 Installation . . . . . . . . . . . . . . . . . . 7-21
SOL10 Reassembly . . . . . . . . . . . . . . . . . . 7-22
Test . . . . . . . . . . . . . . . . . . . . . . .6-102 Removal . . . . . . . . . . . . . . . . . . . . 7-18
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 Service . . . . . . . . . . . . . . . . . . . . . 7-22
Torque Specs . . . . . . . . . . . . . . . . 7-78 Steer Motor . . . . . . . . . . . . . . . . . . . . 7-18
SOL2 Steer Position Sensor Theory . . . . . . . . 8-4
Test . . . . . . . . . . . . . . . . . . . . . . .6-106 Steer Valve Theory . . . . . . . . . . . . . . . . 8-5
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 Steerable Wheel Assembly . . . . . . . . . 7-18
Torque Specs . . . . . . . . . . . . . . . . 7-78 Steering
SOL3 Indicator Lights . . . . . . . . . . . . . . . 3-8
Test . . . . . . . . . . . . . . . . . . . . . . .6-104 System Theory . . . . . . . . . . . . . . . . 8-8
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 Storage
Torque Specs . . . . . . . . . . . . . . . . 7-78 Hydraulic Cylinders . . . . . . . . . . . 3-22
SOL4 Hydraulic System . . . . . . . . . . . . . 3-22
Test . . . . . . . . . . . . . . . . . . . . . . .6-117 Lift Chains . . . . . . . . . . . . . . . . . . 3-22
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 Motors . . . . . . . . . . . . . . . . . . . . . 3-22
Torque Specs . . . . . . . . . . . . . . . . 7-78 Warranty Issues . . . . . . . . . . . . . . 3-22
SOL5 STR Contactor . . . . . . . . . . . . . . . . . . . 8-4
Test . . . . . . . . . . . . . . . . . . . . . . .6-118 Theory of Ops . . . . . . . . . . . . . . . . . 8-4
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 Switches
Torque Specs . . . . . . . . . . . . . . . . 7-78 Tests
SOL6 S11 . . . . . . . . . . . . . . . . . . . . . 6-79
Test . . . . . . . . . . . . . . . . . . . . . . .6-101 S12 . . . . . . . . . . . . . . . . . . . . . 6-80
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 S18 . . . . . . . . . . . . . . . . . . . . . 6-88
Torque Specs . . . . . . . . . . . . . . . . 7-78 S2 . . . . . . . . . . . . . . . . . . . . . . 6-78
SOL7C/R S21 . . . . . . . . . . . . . . . . . . . . . 6-66
Test . . . . . . . . . . . . . . . . . . . . . . .6-119 S22A . . . . . . . . . . . . . . . . . . . . 6-92
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 S22B . . . . . . . . . . . . . . . . . . . . 6-93
Torque Specs . . . . . . . . . . . . . . . . 7-78 S3 . . . . . . . . . . . . . . . . . . . . . . 6-83
SOL9L/R S6 . . . . . . . . . . . . . . . . . . . . . . 6-57
Test . . . . . . . . . . . . . . . . . . . . . . .6-103 S7 . . . . . . . . . . . . . . . . . . . . . . 6-56
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 S9 . . . . . . . . . . . . . . . . . . . . . . 6-59
Torque Specs . . . . . . . . . . . . . . . . 7-78 SW1 . . . . . . . . . . . . . . . . . . . . 6-83
Soldering Procedures . . . . . . . . . . . . . 7-67 SW2 . . . . . . . . . . . . . . . . . . . . 6-65
Solenoid Tests SW3 . . . . . . . . . . . . . . . . . . . . 6-63
Aux. Direction . . . . . . . . . . . . . . .6-101 SW4 . . . . . . . . . . . . . . . 6-58, 6-61
Aux. Relief . . . . . . . . . . . . . . . . . .6-118 Symptom Tables
HSA1 . . . . . . . . . . . . . . . . . . . . . .6-119 Drive Units . . . . . . . . . . . . . . . . . . 5-27
Lift Relief . . . . . . . . . . . . . . . . . . .6-104 Electrical Symptoms . . . . . 5-30 to 5-31
Lift/Lower . . . . . . . . . . . . . . . . . .6-106 Hydraulic Functions . . . . . 5-23 to 5-26
Load Hold . . . . . . . . . . . . . . . . . .6-105 Travel Functions . . . . . . . . 5-28 to 5-29
Priority Bypass . . . . . . . . . . . . . .6-117 System Architecture . . . . . . . . . . . . . . . 8-2
Sideshift . . . . . . . . . . . . . . . . . . .6-103
Tilt . . . . . . . . . . . . . . . . . . . . . . .6-102 T
Special Tools . . . . . . . . . . . . . . . . . . . 7-12
Specification Tag . . . . . . . . . . . . . . . . . 3-3 Terminals, Motor Power Cable . . . . . . 7-56

Publication: 1193671C, Revised: 15 Aug 2022 I-7

Section I. Index Models 4150/4250 Maintenance Manual

Tests A99 – H20 Snse . . . . . . . . . . . . . . 6-73

A04 - Travel Pot . . . . . . . . . . . . . . . 6-34 I00 - Deadman (S2) . . . . . . . . . . . 6-78
A05 - L/L Pot . . . . . . . . . . . . . . . . 6-35 I02 - Mast Tilt Speed Reduction
A08 - Left Trac Motor Temp . . . . . . 6-36 (S11) . . . . . . . . . . . . . . . . . . . . 6-79
A09 - Lift Motor Temp . . . . . . . . . . 6-37 I05 - Lift Limit (S12) . . . . . . . . . . . 6-80
A10 - Left TPA Temp . . . . . . . . . . . 6-38 I13 - Lift Contactor (DC Lift) . . . . . 6-81
A100 – BSM Comm . . . . . . . . . . . . 6-74 I14 - Steer Contactor . . . . . . . . . . 6-82
A103 – Max EPS Discharge . . . . . . 6-75 I15 - Horn (S3) . . . . . . . . . . . . . . . 6-83
A104 – Max EPS Regen Charge . . . 6-76 I15 - Horn (SW1) . . . . . . . . . . . . . 6-83
A11 - Left Traction Current . . . . . . 6-39 I19 - Left Traction RPM . . . . . . . . . 6-84
A13 - Press Sensor Voltage . . . . . . 6-40 I20 - Lift Motor RPM . . . . . . . . . . . 6-85
A14 - Ext. Supply Sense (12VDC) . 6-41 I23 - CAN Communication Test . . 6-86
A15 - Battery Voltage . . . . . . . . . . 6-42 I65 - Tilt Position SW (S18) . . . . . . 6-88
A19 - LPA Temp . . . . . . . . . . . . . . 6-43 I80 - OCSS - Low . . . . . . . . . . . . . 6-89
A20 - Lift Motor Current . . . . . . . . 6-44 I81 - OCSS - High . . . . . . . . . . . . . 6-90
A22 - Traction Throttle Request . . . 6-45 I82 - Right Traction RPM . . . . . . . 6-91
A23 - Lift Request . . . . . . . . . . . . . 6-46 I87 - Battery Gate 1 . . . . . . . . . . . 6-92
A26 - Pot Supply (5VDC) . . . . . . . . 6-47 I88 - Battery Gate 2 . . . . . . . . . . . 6-93
A34 - Lift/Lower Current (SOL2) . . 6-48 I89 - Steer Position Sensor . . . . . . 6-94
A35 - Brake Armature . . . . . . . . . . 6-49 I91 - iPort Communication . . . . . . 6-95
A36 - Ambient Temperature . . . . . 6-50 O00 - TPC Contactor . . . . . . . . . . 6-98
A40 - Handle Heater O01 - Steer Contactor (STR) . . . . . 6-99
Reference Voltage . . . . . . . . . . 6-51 O02 - Lift Contactor (LPC) . . . . . . 6-100
A65 - Right TPA Temp . . . . . . . . . . 6-52 O04 - Aux. Direction Solenoid
A67 - Right Trac Motor Current . . . 6-53 (SOL6) . . . . . . . . . . . . . . . . . 6-101
A68 - Right Trac Motor Temp . . . . 6-54 O07 - Tilt Solenoid (SOL10) . . . . 6-102
A69 - Mast Tilt Centering Pot O08 - Sideshift Solenoid
(VR6) . . . . . . . . . . . . . . . . . . . . 6-55 (SOL9L, SOL9R) . . . . . . . . . . 6-103
A71 - Tilt Down (S7) . . . . . . . . . . . 6-56 O09 - Lift Relief Solenoid
A72 - Tilt Up (S6) . . . . . . . . . . . . . 6-57 (SOL3) . . . . . . . . . . . . . . . . . 6-104
A72 - Tilt Up/Down (SW4) O11 - Load Hold Solenoid
(Optional Handle) . . . . . . . . . . 6-58 (SOL1) . . . . . . . . . . . . . . . . . 6-105
A73 - Sideshift Right (S9) . . . . . . . 6-59 O12 - Lift/Lower Solenoid
A74 - Sideshift Left (S8) . . . . . . . . . 6-60 (SOL2) . . . . . . . . . . . . . . . . . 6-106
A74 - Sideshift Switch (SW4) O18 - Horn . . . . . . . . . . . . . . . . . 6-107
(Optional Handle) . . . . . . . . . . 6-61 O20 - Travel Alarm . . . . . . . . . . . 6-109
A75 - Attach Func 1 O23 - Toggle Amplifier Fan . . . . . 6-110
(Optional Handle) . . . . . . . . . . 6-63 O28 - Ramp Lift Motor (AC Lift) . 6-111
A75 - Attach Func 1 (S4) . . . . . . . . 6-62 O29 - Ramp Traction Motors . . . 6-112
A76 - Attach Fcn 2 (SW2) O30 - Electric Brakes . . . . . . . . . 6-114
(Optional Handle) . . . . . . . . . . 6-65 O32 - Toggle Relay Enable . . . . . 6-115
A76 - Attach Func 2 O33 – Handle Heater . . . . . . . . . 6-116
(Optional Handle) . . . . . . . . . . 6-65 O36 - Priority Bypass Solenoid
A76 - Attach Func 2 (S5) . . . . . . . . 6-64 (SOL4) . . . . . . . . . . . . . . . . . 6-117
A77 - EPO (S21) . . . . . . . . . . . . . . 6-66 O37 - Aux. Relief Solenoid
A80 - Aux Select Current (SOL6) . . 6-67 (SOL5) . . . . . . . . . . . . . . . . . 6-118
A81 - Priority Bypass Current O45 - HSA1 Solenoid
(SOL4) . . . . . . . . . . . . . . . . . . . 6-68 (SOL7C, SOL7R) . . . . . . . . . . 6-119
A82 - Aux. Relief Current (SOL5) . . 6-69 O47 - Customer Output . . . . . . . 6-120
A96 – EPS Current Actual . . . . . . . 6-70 Shorts to Frame . . . . . . . . . . . . . . . 5-2
A97 – EPS Voltage Actual . . . . . . . 6-71
A98 – EPS Temp . . . . . . . . . . . . . . 6-72

I-8 Publication: 1193671C, Revised: 15 Aug 2022

Models 4150/4250 Maintenance Manual Section I. Index

Theory of Ops DC motors

BSOC . . . . . . . . . . . . . . . . . . . . . . 5-4 short-circuited armature . . . . . 5-17
CAN Bus . . . . . . . . . . . . . . . . . . . . 8-3 Drive Units . . . . . . . . . . . . . . . . . . 5-27
Fuse/Relay Card . . . . . . . . . . . . . . 8-4 Electrical . . . . . . . . . . . . . . . . . . . . 5-2
Lift Power Amp . . . . . . . . . . . . . . . 8-3 Fuse/Relay Card . . . . . . . . . . . . . . 5-12
Lift/Lower . . . . . . . . . . . . . 8-9 to 8-11 Fuses . . . . . . . . . . . . . . . . . . . . . . . 5-6
LPC Contactor . . . . . . . . . . . . . . . . 8-4 Hydraulic Functions . . . . . . . . . . . 5-23
Operator Display Card . . . . . . . . . . 8-4 Motors . . . . . . . . . . . . . . . 5-14 to 5-18
Pinout Matrix . . . . . . . . . 8-13 to 8-26 AC . . . . . . . . . . . . . . . . . . . . . . 5-18
Steer Position Sensor . . . . . . . . . . . 8-4 DC . . . . . . . . . . . . . . . . . . . . . 5-14
Steer Valve . . . . . . . . . . . . . . . . . . 8-5 Pinout Matrix . . . . . . . . . . 8-13 to 8-26
Steering System . . . . . . . . . . . . . . . 8-8 Power Source Limit Faults . . . . . . 5-20
STR Contactor . . . . . . . . . . . . . . . . 8-4 Public Standard Interface . . . . . . . 5-21
TPC Contactor . . . . . . . . . . . . . . . . 8-4 Shorts to Frame Test . . . . . . . . . . . 5-2
Traction Power Amps . . . . . . . . . . . 8-3 Symptom Tables . . . . . . . . 5-23 to 5-31
Traction System . . . . . . . . . . . . . . . 8-6 Travel Functions . . . . . . . . . . . . . . 5-28
Vehicle Manager . . . . . . . . . . . . . . 8-3 Truck Installation . . . . . . . . . . . . . . . . . 3-5
Thread Adhesives, Specifications . . . . . A-3
Tilt Cylinders, Theory of Ops . . . . . . . . 8-4 U
Tilt Solenoid (SOL10) . . . . . . . . . . . . . . 8-5
Tilt, Mast, Adjustment . . . . . . . . . . . .7-144 Unclamp Attachment . . . . . . . . . . . . . 3-18
Tire Pressing . . . . . . . . . . . . . . . . . . . 7-45
Tools, Special . . . . . . . . . . . . . . . . . . 7-12 V
Torque Chart
Component Specific . . . . . . . . . . . . A-4 Valve
Face Seal O-Rings . . . . . . . . . . . . . A-7 CB1 - CB2 Counterbalanced
Ferrous, Metric . . . . . . . . . . . . . . . A-9 Check Valve . . . . . . . . . . . . . . 7-78
Ferrous, Standard . . . . . . . . . . . . . A-8 Check
Hydraulic Fittings . . . . . . . . . . . . . A-6 Quad Mast . . . . . . . . . . . . . . 7-138
Metric, Brass . . . . . . . . . . . . . . . . A-11 CV1 Check Valve . . . . . . . . . . . . . 7-78
Standard, Brass . . . . . . . . . . . . . A-10 Pressure Relief . . . . . . . . . . . . . . . 7-83
Thread-Forming Screws . . . . . . . . A-12 Proportional Lowering
Towing Safety . . . . . . . . . . . . . . . . . . 2-11 Adjustment . . . . . . . . . . . . . . . 7-84
TPC Contactor . . . . . . . . . . . . . . . . . . . 8-4 SOL1
Theory of Ops . . . . . . . . . . . . . . . . 8-4 Test . . . . . . . . . . . . . . . . . . . . 6-105
Traction Motor Torque Spec . . . . . . . . . . . . . . 7-78
Power Cable Terminal Nuts . . . . . 7-56 SOL10
Traction Motor, Test . . . . . . . . . . . . . . . . . . . . 6-102
see Motors, Traction . . . . . . . . . . 7-62 Torque Spec . . . . . . . . . . . . . . 7-78
Traction Power Amplifier Connector SOL2
Assembly . . . . . . . . . . . . . . . . . . . 7-72 Test . . . . . . . . . . . . . . . . . . . . 6-106
Contact Insertion . . . . . . . . . . . . . 7-72 Torque Spec . . . . . . . . . . . . . . 7-78
Disassembly . . . . . . . . . . . . . . . . 7-72 SOL3
Testing . . . . . . . . . . . . . . . . . . . . 7-74 Test . . . . . . . . . . . . . . . . . . . . 6-104
Traction Power Amplifiers . . . . . . . . . 7-65 Torque Spec . . . . . . . . . . . . . . 7-78
Theory of Ops . . . . . . . . . . . . . . . . 8-3 SOL4
Traction System Theory of Ops . . . . . . 8-6 Test . . . . . . . . . . . . . . . . . . . . 6-117
Travel Potentiometer . . . . . . . . . . . . . 7-30 Torque Spec . . . . . . . . . . . . . . 7-78
Troubleshooting SOL5
Chains . . . . . . . . . . . . . . . . . . . . . 4-11 Test . . . . . . . . . . . . . . . . . . . . 6-118
Communication Error Codes . . . . 5-19 Torque Spec . . . . . . . . . . . . . . 7-78

Publication: 1193671C, Revised: 15 Aug 2022 I-9

Section I. Index Models 4150/4250 Maintenance Manual

SOL6
Test . . . . . . . . . . . . . . . . . . . . 6-101
Torque Spec . . . . . . . . . . . . . . 7-78
SOL7C/R
Test . . . . . . . . . . . . . . . . . . . . 6-119
Torque Spec . . . . . . . . . . . . . . 7-78
SOL9L/R
Test . . . . . . . . . . . . . . . . . . . . 6-103
Torque Spec . . . . . . . . . . . . . . 7-78
Valve, Check, Quad Mast . . . . . . . . . 7-138
Valves
CB1, CB2 . . . . . . . . . . . . . . . . . . . .8-5
CV1 . . . . . . . . . . . . . . . . . . . . . . . . .8-5
Vehicle Manager
Circuit Card Connectors . . . . . . . . 5-10
Vehicle Manager, Theory of Ops . . . . . .8-3
Vehicle Specifications . . . . . . . . . . . . . .3-3
VR1 Test . . . . . . . . . . . . . . . . . . . . . . . 6-34
VR2 Test . . . . . . . . . . . . . . . . . . . . . . . 6-35

Warranty
Storage Issues . . . . . . . . . . . . . . . . 3-22
Welding Safety . . . . . . . . . . . . . . . . . . 2-12
Wheel, Steerable . . . . . . . . . . . . . . . . . 7-18
Wiring
Connectors . . . . . . . . . . . . . . . . . . 7-67
Harness Terminology . . . . . . . . . . . .5-7
Soldering Procedures . . . . . . . . . . . 7-67

I-10 Publication: 1193671C, Revised: 15 Aug 2022

 1193671C
Printed by the Digital Print Center
The Raymond Corporation, Greene, NY
 Schematics

Models Serial Numbers

4150 42,000 and up
This publication applies to the all subsequent releases of this product until
otherwise indicated in new editions or bulletins. Changes occur periodically
4250 42,067 and up
to 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 Solutions and Support
Center. To locate your local authorized Raymond Solutions and Support
Center, go to www.raymondcorp.com.

Publication: 1193671C Revised: 15 Aug 2022

©2022 The Raymond Corporation.

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Section 1.

Figure 1-1. Power Distribution Diagram - Model 4150

Model 4150 - AC LIFT

Publication: 1193671C, Revised: 15 Aug 2022 2
Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-2. Power Distribution Diagram - Model 4250

Model 4250 - AC LIFT

Publication: 1193671C, Revised: 15 Aug 2022 3
Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-3. Electrical Schematic - Model 4250 (AC Lift) - Sheet 1 of 5

Model 4250 - AC LIFT

Publication: 1193671C, Revised: 15 Aug 2022 4
Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-4. Electrical Schematic - Model 4150 - Sheet 2 of 5

Model 4150 - DC LIFT

Publication: 1193671C, Revised: 15 Aug 2022 5

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-5. Electrical Schematic - Options - Sheet 3 of 5

Publication: 1193671C, Revised: 15 Aug 2022 6

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-6. Electrical Schematic - Control Handle and PSI - Sheet 4 of 5

Publication: 1193671C, Revised: 15 Aug 2022 7

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-7. Electrical Schematic - Legend - Sheet 5 of 5

Publication: 1193671C, Revised: 15 Aug 2022 8

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-8. Hydraulic Schematic - Model 4250 - AC Lift (Sheet 1 of 3)

Shown with Integral Sideshift,

attachment ready, and optional Lift
Pressure Transducer

Model 4250 - AC LIFT

Publication: 1193671C, Revised: 15 Aug 2022 9
Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-9. Hydraulic Schematic - Model 4150 - DC Lift (Sheet 2 of 3

Shown with Integral Sideshift

Model 4150 - DC LIFT

Publication: 1193671C, Revised: 15 Aug 2022 10
Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-10. Hydraulic Schematic - Auxiliary Function Options (Sheet 3 of 3)

Auxiliary Function Options

Publication: 1193671C, Revised: 15 Aug 2022 11
Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics

Publication: 1193671C, Revised: 15 Aug 2022 12

 Schematics

Models Serial Numbers

4150 42,000 and up* This publication applies to the all subsequent releases of this product until
otherwise indicated in new editions or bulletins. Changes occur periodically
4250 42,067 and up* to the information in this publication.

*With Curtis 1234/1236 Controllers If you need assistance with your lift truck, or to order additional copies of this
document, contact your local authorized Raymond Solutions and Support
Center. To locate your local authorized Raymond Solutions and Support
Center, go to www.raymondcorp.com.

Publication: 1193671C Revised: 15 Aug 2022

©2022 The Raymond Corporation.

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Section 1.

Figure 1-1. Power Distribution Diagram - Model 4150

Model 4150 - AC LIFT

Publication: 1193671C, Revised: 15 Aug 2022 2
Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-2. Power Distribution Diagram - Model 4250

Model 4250 - AC LIFT

Publication: 1193671C, Revised: 15 Aug 2022 3
Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-3. Electrical Schematic - Model 4250 (AC Lift) - Sheet 1 of 5

Model 4250 - AC LIFT

Publication: 1193671C, Revised: 15 Aug 2022 4
Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-4. Electrical Schematic - Model 4150 - Sheet 2 of 5

Model 4150 - DC LIFT

Publication: 1193671C, Revised: 15 Aug 2022 5

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-5. Electrical Schematic - Options - Sheet 3 of 5

Publication: 1193671C, Revised: 15 Aug 2022 6

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-6. Electrical Schematic - Control Handle and PSI - Sheet 4 of 5

Publication: 1193671C, Revised: 15 Aug 2022 7

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-7. Electrical Schematic - Legend - Sheet 5 of 5

Publication: 1193671C, Revised: 15 Aug 2022 8

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-8. Hydraulic Schematic - Model 4250 - AC Lift (Sheet 1 of 3)

Shown with Integral Sideshift,

attachment ready, and optional Lift
Pressure Transducer

Model 4250 - AC LIFT

Publication: 1193671C, Revised: 15 Aug 2022 9
Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-9. Hydraulic Schematic - Model 4150 - DC Lift (Sheet 2 of 3

Shown with Integral Sideshift

Model 4150 - DC LIFT

Publication: 1193671C, Revised: 15 Aug 2022 10
Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Figure 1-10. Hydraulic Schematic - Auxiliary Function Options (Sheet 3 of 3)

Auxiliary Function Options

Publication: 1193671C, Revised: 15 Aug 2022 11