Models 5300/5500/5600 Maintenance Manual Visual Table of Contents

Maintenance Manual
5300 Serial Numbers: 00001 and Up
5500/5600 Serial Numbers: 44001 and Up

Scheduled Maintenance

Messages and Codes

Symptom Tables

Publication: 1301126/001A, Issued: 12 Nov 2018

Visual Table of Contents Models 5300/5500/5600 Maintenance Manual

Maintenance Manual
5300 Serial Numbers: 00001 and Up
5500/5600 Serial Numbers: 44001 and Up

Publication: 1301126/001A, Issued: 12 Nov 2018

Maintenance Manual

High-Level Orderpicker Lift Truck

Models Serial Numbers

5300 00001 and Up
5500, 5600 44001 and Up

Publication: 1301126/001A Issued: 12 Nov 2018

This publication, 1301126/001A, applies to High-Level Orderpicker Models 5300, S/N 00001 and up and
to Models 5500 and 5600, S/N 44001 and up, and to all subsequent releases of this product until
otherwise indicated in new editions or bulletins. Changes occur periodically to the information in this
publication.

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

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

©2018 The Raymond Corporation.

The following terms are trademarks of The Raymond Corporation: The ACR System, intellidrive,
intellispeed, iPort, iBattery, and Raymond. All other brand and product names are trademarks or registered
trademarks of their respective companies.
Models 5300/5500/5600 Maintenance Manual Table of Contents

Table of Contents
Document Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-v
Service Information List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-v
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Interactive Electronic Technical Manuals . . . . . . . . . . . . . . . . . . . . . . 1-3
Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Emergency Lower Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Tie-Down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
FlashWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Wire Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
UL Label “EE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Minder ™ Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial 90 Day/250 Deadman Hours (HD) Maintenance . . . . . . . . . . . 4-5
Every 180 Days or 500 Deadman Hours (HD) . . . . . . . . . . . . . . . . . . 4-6
Every 360 Days or 2000 Deadman Hours (HD) . . . . . . . . . . . . . . . . 4-10
Chain Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Contactor Tip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drive Unit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Troubleshooting Aisle Exit Error Code J2 . . . . . . . . . . . . . . . . . . . . . 5-23
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . 5-25
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . 5-29
Messages, Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Power Amp LED Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Summary List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Analog Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71

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Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Special Tools and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Decals and Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Steering and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Steer Motor/Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Home Proximity Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Deadman Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Drive Unit - Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Drive Unit - Heavy Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Battery Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
AC Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Power Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Carriage Control Card Replacement . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Wiring and Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89
Flow Sensor Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90
High Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . 7-93
Lift/Lower and Load Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . 7-94
Bleeding Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
Lift Pump and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-96
Main Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
Free Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101
Mast Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-105
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-106
Mast Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109
Upper Mast Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 7-111
Lift Chains, Three-Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-116
Free Lift Cylinder Ride Spring Chain Anchors . . . . . . . . . . . . . . . . 7-118
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-119
Pallet Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-120
Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-121
Lift Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Wire Guidance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Pin-Out Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

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

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Models 5300/5500/5600 Maintenance Manual

Document Revision History

Document Revision History

Revision Date Description of Changes

1301126/001A 12 Nov 2018 Initial Release

Service Information List

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

Revision
Document Number Subject
Incorporated

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 Models 5300/5500/5600 Maintenance Manual

Service Information List

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Models 5300/5500/5600 Maintenance Manual Section 1. How to Use This Manual

Section 1. How to Use This Manual

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Section 1. How to Use This Manual Models 5300/5500/5600 Maintenance Manual

Manual Design

Manual Design • 7. Component Procedures contains

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

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Interactive Electronic Technical Manuals

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

Blue text in the Maintenance Manual is linked

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

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Section 1. How to Use This Manual Models 5300/5500/5600 Maintenance Manual

Abbreviations and Symbols

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

Term/Symbol Definition Term/Symbol Definition

A Ampere
AC Alternating Current FF Forks-first
Agnd analog ground fpm feet per minute
amp Ampere or amplifier FRC Fuse/Relay Card
approx approximately ft. foot or feet
Assy assembly
aux auxiliary gal. gallon or gallons
AWG American Wire Gauge GM Guidance Manager
gm gram
BSOC Battery State-of-Charge Gnd ground
BWI brush wear indicator
HA Heading Angle
CAN Controller Area Network HD hours on deadman
CCC Carriage Control Card Ht height
CCW counterclockwise Hgt/Wgt Height/Weight
CFP Contactor Fuse Panel Hz Hertz
cm centimeter
COP Computer Operating IETM Interactive Electronic
Program Technical Manual
CW clockwise in. inch or inches
CS cold storage
kg kilogram(s)
DC Direct Current kHz kilohertz
DFW Distance From Wire km/h kilometers per hour
Dgnd digital ground kPa kilo Pascal
DMM Digital Multi Meter
DVM Digital Voltmeter lb. pound or pounds
LED Light Emitting Diode
EE UL Electric Truck Type L/H Load Holding
Certification Rating where L/L Lift/Lower
electrical equipment is LPA Lift Power Amplifier
completely enclosed
LPC Lift Power Contactor
EMF ElectroMotive Force
EOA End-of-Aisle
mA milliampere
EPO Emergency Power Off
max maximum
ESD Electrostatic Discharge
min minute or minimum
ESDS Electrostatic Discharge
Sensitive

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Models 5300/5500/5600 Maintenance Manual Section 1. How to Use This Manual

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

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

RAM Random Access Memory

RDP Raymond Data Port
rpm Revolutions per Minute

SAE Society of Automotive

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

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

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Abbreviations and Symbols

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Models 5300/5500/5600 Maintenance Manual Section 2. Safety

Section 2. Safety

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Section 2. Safety Models 5300/5500/5600 Maintenance Manual

Definitions

Definitions
This manual contains two kinds of safety
reminders:

Warning means a potentially hazardous

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

Caution means a potentially hazardous

situation exists, which, if not avoided,
may result in minor or moderate injury
or in damage to the lift truck or nearby
objects. It may also be used to alert
against unsafe practices.

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Models 5300/5500/5600 Maintenance Manual Section 2. Safety

General Safety

General Safety Before working on this lift truck, always turn

the key switch OFF and disconnect the lift
truck’s battery connector (unless this manual
Do not operate or work on this lift truck unless tells you otherwise).
you are trained, qualified, and authorized to do
so, and have read the Owner and Operator
Manuals.

Do not wear watches, rings, or jewelry when

working on this lift truck.

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

Follow the scheduled lubrication, maintenance,

and inspection steps.
Do not operate this lift truck if it needs repair or
if it is in any way unsafe.

Follow exactly the safety and repair instructions

in this manual. Do not take “shortcuts.”
Operate this lift truck only from the operator’s
position.

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Section 2. Safety Models 5300/5500/5600 Maintenance Manual

General Safety

Do not use an open flame near the lift truck. Do not wash this lift truck with a hose.

Do not use gasoline or other flammable liquids Do not add to or modify this lift truck until you
for cleaning parts. contact your local Raymond Sales and Service
Center to receive written manufacturer
approval.

Clean up any hydraulic fluid, oil, or grease that

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

Always operate and park this lift truck indoors.

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Models 5300/5500/5600 Maintenance Manual Section 2. Safety

Battery Safety

Battery Safety Wear personal protective equipment to protect

eyes, face, and skin when checking, handling,
or filling batteries. This equipment includes
goggles or face shield, rubber gloves (with or
without arm shields), and a rubber apron.

As a battery is being charged, an

explosive gas mixture forms within and
around each cell. If the area is not
correctly ventilated, this explosive gas
can remain in or around the battery for
several hours after charging. Make sure
there are no open flames or sparks in
the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury. Make sure a shower and eyewash station are
nearby in case of an accident.
Battery electrolyte is a solution of
sulfuric acid and water. Battery
electrolyte causes burns. If any
electrolyte comes in contact with your
clothing or skin, flush the area
immediately with cold water. If the
solution gets on your face or in your
eyes, flush the area with cold water and
get medical help immediately.

Read, understand, and follow procedures, A battery gives off explosive gases. Never
recommendations, and specifications in the smoke, use an open flame, or use anything that
battery and battery charger manufacturer’s gives off sparks near a battery.
manuals.

Keep the charging area well-ventilated to avoid

hydrogen gas concentration.

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Section 2. Safety Models 5300/5500/5600 Maintenance Manual

Battery Safety

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

Do not lay tools or metal objects on top of the

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

Make sure the vent holes in the filler plugs are

open to allow the gas to escape from the cells.

Vent
Hole

Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.

Do not allow cleaning solution, dirt, or any

foreign matter to enter the cells.

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Models 5300/5500/5600 Maintenance Manual Section 2. Safety

Battery Safety

Make sure you install the correct size battery. A

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

Never plug a battery charger into the lift truck’s

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

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Section 2. Safety Models 5300/5500/5600 Maintenance Manual

Static Precautions

Static Precautions • If you are removing or installing ESDS

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

Whenever working on or near ESDS

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

ESD Ground Jack

Figure 2-1. ESD Ground Jack Location

• Handle circuit boards by the edges only.

Avoid touching the edge connectors.

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Models 5300/5500/5600 Maintenance Manual Section 2. Safety

Jacking

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

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

Jacking Lift Truck

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

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

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Section 2. Safety Models 5300/5500/5600 Maintenance Manual

Operator Platform

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

Figure 2-5. Blocking Operator Platform

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Models 5300/5500/5600 Maintenance Manual Section 2. Safety

Emergency Lower Valve

Emergency Lower Valve

In the event that it is necessary to lower the
carriage to the ground without using the
standard controls, do the following:
1. Remove the tractor cover. The Emergency
Lower Valve is located on the lift/lower
manifold. See Figure 2-6.
2. Slowly turn the valve counterclockwise,
allowing the operator platform to lower by
its own weight.
NOTE: Leaving the valve open prevents the
operator platform from elevating.
3. Turn the valve clockwise to close. This
allows the operator platform to elevate
when the main lift control is operated.

Emergency
Lower Valve

21750_037.TIF

Figure 2-6. Emergency Lower Valve

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Section 2. Safety Models 5300/5500/5600 Maintenance Manual

Tie-Down for Transport

Tie-Down for Transport

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

a. Install eye-bolts (3/4 in. [19 mm] Figure 2-8. Tie-Down for Vertical Transport
thread size) in the holes in the bumper.
See Figure 2-7. Horizontal Transport
b. Secure a chain from the eye-bolts to the 1. Remove forks from carriage.
vehicle bed. See Figure 2-8.
2. Replace the cap and screen in the
4. Strap the lift truck from the bumper or hydraulic reservoir with shipping cap and
guide roller to the floor of the transport screws.
vehicle.
3. Band down the carriage and battery
5. Chock the drive wheel to prevent rollers.
tractor-first movement.
4. Remove the dipstick, and plug the drive
6. Place a block between the baselegs and unit.
platform, 7.5 in. (190.5 mm) from the front
edge of the platform. 5. Remove the bottom two bumper plate bolts
(to be reinstalled after shipping).
7. Position an additional adjustable chain or
strap perpendicular to the forks, over 6. Use two hoists in conjunction and lay the
operator platform, and attach it to the lift truck on the cradle.
vehicle bed. This prevents tip-over during 7. Install long bolts through the holes in the
transport. See Figure 2-8. bumper and secure to the cradle.
8. Band the lift truck to the cradle.
Eye-bolts 9. Secure the forks to the cradle below the
mast.

Figure 2-7. Eye-Bolts Installed for Transport

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Models 5300/5500/5600 Maintenance Manual Section 2. Safety

Towing

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

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

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

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

Brake Release Bolt Holes

Figure 2-9. Brake Release Bolt Installation

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Section 2. Safety Models 5300/5500/5600 Maintenance Manual

Welding Safety

Welding Safety • Test for shorts to frame. See Shorts to

Frame on page 5-2. Correct any shorts
before you weld.
• Clean the area to be welded.
• Protect all lift truck components from
Flame cutting or welding on painted heat, weld spatter, and debris.
surfaces can produce potentially • Attach the ground cable as close to the
harmful fumes, smoke, and vapors. weld area as possible. Do not attach the
Before you do flame cutting or welding, ground cable to fasteners or other
remove the coating in the area where removable components.
the operation will occur.
• Disconnect all electrical connectors from
circuit cards before doing any type of
Coating removal can occur by
electric resistance welding.
mechanical and/or chemical methods.
Perform flame cutting and/or welding • Do not weld near electrical components.
operations only in well ventilated areas. • If you must weld near the battery
compartment, remove the battery from the
Before working on this lift truck, make sure lift truck.
that:
• Fire protection equipment is nearby.
• You know where the nearest eyewash
station is.

Disconnect the battery before you

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

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Models 5300/5500/5600 Maintenance Manual Section 3. Systems Overview

Section 3. Systems Overview

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

Introduction

Introduction
This manual provides information for
maintenance and repair of Model
5300/5500/5600 Orderpicker lift trucks by
Raymond.

This manual contains the most current and

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

For the latest information on your Raymond lift

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

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Models 5300/5500/5600 Maintenance Manual Section 3. Systems Overview

Lift Truck Specifications

Lift Truck Specifications

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

Raymond Model # Serial number Approximate weight

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

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

Max Battery
Rated Capacity

Max load capacity of

this lift truck

*Battery weight must be between the

min and max weight.

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

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

General Information

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

Configuration Code Cross Reference

Code Model # Traction/Lift Configuration

5500 AC/AC 24V, Max Elevated Height equal to or less than 315 in.
A
5600 AC/AC 36V, Max Elevated Height equal to or less than 315 in.

5500 AC/AC 24V, Elevated Height greater than 315 in. with a maximum
of 366 in.
B
5600 AC/AC 36V, Elevated Height greater than 315 in. with a maximum
of 390 in.

C 5300 AC/DC 24V, 240 in. Max Elevated Height

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

Battery Specifications

UL note 583 specifies that a battery should

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

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

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

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

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

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

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

18.12 2300 (1043) 2600 (1179)

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

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

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Models 5300/5500/5600 Maintenance Manual Section 3. Systems Overview

Fluid Capacities

Fluid Capacities
Heavy Duty Drive Hydraulic
Standard Drive Unit
Units Reservoir

Fill to middle line

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

Refer to “Lubrication Specification Chart” on

page A-2.

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

Installation

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

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Models 5300/5500/5600 Maintenance Manual Section 3. Systems Overview

Operator Display

Operator Display Steering Indicator Lights

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

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

The OD is not required for Run Mode or to pass

SelfTest.

Status/Fault Message Display

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

Wire Guidance
LEDs

3
Figure 3-2. Operator Display Messages

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

Modes of Operation

Modes of Operation If a problem occurs in the lift system, lift is

prevented. Travel, lower, horn, and
steering functions are still permitted.
This vehicle can operate in one of two modes of
operation: Tone 4. A continuous tone with the deadman
pedal pressed and the Auto/Manual switch in
• Run Mode
Manual indicates the lift truck is over the guide
• Program Mode wire.
Tone 5. Tone ramps up then repeats is an
Run Mode indication that the lift truck is seeking and
Run Mode is the normal operating mode for the aligning over the guide wire. The tone continues
vehicle. Run Mode is the only mode that normal until the lift truck is locked on the guide wire or
vehicle travel is allowed. In this mode, the the Auto/Manual switch is changed to Manual.
selectable display is shown on the OD. Run Tone 6. Descending tone (bomb drop) that
Mode starts automatically when Program Mode indicates an incorrect Password or Electronic
is exited or after SelfTest passes. Passkey was entered.
The tones described do not repeat continuously.
Audible Alarm Description A fault code and associated message scroll
Within Run Mode, various lift truck situations across the OD. The message repeats
are identified using different audible tones and continuously until the key switch is turned
patterns. Run Mode Tones describes the six OFF.
tones/patterns and possible cause for different
operating conditions. Password Levels
Two password levels are used with this system:
Run Mode Tones
• Password
Tone 1. A single tone that indicates:
• SuperWord
• Up/Down buttons or Enter is pressed
• Maximum steer request is reached Password
Tone 2. Two tones (high/low) that indicate the Password allows access to Configure Mode
Traction Power Contactor (TPC) and Lift Power (Config) only. Instructions for using Config are
Contactors (LPC) are disabled (opened). Travel, outlined on page 3-13.
steering, and lift/lower are disabled and the
brake is applied until the problem is corrected.
SuperWord
Tone 3. Three tones (high/medium/low) that
indicate: SuperWord (Superwrd) allows access to all
program levels available. Only qualified service
• A travel performance limitation
technicians should have access to SuperWord.
A travel performance limitation allows the
lift truck to travel at a maximum of 1 mph Instructions for entering or changing Password
(1.6 km/h). Lift, lower, steering, and horn or SuperWord are described on page 3-9.
functions operate normally. It is strongly recommended that the SuperWord
• A traction system shutdown be changed from the factory default to
something else during installation so access to
A traction system shutdown does not allow
programming is limited to qualified personnel.
the lift truck to travel. Lift, lower, steering,
With that in mind, it is very important to
and horn functions operate normally.
remember the unique SuperWord code that was
• A shutdown in the lift system entered and saved. If the code is lost or
forgotten, it is necessary for a technician to
reset the lift truck to factory default settings.

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Models 5300/5500/5600 Maintenance Manual Section 3. Systems Overview

Program Mode

This requires the reconfiguration of all variable under both active and static conditions to
settings (Speed, Acceleration, Password, further aid in problem diagnosis.
SuperWord, and so on).
Static Maintenance Mode
NOTE: Password recovery can be performed via
the Raymond Portal if FlashWare is not This mode allows one function at a time to be
available. Within the Raymond Portal, tested.
select Service > Software > SuperWord
Recovery Passkey Program and follow Active Maintenance Mode
the procedure in the SuperWord_readme
This mode allows all input and analog tests to
file.
be active in Run Mode. Navigate through the
OD using the Up/Down buttons, then enter
Program Mode Analog or Input by pressing the Enter button.
You can now scroll through all input and
Program Mode is divided into three categories:
output tests. There is no need to select items for
• Configure (Config) Active Maintenance, and you are not limited to
• Learn (Learn) the number of items. They are all available. To
return to the OD, navigate to Quit and press
• Maintenance (Maint) - Static or Active
Enter.

Configure Mode To access Maint, SuperWord must be used. For

a detailed description of Maintenance Mode,
The Configure Mode (Config) is used to adjust refer to page 3-23.
the vehicle’s performance to specific customer
requirements. To access Config, Password or
SuperWord must be used. For a detailed
Entering Program Mode
description of Configure Mode, refer to Program Mode can be entered by one of the
page 3-13. following two methods.

Learn Mode Method One

The Learn Mode is used to calibrate: 1. With the key switch OFF, hold the horn
• Throttle potentiometer (VR1) (Controls) button in and move the lift/lower control
to full lift.
• Lift/lower potentiometer (VR2) (Controls)
2. Turn the key switch ON.
• intellispeed™ sensor - height (optional)
• Pressure transducer - weight (optional)
• Wire guidance frequency and offset
(optional)
A discussion of the Learn process for these
items is included in this section.
To access Learn, SuperWord must be used.

Maintenance Mode
The Maintenance Mode (Maint) is used to verify
the operation of various circuits of the lift truck.
In Maintenance Mode, individual circuits can
be energized and cycled to aid in
troubleshooting. Some tests can be performed

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

Entering Program Mode

3. The OD will show all eight segments with a 4. Repeat steps 2 and 3 for all character
solid bar in each segment. See Figure 3-3. positions in the Password or SuperWord.
NOTE: Initial factory set Password is 1.
Initial factory set SuperWord is 2.
_ _ _ _ _ _ _ _ 5. When the Password or SuperWord is
displayed, press the Enter button once.
NOTE: If an invalid Password or SuperWord is
entered, the following message appears:
Invalid password...
To make a correction, repeat steps 2
through 4.

NOTE: To reset the SuperWord to factory

default, use FlashWare. See “FlashWare”
on page 3-25.
6. The menus that can be accessed depend
Down Button Enter Button
on whether SuperWord or Password was
3 entered. Refer to Table 3-1.
Figure 3-3. Operator Keypad and Display
Config is the first selection on the OD. If
Config is the desired selection, press
Method Two
Enter. If Learn or Maint is desired
1. With the key switch OFF, press and hold (available only if Program Mode is entered
the Enter button and Down button at the with SuperWord), use the Up/Down
same time. See Figure 3-3. buttons to scroll to that menu, then press
2. Turn the key switch ON. Enter.
To exit Program Mode, use the Up/Down
NOTE: The OD will show all eight segments
buttons to scroll to Quit, then press Enter.
with a solid bar in each segment.
NOTE: If the output tests are selected in Maint,
Entering Password or SuperWord the OD reminds the service technician
to jack the lift truck so the drive tire is
Refer to Figure 3-4. off the floor and to open the emergency
1. Observe the OD. The flashing bar at the lowering valve while in Maintenance
bottom of the left-most segment indicates Mode. When Ready? appears on the OD,
the segment that is currently active. press Enter to enter Maintenance Mode
output tests.
2. Hold the Enter button down and press the
Up button to move the cursor to the right.
Hold the Enter button down and press the
Down button to move the cursor to the
left. Release the Enter button.
3. Once the segment that you want to change
is selected:
• Press the Up button to advance through
the numbers then letters
(0 1 2 3 4 . . . . . . . . . X Y Z ).
• Press the Down button to select letters
then numbers (Z Y X W V. . . . . . . . 4 3 2 1 0 ).

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Entering Program Mode

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

-0123456789ABCDEFGHIJKLMNOPQRSTUVWXYZ

Pushing the DOWN button repeatedly scrolls the information in the opposite direction.

With the Enter button

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

Number Space (indicated by Letter

underscore)

Password or SuperWord
may be 1 - 8 characters
Enter the correct letter 3 a 7 t - 4 9 k in length, using
or number for each numbers, letters, spaces
segment that makes up (indicated by an
the Password or underscore), or any
SuperWord. combination of each.

3
Figure 3-4. Operator Display for Program Mode (Example)

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

Entering Program Mode

Table 3-1. Program Mode Menu

PROGRAM MODE MENU

Menu Item Selection Description

Quit Exits Program Mode

Config Enters Configure Mode - Refer to Configure Mode and

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

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

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

Maint Maintenance Mode - See Maintenance Mode on page 3-23.

(SuperWord only) Analog See Analog Input Tests on page 6-43.
Input See Input Tests on page 6-71.
Output See Output Tests on page 6-117.
PA Reset See Power Amplifier Reset on page 3-24.
WGReset Reset? N
Reset? Y
EvtLog See Event Log on page 3-24.
Act Maint See Active Maintenance Mode on page 3-24.
Enable
Disable
Quit Mnt Exits Maintenance Mode

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Entering Program Mode

Configure Mode The minimum number of characters is one, the

maximum is eight.
Configure Mode can be accessed with
SuperWord or Password, however some items in To change Password or Superwrd:
Config will only appear if SuperWord is entered. 1. Enter Config using the current password
Table 3-2 outlines all menus and submenus or SuperWord.
available in Config. 2. Select Password or Superwrd (as
applicable) from the Config menu and
Quit Cfg is first displayed when Config is
press Enter.
selected. Use the Up/Down buttons until the
desired selection is displayed. Press Enter. This 3. Enter the new code using the Up/Down
takes you into the submenu for that item. and Enter buttons.

Current values of configurable items or the 4. When the new code is displayed, press
ability to enable and disable an option appear Enter. The display returns to the main
in the submenu. To change the value, press the menu.
Up/Down button. When the desired value
appears, press Enter. This selects the item
currently displayed and returns to the main
menu.
All possible lift truck configurations and options
are listed in these instructions. Only the
options associated with that particular lift truck
are displayed on the OD.
To save changes, select Quit Cfg from the Config
menu and press Enter. Select Save? Y to save
the changes made and exit Config.
To disregard changes made in Config, select
Save? N. Config exits without saving changes.

Default Settings
NOTE: Once defaults are reset (Reset? Y), the
previous settings cannot be recalled.
To reinstate factory default settings:
1. Select Defaults from the main menu and
press Enter. Select Reset? Y.
2. Select Quit Cfg.

Changing Password or SuperWord

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

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

Entering Program Mode

Table 3-2. Configure Mode Menu

CONFIGURE MODE MENU

Can be entered with Password unless SuperWord is specified

Menu Item Selection Description

Exits Configure Mode

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

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

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

iP Lim Refer to iPORT

® Kit and Installation and Maintenance
Instructions.

iP Spd Refer to iPORT Kit and Installation and Maintenance

Instructions.

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

Sets End-of-Aisle Slowdown Speed

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

Sets Travel Acceleration

Hard
Accel Medium (default)
Soft

Long Sets Coast

Coast Medium (default)
Short

Sets Lift/Lower Start/Stop Acceleration

Hard
Lift Medium (default)
Soft

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

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

BSOC Resets Battery State-of-Charge

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

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Entering Program Mode

Table 3-2. Configure Mode Menu

CONFIGURE MODE MENU

Can be entered with Password unless SuperWord is specified

Menu Item Selection Description

ActMaint Enable (default) Sets Active Maintenance

(SuperWord only) Disable

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

Cut Out 20 (default)
(SuperWord only)

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

Instructions.

Set the 24 in. (610 mm) mast switch speed from 0.5 to 2.5 mph
24 Speed 2.5 mph (default) (0.8 to 4 km/h)
(optional)
(SuperWord only)

Sets Lift/Lower Bypass

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

Sets Lift Limit Bypass and Travel Cutout

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

Sets Lift Limit Bypass Alarm

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

Cust Int Customer Interlock Input - enabled in FlashWare

(SuperWord only) CITrav
CI Speed 0.1 mph (0.16 km/h) increments
CI Lift
This option can limit or disable travel and/or lift based on the
state of the input to the VM.

Selects English or Metric units of measure.

Units English (default)
Metric

Language No selections
available

Selects between Wire and Rail Guidance (will only appear if

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

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

Entering Program Mode

Table 3-2. Configure Mode Menu

CONFIGURE MODE MENU

Can be entered with Password unless SuperWord is specified

Menu Item Selection Description

Sets Heading Angle and Distance From Wire Exit Guideset

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

Sets Acquire Speed (tractor-first only)

Acquire 1.0 mph (default) 1.0 to full speed in 0.1 mph (0.16 km/h) increments
(optional)
(SuperWord only) Note: Forks-first acquire speed is fixed at 1.0 mph (1.6 km/h).

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

WrSnLim Enable Sets Wire Sense Creep Speed

Disable
WrSnSpd 1.0 mph 1.0 (1.6 km/h) mph when enabled.
(optional)
(SuperWord only)

Enters New Electronic Key

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

Enters New Password

Password 1_______ Displays Current Password
(factory setting)

Enters New SuperWord

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

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Entering Program Mode

Table 3-2. Configure Mode Menu

CONFIGURE MODE MENU

Can be entered with Password unless SuperWord is specified

Menu Item Selection Description

Displays Software Version

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

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

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

Sets Alarm for Travel

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

Sets Alarm for Lift

None Exit
AlarmL Both (default) ON in Both directions
(optional) Lift ON/OFF
(SuperWord only) Lower ON/OFF

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

Entering Program Mode

Table 3-2. Configure Mode Menu

CONFIGURE MODE MENU

Can be entered with Password unless SuperWord is specified

Menu Item Selection Description

Setup for Maintenance Minder ™

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

Sets idle time for automatic shut-off

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

Displays Height of Upper Reference Switch

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

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

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

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

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Entering Program Mode

Learn Mode The VM interprets the height and weight inputs

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

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

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

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Entering Program Mode

When to Run Learn

Table 3-3. When to Run Learn

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

Vehicle Manager Yes — Controls, Height, Weight, Steer

Upper Mast Switch — No —

Lower Mast Switch — No —

Carriage Control Card (CCC) Yes — Controls

Carriage Control Card PROM Yes — Controls

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

Deadman Switch (S2/S23) — No —

Lift Potentiometer (VR2) Yes — Controls

Guidance Manager Yes — Frequency and Offset

Pressure Transducer Yes — Height, Weight

Lift/Lower Solenoid — No —

Load Holding Solenoid — No —

Brake — No —

Throttle Potentiometer (VR1) Yes — Controls

Flow Sensor Module Yes — Height, Weight

Antenna Card Yes — Frequency and Offset

Home Proximity Sensor Yes — Steer

carriage immediately begins to lift. The display

continuously scrolls the following message:
To abort, step off deadman
Before Learning height and weight, the
vehicle must be placed in an area where If all the parameters measured during Learn are
the platform is able to lift beyond the within tolerance, the following message
upper mast reference switch (156 in. appears:
[396 cm] plus the height of the carriage). Done learning
If, at any time during Learn, the operator steps
When Hgt/Wgt is selected, the following
off the deadman pedal or the measurements fall
message appears:
outside a tolerance, the following message
Carriage will automatically lift/lower
appears:
between the reference switches
Unable to learn...lower then press enter to
The operator is prompted as follows: continue
Step on deadman to start learn
If the failure is not the result of stepping off the
This message scrolls continuously until the deadman, attempt to Learn again. If repeated
operator steps on the deadman pedal. After the attempts to learn fail, run tests:
operator steps on the deadman pedal, the • Test A13 - Pressure Sensor Voltage
(optional) (Page 6-50)

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Models 5300/5500/5600 Maintenance Manual Section 3. Systems Overview

Entering Program Mode

• Test I02 - Lower Mast Reference (24 in.) Phase 2

Switch (Page 6-74)
• Test I69 - Upper Mast Reference Switch 8. The OD scrolls Must lock onto wire. Place
(Page 6-103) the Auto/Manual switch to the Auto
• Test I26 - Flow Sensor Count (Without Full position.
Height Sensing) (Page 6-86) (use Active 9. The OD scrolls Guide tractor first. Drive the
Maintenance) lift truck tractor-first for roughly 20 feet.
Steering will be automatic during this
Learning Wire Frequency time. Once you have driven far enough,
The new GM no longer has the option to select the OD scrolls Gently coast to stop.
wire frequency. The GM will automatically 10. Return the control handle to neutral and
detect and set the correct values. The new GM allow the lift truck to gently coast to a
learn procedure has 3 phases. To store all of the stop. Select ENTER.
Wire Guidance values, the learn procedure
You are now finished with Phase 2 of the Learn
must be completed.
process.
NOTE: The Heading Angle and Distance From
NOTE: The lift truck speed will be limited to
Wire settings are temporarily set to the
2.5 mph (4 km/h) for the duration of
maximum values during the learn
this procedure.
process. Travel slowdowns may occur
when learning. Phase 3
The Learn Procedure is as follows:
11. The system will scroll Guide both directions
Phase 1
until centered OK.
1. Center the lift truck over the wire with the
12. Drive the lift truck through the aisle to
Auto/Manual switch in the Manual
start collecting data points.The lift truck
position.
will beep each time a data point is
2. Cycle the Key Switch OFF, then ON. captured. The display will indicate how far
3. Enter SuperWord Mode. the lift truck is deviating from the wire.
See Figure 3-5.
4. Enter Learn Mode and select Guidance.
The OD reads Step on deadman or
ENTER to Abort.
5. Step on the deadman pedal.
6. The OD shows Center on wire, then
Figure 3-5. Deviation From Wire
ENTER. The lift truck is already centered
over the wire. Select ENTER. NOTE: A beep no longer means that the learn
7. The OD shows Wait…, and may take up to procedure is finished.
30 seconds to gather signal samples.
13. If possible, travel the full length of the wire
You are now finished with Phase 1 of the Learn or until the letter of your travel direction
process. begins to flash. The display will show a T
for tractor-first or F for forks-first. See
NOTE: The wire guidance does not have a
Figure 3-6.
frequency selection. Step 6 is the lift
truck learning the correct frequency.

Figure 3-6. Example of Tractor-First

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

Entering Program Mode

14. Once all data points are captured in one

direction, or wire has run out, plug to a
stop and travel in the opposite direction.
15. Continue to drive up and down the wire in
both directions until the display flashes
OK. See Figure 3-7. This indicates that
both directions have collected sufficient
data points.

Figure 3-7. Collection of Data Points Complete

16. Coast to a stop.

17. After coming to a stop, the system will
scroll Press ENTER. Select ENTER.
You are now finished with the Phase 3 of the
Learn process.

18. Exit Learn by using the Up and Down

arrows to cycle through the menu. Select
Quit Lrn. Select ENTER. You are now back
to the main menu.
19. Select Quit.

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Entering Program Mode

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

By entering Static Maintenance Mode,

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

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

Entering Program Mode

Active Maintenance Mode Event Log

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

Power Amplifier Reset

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

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FlashWare

FlashWare the key switch OFF, connect cable

P/N 1120332/XXX to a USB port on the
device and the P3 connector on the
Overview manager. See Figure 3-8.
• USB to Serial - this method requires the
FlashWare allows you to update software, view correct drivers to be installed on the
and configure options on the lift truck through device. With the key switch OFF, connect a
the following features: cable P/N 610-809/W7P to a USB port on
• Update Vehicle Manager software the PC and the J9 connector on the VM.
See Figure 3-8.
• Clear Primary Memory
• Clear Vehicle Manager Serial connector (J9) USB connector (P3)
• Reset factory default settings
• Update Display software
• Update Power Amplifier Software

For more detailed FlashWare information, click

on “Help” and select “Help Topics” from the
menu bar.

FlashWare can be installed on any PC. The PC

communicates with the truck software via a
serial (9 pin) or USB port. Figure 3-8. Lift Truck FlashWare Connections

Installing FlashWare on a Starting FlashWare

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

If you are a Raymond Sales and Service Center

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

To install FlashWare on the PC, double-click the

installation file and follow the instructions on
the screen. The software package is a
self-extracting executable file. Read the
“Readme” file in the software package for the
latest detailed installation instructions.

Connecting Device to Lift Truck Figure 3-9. Lift Truck Opening Screen
There are two methods available to connect the
NOTE: When entering or using FlashWare, it is
device to a manager:
normal for a 50 Series Code to be
• USB to USB - this method requires the displayed.
correct drivers to be installed on the
device. Typically, this type of connection is
much faster than a serial connection. With

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Starting FlashWare

2. From the menu bar, click

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

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Wire Guidance

Wire Guidance Wire Guidance Setup

This procedure should not normally have to be
Wire guidance is a means to automatically steer performed. For the lift truck to guide correctly,
the lift truck while traveling in an aisle. It offers the following must be true, depending on the lift
precise steering at full-speed travel in Very truck configuration:
Narrow Aisle (VNA) applications.
• for 5.2 kHz, the current through the guide
A wire guidance system consists of two wire must be 100 mA peak-to-peak ±10%
sub-systems. • for 5.2 kHz, the current through the guide
• Warehouse-installed equipment includes a wire must be 300 mA peak-to-peak ±10%
guide wire and line driver. The guide wire
• for 6.25 kHz, the current through the
is installed in the floor and emits an
guide wire must be 225 mA peak-to-peak
Alternating Current (AC) signal at a
±10%
specific frequency and amplitude
generated from the line driver. If the warehouse portion of the guidance system
has a different line driver output, refer to
• Lift truck-installed equipment includes:
Learning Wire Frequency on page 3-21.
• Two guidance sensors, tractor end and
load end
• Guidance Manager (GM)
• Steer feedback encoder
• Auto/Manual switch, on operator
console
• Associated cables and mounting
brackets
The lift truck must learn the amplitude
and frequency of the guidance signal to
correctly track the guide wire.
NOTE: This manual covers all lift
truck-installed equipment. For
information on warehouse-installed
equipment, refer to the applicable Wire
Guidance maintenance manual.
To operate wire guidance, refer to the operator
manual.

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

Cold Storage

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

Heater Assemblies

Location
Components
Carriage Control Card Control Handle Deadman Pedal

Heating elements HTRC HTRH HTRDM

Thermostats S81 S91 S80

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

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Storage

Storage the reservoir is full before storing. Before

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

Use extreme care when the lift truck is

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

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

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

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

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Section 3. Systems Overview Models 5300/5500/5600 Maintenance Manual

UL Label “EE”

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

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Models 5300/5500/5600 Maintenance Manual Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance

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Section 4. Scheduled Maintenance Models 5300/5500/5600 Maintenance Manual

Maintenance Guidelines

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

Scheduled Maintenance includes:

• Lubrication
• Cleaning
• Inspection
• Service

Perform all of the scheduled inspections and

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

When operating under severe or extreme

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

Table 4-1. Maintenance Frequency

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

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Models 5300/5500/5600 Maintenance Manual Section 4. Scheduled Maintenance

Maintenance Minder™ Tool

Maintenance Minder™ Setting Time Interval and Action

Option
Tool
The first time you enter the time interval menu,
Maintenance Minder Tool is a feature that alerts the factory default setting is displayed.
the operator when the lift truck is due for Afterward, when you enter the time interval
scheduled maintenance. menu, the last used setting is displayed. Values
from 50 to 500 hours, in increments of 50, are
Maintenance Minder, when configured and available. Use the Up/Down button to scroll to
enabled, monitors the Hours on Deadman (HD) the desired time interval. With the desired value
meter. When the time interval for scheduled displayed, press the Enter button.
maintenance is exceeded, the operator is
informed in the following ways: Use the Up/Down button to select the desired
action option. Then press the Enter button.
• One of two messages scrolls on the OD for
at least 30 seconds following the DAILY • MSG ONLY causes the OD to show
CHECKLIST message: SCHEDULED MAINTENANCE DUE when the
scheduled maintenance time interval is
Scheduled maintenance due
exceeded.
or
• L CUTOUT causes the OD to show LIFT CUT
Lift cutout, scheduled maintenance due
OUT, SCHEDULED MAINTENANCE DUE when the
• A wrench icon flashes scheduled maintenance time interval is
• The audible alarm sounds the high-low exceeded. Lift is disabled the next time the
tone for approximately 5 seconds power circuits are cycled.

Lift Cutout, when active, does not disable the Use the Up/Down button to select QUIT MM from
lift function until power to the control circuits is the submenu. If the status has changed, you
cycled (key switch OFF or battery are prompted to save changes. Press the Enter
disconnected). When control circuit power is button.
cycled, lift is disabled until Maintenance Minder NOTE: From the Config Menu, exit by selecting
is reset or disabled, or the lift cutout option is QUIT CFG. You will not be prompted again
turned OFF. to save changes, but any changes saved
when you QUIT MM are retained.
Enabling
Changing Time Interval or
Once installed in the configuration options,
MAINTENANCE MINDER appears in the Configure
Action Option
Mode menu. The initial factory setting is
DISABLE. To enable the feature, enter Configure When Maintenance Minder is active, and you
Mode. wish to change the time interval or action
option, enter Configure Mode.
NOTE: For instructions on selecting Modes of
Operation, see Operator Display on With Configuration Mode selected, use the
page 3-7. Up/Down button to display the MNT MIND item.
Press the Enter button. When entered from an
With Configuration Mode selected, use the enabled state, Maintenance Minder offers a
Up/Down button to scroll to display submenu with the options QUIT MM, RESET,
MAINTENANCE MINDER. Press the Enter button. DISABLE, and SETUP. Use the Up/Down button to
When entered from a disabled state, select SETUP, then press the Enter button. The
Maintenance Minder offers a submenu with the current time interval is displayed (hours).
options QUIT MM and ENABLE. Use the Up/Down Proceed as described under “Setting Time
button to select ENABLE. Press the Enter button. Interval and Action Option” on page 4-3.

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Section 4. Scheduled Maintenance Models 5300/5500/5600 Maintenance Manual

Resetting Maintenance Minder

Resetting Maintenance Minder

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

With Configuration Mode selected, use the

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

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

With Configuration Mode selected, use the

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

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Models 5300/5500/5600 Maintenance Manual Section 4. Scheduled Maintenance

Initial 90 Day/250 Deadman Hours (HD) Maintenance

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

Component What to do

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

Hydraulic Tank Change filter.

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

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Section 4. Scheduled Maintenance Models 5300/5500/5600 Maintenance Manual

Every 180 Days or 500 Deadman Hours (HD)

Every 180 Days or 500

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

Component What to do Refer to

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

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

(3.2 to 4.8 km/hr) empty, push the EPO switch. The empty lift truck Page 7-61
should stop within 2 to 4 feet (0.6 to 1.2 m). During normal
operation, with a rated load and traveling at top speed, the lift truck
should stop within approx. one and one-half lift truck lengths.
Stopping distance depends on the load, floor, and tire condition.
Examine for signs of oil on the pads or rotor. If oil is present,
disassemble the brake, clean the rotor and replace the pads. Check
brake gap.

Contactors Inspect contactor tips for burnt or pitted surfaces. Failure to replace
the tips may prevent the contactor from opening or closing causing Page 4-12
unscheduled downtime. With the key switch OFF and the battery
disconnected, check the plunger for smooth operation with no
binding. If binding occurs, the lift truck may malfunction or exhibit
intermittent fault codes.

Control Handle Verify that travel function is smooth and responsive through full Page 7-19
range of motion. Check for play in the center position of the travel
control. Verify all handle switches function correctly.

Deadman Pedal Check for smooth operation with no binding. Check for correct Page 7-25
activation and deactivation of the deadman switch by the pedal.

Drive Unit Inspect for leaks. Check the fluid level. Make sure the O-ring is Page 7-27
present on the dipstick. Examine for radial ring wear. Apply grease to
the steer gear on the drive unit. Lubricate all grease points on the
drive unit.

Electrical Cables Inspect all power cables for nicks or cuts. Give special attention to
cables that are not stationary, for example, cables to the drive motor.
Replace any cable that is damaged or shows signs of excessive heat.
Failure to do so causes intermittent system shutdowns and/or
electronic failures. Check the tension of the over-the-mast pulley
cables. Set tension so the cables just stay on the pulleys. Higher
tension causes premature failure. Maximum spring tension is 5 to 7
in. lb. (0.57 to 0.79 Nm).

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Models 5300/5500/5600 Maintenance Manual Section 4. Scheduled Maintenance

Every 180 Days or 500 Deadman Hours (HD)

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

Component What to do Refer to

Forks Examine for excessive wear, bends, cracks, welding arcs, excessive Page 7-119
heat, or unauthorized modifications and replace if found. Check fork
up tilt. It must be between level and 0.5 in. (12.7 mm) maximum.
Check fork tip height. Verify they are within 0.25 in. (6.3 mm) of each
other (31 in. and longer) or 0.125 in. (3.2 mm) of each other (under 31
in.) at the tips.

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

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

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

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

Hydraulic Tank Check the fluid level.

Lift Chains Check adjustment. Adjust the main lift chain so the top of the inner Page 4-11
telescopic is even with the outer telescopic ±0.125 in. (3.2 mm) and Page 7-122
both chains have equal tension. Adjust the free lift chains so the top
of the fork just in front of the platform is at a minimum of 2.75 in. (70
mm) from the floor and the tips are at a maximum of 3.5 in. (89 mm)
from the floor. Inspect free lift cylinder chain anchors and springs.
Inspect for excessive stretch or wear (tool P/N 939-10606).

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

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Section 4. Scheduled Maintenance Models 5300/5500/5600 Maintenance Manual

Every 180 Days or 500 Deadman Hours (HD)

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

Component What to do Refer to

Mast Wipe old grease off mast uprights and apply new grease. Inspect
anti-rattle pads. Examine mast bearings. Inspect mast and carriage Page 7-111
stops for tightness and wear. Inspect rails for abnormal wear, metal
flakes, or shavings. Repair any grooves worn in the mast deeper than
1/8 in. (3 mm).

Motors AC - Check cable lugs. Make sure they are tight to the terminal
studs. The outside nut should be torqued to the value listed on
page 7-72. Replace any cable that shows signs of excessive heat.
Check sensor wires for sound connection and condition. Blow out the
inside of the motor with compressed air.

DC - Visually inspect brushes for excessive heat (discoloration of the

pigtails). If excessive heat is evident, inspect the armature circuit for
loose connections. Check the condition of the commutator per photos
on page 5-12. Find the shortest brush in the holder. Remove each
brush and check overall dimension per the table on page 7-74.
Inspect each brush for even wear over the full surface of the brush. If
the brush is not contacting the complete surface, replace the
brushes. Inspect the brush rigging for damage or loose brush
holders. Make sure the connections on the brush leads are tight.
Check the brush spring tension. Blow out the inside of the motor
with compressed air. Blow out the impeller and cooling fins. Make
sure cable lugs are tight to the terminal studs. The inside and outside
nuts should be torqued to the values listed on page 7-72. Replace any
cable that shows signs of excessive heat. Check sensor wires for
sound connection and condition.

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

Pallet Clamp Check the operation of the pallet clamp.

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

Safety Harness and Check for signs of wear, fraying, or damage.

Tether

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

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

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

Steering Check that the steering system function is smooth and responsive,
without binding and excessive play. Inspect the teeth on the steer
gear and drive unit for wear.

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Models 5300/5500/5600 Maintenance Manual Section 4. Scheduled Maintenance

Every 180 Days or 500 Deadman Hours (HD)

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

Component What to do Refer to

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

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

Warning Decals Replace any illegible or damaged decals.

Warning Lights Check for correct operation.

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

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

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Section 4. Scheduled Maintenance Models 5300/5500/5600 Maintenance Manual

Every 360 Days or 2000 Deadman Hours (HD)

Every 360 Days or 2000

Deadman Hours (HD)

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

Component What to do Refer to

Drive Unit Change the fluid. Page A-2

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

Lift Pump Separate the lift pump and motor. Apply lubricant (P/N 1223184) to Page 7-96
the spines.

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Models 5300/5500/5600 Maintenance Manual Section 4. Scheduled Maintenance

Chain Maintenance

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

Condition Cause Maintenance Procedure

Use a chain gauge or lay the chain on a flat

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

Steam cleaning or degreasing new

Rust and Corrosion Lubricate chain frequently.
lift truck chains

Infrequent Oiling

Rust
Cracked Plates Replace the chain.
Corrosion

Chain Fatigue

Bent pins or plates Replace the chain.

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

Chain Side Wear Chain misalignment Replace the chain.

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Section 4. Scheduled Maintenance Models 5300/5500/5600 Maintenance Manual

Contactor Tip Inspection

Contactor Tip Inspection

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

Figure 4-1. Severely Pitted Contactor

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Models 5300/5500/5600 Maintenance Manual Section 5. Troubleshooting

Section 5. Troubleshooting

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Section 5. Troubleshooting Models 5300/5500/5600 Maintenance Manual

Electrical Troubleshooting

Electrical • Whenever measuring resistance, turn the

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

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Models 5300/5500/5600 Maintenance Manual Section 5. Troubleshooting

Shorts to Frame

• Contactors 4. With the battery disconnected (or removed

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

Install another battery in the lift truck and • Motors

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

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

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Section 5. Troubleshooting Models 5300/5500/5600 Maintenance Manual

Shorts to Frame

shorts to frame in the travel circuit,

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

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Models 5300/5500/5600 Maintenance Manual Section 5. Troubleshooting

Battery State-of-Charge

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

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

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Section 5. Troubleshooting Models 5300/5500/5600 Maintenance Manual

Fuses

Fuses
Test /Inspection

Examine the fuse for signs of overheating,

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

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

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

Fuse Function Location Amps

FU1 Power Fuse for Steer Power Amplifier 100

FU2 Power Fuse for Traction Power Amplifier 350

Contactor Panel
Power Fuse for Lift Power Amplifier - Model 5500, 5600 500
FU3
Power Fuse for Lift Motor - Model 5300 500

FU5 Control Fuse for Vehicle Manager and Carriage Control 15

Card B+

FU6 Control Fuse for Vehicle Manager and Carriage Control 15

Card B–

FU7 Control Fuse for Warning Lights and Options B+ Fuse/Relay Card 5

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

FU8 Control Fuse for Warning Lights and Options B– 5

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

FU9 Control Fuse for 2A Power Option B+ Carriage Console 2

FU10 Control Fuse for 2A Power Option B– Plate 2

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

Control Fuse for Cold Storage Deadman Heater Carriage Console 5

FUDM
Plate

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Models 5300/5500/5600 Maintenance Manual Section 5. Troubleshooting

Fuses

Electrical Connector Locator Chart

Table 5-2. Connector Locator Chart

Connector Function or Routing Location

FSUP Connector on Fan Suppressor Near Fan

HTR3 Connector for Deadman Heater Near Deadman

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

JP1 Connector for Lights Light Assembly

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

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

JP2 Connector for Lights Light Assembly

JP10 Connector for Warning Light Under Warning Light

JPA7 Connector for Home Sensor Hydraulic Compartment

JPB– (–) Battery Connector

Battery Connector
JPB+ (+) Battery Connector

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

JPBR Connector for Brake Near Brake Assembly

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Section 5. Troubleshooting Models 5300/5500/5600 Maintenance Manual

Fuses

Connector Function or Routing Location

JPC1 Connector for Steering Encoder

JPC2 Connector for Display Card

JPC3 Connector for 60 in. Limit Switch

JPC4 Connector for Lower Inhibit

JPC5 Connector for Lights/Fans

JPC6 Connector for Lift/Lower Bypass Switch

JPC7 Connector for Deadman Switches

JPC8 Connector for 24 in. Limit Switch

JPC9 Connector for Control Handle

Carriage Control Card
JPC11 Connector for Over-the-Mast Cable B

JPC12 Connector for Spare Power

JPC13 Connector for Sidegate Switches

JPC14 Connector for Sidegate Switches

JPC15 Connector for Light Display Card

JPC16 Connector for Over-the-Mast Cable A

JPC19 Connector for Aux Lift and Lower Switch

JPC20 Connector for Aux Limit Switch

JPC21 Connector for Secondary Steer Input Encoder

JPE4 Connector for Steer Motor Encoder Hydraulic Compartment

JPF1 Fuse/Relay Card Amp and Aux Power Connector

JPF2 Fuse/Relay Card Relay Connector

Fuse/Relay Card
JPF3 Fuse/Relay B- Connector

JPF4 Fuse/Relay B+ and Key Switch Control Connector

JPLA1 Lift Amp Connector Lift Amplifier

JPLA2 Lift Motor Encoder Connector

Near bottom of Lift Motor
JPLA3 Lift Motor Temperature Sensor Connector

JPLA4 Lift Motor Encoder/Temperature Sensor Connector Hydraulic Compartment

JPS1 Contactor Panel Connector Contactor Panel

JPS2 Guidance Manager Power Connector

Guidance Manager Card
JPS4 Guidance Manager CAN Bus Connector

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

Behind Fuse/Relay Card
JPS10 Connector for Lift Limit Switch

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Models 5300/5500/5600 Maintenance Manual Section 5. Troubleshooting

Fuses

Connector Function or Routing Location

JPS15 Connector for Travel Alarm Near Lift Amp

JPS16 Connector for Travel Limit or Battery Gate Sensor Harness

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

JPS26 Connector for Over-the-Mast Cable A

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

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

JPS50 Connector for Intellispeed Pressure Sensor

Hydraulic Compartment
JPS51 Connector for Flow Module/Main Lift Encoder

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

JPS53 Connector for Rail Sense Switch Near Horn Assembly

JPS54 Connector for End-of-Aisle Harness

Hydraulic Compartment
JPS55 Connector for End-of-Aisle Harness

JPSC1 Splice for CAN Bus Below Battery Connector

JPSC2 Splice for CAN Bus Behind Drive Motor

JPT2 Vehicle Manager USB Port

JPT4 Vehicle Manager General Purpose I/O Connector

JPT6 Vehicle Manager Electric Steer Connector

JPT9 Vehicle Manager RS-232 Serial Port

JPT10 Vehicle Manager CAN Bus and Digital I/O Connector

JPT12 Lift Pendant Connector Vehicle Manager

JPT14 Vehicle Manager Power and CAN Bus Connector

JPT18 Vehicle Manager Coil Drivers Connector

JPT20 Vehicle Manager Coil Drivers Connector

JPT22 Vehicle Manager Digital I/O Connector

JPT24 Vehicle Manager Analog I/O Connector

JPTA1 Traction Power Amp Connector Traction Amplifier

JPTA2 Traction Motor Encoder Connector Near Bottom of Drive

JPTA3 Traction Motor Temperature Sensor Connector Motor

JPTA4 Traction Amp Sensor Harness Connector Top of Drive Motor Power
Cables

JPW1 Connector for Guidance Manager Tractor Harness Guidance Manager Card

JPW2 Connector for Guidance Manager Load Harness

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Section 5. Troubleshooting Models 5300/5500/5600 Maintenance Manual

Fuses

Connector Function or Routing Location

JPY1 Connector for Flow Module

JPY2 Connector for Flow Module Temperature Sensor

Flow Module
JPY6 Connector for Flow Module Flow Sensor

JPY7 Connector for Flow Module Flow Sensor

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Models 5300/5500/5600 Maintenance Manual Section 5. Troubleshooting

DC Motors

DC Motors
Mica Segment
Types of DC Motors
NORMAL
There are two primary types of DC Motors (refer UNDERCUT
to Figure 5-1):
• A series-wound motor has only two
High Mica
external connections because the
armature and field windings are connected
internally.
• A permanent magnet motor has two
HIGH MICA
external connections. The field is produced
by an internal magnet. Figure 5-2. Mica Undercutting
NOTE: Field connections may be labeled A or S.
Series wound motor field connections The commutator must be smooth and clean to
may be labeled D. provide maximum brush wear. When
commutators are not correctly maintained,
Series-Wound Motor carbon dust can collect in the grooves between
Permanent Magnet
the segments. This can lead to a short circuit in
S/D Motor
the armature.
MS+
A2
Remove the brushes from their box. Inspect the
MS contact surface and brush length. If the brush
surface has groove(s) or pit marks, it indicates
MS– the presence of a burr on the commutator
A1
MP surface.

Good commutation is indicated by a dark

A brown polished commutator and an evenly
polished brush wearing surface. See
Figure 5-1. Motor Circuits
“Commutator Surfaces” on page 5-12.

Inspection If the commutator appears rough, pitted, or has

signs of burning or heavy arcing between the
Inspect the commutator for surface condition commutator bars, remove the motor for
and high mica. Most armatures have the mica servicing.
undercut. If the armature on your motor does
not, do not attempt to cut it. Servicing

Some conditions identified in Table 5-3 may be

resolved by cleaning the commutator with a
special polishing stone. Polishing the
commutator should only be attempted for these
specified conditions. Refer to “Polishing the
Commutator” on page 7-74.

Some conditions can be resolved by recutting

the commutator on a lathe. This requires
special equipment and training and should only

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Section 5. Troubleshooting Models 5300/5500/5600 Maintenance Manual

DC Motors

be attempted at a qualified DC motor repair

facility.
Table 5-3. Commutator Surfaces

Condition Probable Cause Commutator Surface

Uniform coloring indicates satisfactory
BRUSHWEAR01.tif

operation of the machine and brushes.

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

This condition can appear in alternating bars as

BRUSHWEA03.tif

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

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

surface. May be accompanied by rattling or loud

Unsatisfactory operation. Frequently due to incorrect brush
Condition-Streaky Film with grade. Environmental conditions such as
No Commutator Wear freezer or low humidity, can be a contributing
factor. This condition may be repaired with a
polishing stone if caught soon enough. Refer to
Polishing the Commutator on page 7-74.
Patchy colors of varying densities and shape.
BRUSHWEAR05.tif

This condition is generally due to unclean

Unsatisfactory operating conditions and does not indicate
Condition-Uneven Film damage to the commutator. Clean the
commutator with a polishing stone and
compressed air (refer to Polishing the
Commutator on page 7-74). Consider more
frequent scheduled maintenance intervals.
Dark areas can be isolated or regular. Indicates
BRUSHWEAR06.tif

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

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

Unsatisfactory brushes to rub on the middle of the bars.

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

Unsatisfactory ride on entry and leaving bar edges. Continued

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

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Models 5300/5500/5600 Maintenance Manual Section 5. Troubleshooting

DC Motors

Condition Probable Cause Commutator Surface

This is a further development of the third
BRUSHWEAR09.tif

example. Earlier corrective action should have

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

pitches apart. May result from an armature

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

brushes in position for long periods. May also

result from operation in prolonged stall
Unsatisfactory conditions. Storage marks are easily removed
Condition-Brush Contact with a polishing stone (refer to Polishing the
Mark Commutator on page 7-74). Stall marks should
be cleaned and inspected for damage or shorts.
Motor should be replaced if damage has
occurred.
Condition is caused by high mica in every slot
BRUSHWEAR12.tif

and can be caused by improper or excessive

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

overloaded machines or low brush pressure.

Check brush spring tension (refer to Motor
Brush Spring Tension on page 7-73). If not
Unsatisfactory corrected, will result in damage to commutator.
Condition-Small Bright Spots May be repaired with a polishing stone (refer to
Polishing the Commutator on page 7-74) if
caught early and no scoring has occurred. If
damaged, motor should be replaced or recut at
a qualified repair facility

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Section 5. Troubleshooting Models 5300/5500/5600 Maintenance Manual

DC Motors

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

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

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Models 5300/5500/5600 Maintenance Manual Section 5. Troubleshooting

AC Motors

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

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

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

AC
3φ

V W
Figure 5-3. AC Drive Motor Circuits

Open Winding

If the AC motor fails with an open winding, the

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

Use a clamping ammeter to measure current in

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

Shorted Winding

If the AC motor fails with a shorted winding, the

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

Use a clamping ammeter to measure current in

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

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Section 5. Troubleshooting Models 5300/5500/5600 Maintenance Manual

AC Motors

Carriage Control Card Connectors

PC26 PC11 PC16 PC12

PC9

PC8

PC15 PC2

PC6

PC5

PC1

PC7

PC4

PC22 PC20

PC3 PC14 PC13

PC23 PC24 PC19 PC10

5
Figure 5-4. Carriage Control Card Connectors

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Models 5300/5500/5600 Maintenance Manual Section 5. Troubleshooting

AC Motors

Vehicle Manager Connectors

5MOTOR_AC3PHASEA.EPS
MOTOR_AC3PHASEB.EPS

Figure 5-5. Vehicle Manager Connectors

Guidance Card Connectors

D1
JW2
J2
Q9

J1
L1

D5

JW1

L2

F1
P6

P1 P2 P4 P5

5MOTOR_AC3PHASEA.EPS
MOTOR_AC3PHASEB.EPS

Figure 5-6. Guidance Card Connectors

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Section 5. Troubleshooting Models 5300/5500/5600 Maintenance Manual

AC Motors

Fuse Relay Card

5MOTOR_AC3PHASEA.EPS
MOTOR_AC3PHASEB.EPS

Figure 5-7. Fuse Relay Card Connectors

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Models 5300/5500/5600 Maintenance Manual Section 5. Troubleshooting

Fuse/Relay Card Troubleshooting

Fuse/Relay Card upper left mounting hole of the Fuse/Relay

Card (marked FGND). If necessary, clean or
Troubleshooting replace this screw to ensure a solid connection
to the frame.
Refer to Figure 5-7 for Fuse/Relay Card
component and connector location information.
To test, measure the resistance from the FGND
screw to any piece of bare metal on the frame
Fuses with a DMM. Resistance should be <0.5 ohm.
Fuses for system power (FU5 and 6) and Aux
power (FU7 and 8) are present on the
Fuse/Relay Card. Refer to page 5-6 for
inspection and testing of fuses.

Relays
Relays are hard-mounted. If a relay fails, the
Fuse/Relay Card must be replaced.
Figure 5-8. FGND Ground
Relay Circuit Possible Symptoms
Key-ON Key-ON options do not
K1
Aux Power power up with the lift truck. Input Diodes
Contactors, solenoids,
NOTE: Remove connectors JP1 through JP4
Subsystem before performing this test.
K2 brake, horn, or fans do not
Power
operate.
To test the relay coil input diodes:
Amps do not power up or
Amp
K3 they have stopped 1. Locate CR5 and CR6 on the Fuse/Relay
Power
communicating. Card.
Keep-alive accessories for 2. Measure the voltage using a DMM set to
Keep Alive
K4 Cold Storage do not the “diode” function.
Power
function.
3. Put the black probe on the banded (right)
side of the diode and the red probe on the
Inspection non-banded (left) side.
Voltage should be approximately 0.5V
Visually inspect each relay for discoloration, across each diode. An open circuit is
melting, or other signs of overheating. If found, displayed if the diodes are tested in the
replace the Fuse/Relay Card. reverse direction.
Test
4. Replace the Fuse/Relay Card as
1. Perform Test O32 - Toggle Relay Enable necessary.
(Page 6-128). Replace the Fuse/Relay Card
if necessary.

Capacitor and FGND

Problems with the filter capacitor (C3) are most
frequently observed on lift trucks equipped with
an RF scanner unit. Visually inspect the
capacitors for any sign of damage. The
capacitors may be physically different from the
one pictured. Inspect the mounting screw in the
Figure 5-9. Fuse/Relay Card Diodes

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Section 5. Troubleshooting Models 5300/5500/5600 Maintenance Manual

Fuse/Relay Card Troubleshooting

Inrush Protection
A resettable fuse protects the VM battery sense
circuit and can be reset by turning the lift truck
OFF momentarily. Opening of the fuse will
frequently manifest 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:
1. Remove JPF4 from the Fuse/Relay Card.
2. Measure the resistance from PF4-1 to
PF4-7. Resistance should be
approximately 1.3 ohms.
3. Replace the Fuse/Relay Card as
necessary.

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Models 5300/5500/5600 Maintenance Manual Section 5. Troubleshooting

Drive Unit Troubleshooting

Drive Unit
Troubleshooting
Refer to page 7-29 for standard drive unit repair
procedures and page 7-49 for heavy duty drive
unit repair procedures.

Table 5-4.

Symptom Probable Cause Required Action

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

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

Housing/cover joint Reseal

Worn or damaged housing Replace drive unit.

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

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

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

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

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

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

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

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

Steering Inadequate bearing lubrication Grease steering bearing.

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

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Section 5. Troubleshooting Models 5300/5500/5600 Maintenance Manual

Communication Error Code Troubleshooting

Communication Error Code Communication Code Every Time Key

Troubleshooting Is Turned ON

Troubleshoot per the code on the display using

Intermittent Communication Codes
Test I23 - CAN Bus (Page 6-81).
If possible, determine what the operator was
doing when the codes were generated such as
driving, plugging, lifting, or sounding the horn.

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 drive motor
is energized or when the horn is 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. If nothing is found in the following
steps, replace the key switch.
1. Test for shorts to frame. See Shorts to
Frame on page 5-2.
2. If equipped with an optional light/fan
package, disconnect PC5. If the code goes
away, troubleshoot the light/fan circuitry.
NOTE: The condition of the light/fan
suppressor module cannot be checked
with a DMM. If the suppressor module is
suspected to be bad, replace it.

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.
1. Test and clean the static straps.
2. Test for shorts to frame. See Shorts to
Frame on page 5-2.

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Models 5300/5500/5600 Maintenance Manual Section 5. Troubleshooting

Troubleshooting Aisle Exit Error Code J2

Troubleshooting Aisle
Exit Error Code J2
Refer to the “sub-codes” in Table 5-5 when
troubleshooting Code J2 - Aisle Exit Error.
NOTE: Subcodes are viewed in the error log.
They will be listed next to the J2 code in
place of BSOC.

Table 5-5. Code J2 Sub-Codes

Sub-Code Description

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

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

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

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

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

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

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

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

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

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

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

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

Publication: 1301126/001A, Issued: 12 Nov 2018 5-23

Section 5. Troubleshooting Models 5300/5500/5600 Maintenance Manual

Troubleshooting Aisle Exit Error Code J2

5-24 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual

Symptom Tables: Hydraulic Functions

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

Intermittent Lift/Lower

Possible Cause Action

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

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

Possible Cause Action

Bad battery Adjust lift cutout as necessary. Replace the battery
with a fully-charged battery.
Bad optional lift limit switch Run Test I05 - Lift Inhibit Switch (optional)
(Page 6-77) and Test I04 - Lift/Lower Inhibit
Bypass (optional) (Page 6-76).
12 Volts to the encoder is open. The motor will Run Test I20 - Lift Motor RPM (AC lift only)
turn very slow and the amperage will go high. (Page 6-80).

Slow Lift - Carriage: Lift motor runs

Possible Cause Action

Bad battery Adjust lift cutout as necessary. Replace the battery
with a fully-charged battery. Test the battery for
bad cells. See Battery Procedures on page 7-68.
Emergency lowering valve not seated correctly Make sure the emergency lowering valve is closed.
Check for contamination. If contamination is
present, clean the valve, flush, fill, and bleed the
hydraulic system.
Bad proportional lift/lower valve Inspect for binding. Run Test O12 - Proportional
Solenoid PWM Ramp (Page 6-121).
Relief valve REL1 stuck open Test system pressure. Check for contamination. If
contamination is present, replace the valve, flush,
fill, and bleed the hydraulic system.

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 Models 5300/5500/5600 Maintenance Manual

Lower Function

Possible Cause Action

Plugged or malfunctioning flow control valve Check for contamination in the hydraulic fluid. If
in lift cylinder contamination is present, inspect and clean the
relief valve, replace the flow control valves, flush,
fill, and bleed the hydraulic system.
Bad lift pump Test system pressure.
Binding in the mast Inspect the mast and bearings for signs of binding.
Bad lift motor DC Lift Trucks: Test the lift motor. Check amp
draw.
AC Lift Trucks: Run Test O28 - Ramp Lift Motor
(AC lift only) (Page 6-125).
Bad lift motor encoder Run Test I20 - Lift Motor RPM (AC lift only)
(Page 6-80).

Unable to Pick Up a Load

Possible Cause Action

Battery problems Adjust lift cutout as necessary.
Replace the battery with a fully-charged battery.
Test battery for bad cells. See Battery Procedures
on page 7-68.
Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Bad lift pump Test system pressure.
Bad lift motor DC Lift Trucks: Test the lift motor. See DC Motors
on page 5-11. Check amp draw.
AC Lift Trucks: Run Test O28 - Ramp Lift Motor
(AC lift only) (Page 6-125).

Lower Function
Slow Lower

Possible Cause Action

Binding proportional valve Check the proportional valve operation. Run Test
O12 - Proportional Solenoid PWM Ramp
(Page 6-121).
Mechanical binding in bearings or telescopic Adjust or replace the bearings. If still slow, check
the mast shimming.
Plugged or malfunctioning flow control valve Open the emergency lower valve. If still slow,
remove and inspect the flow control valves. Check
for contamination in the hydraulic fluid. If
contamination is present, inspect and clean the
relief valve, flush, fill, and bleed the hydraulic
system. If no contamination is found, replace the
flow control valves in the main lift cylinders.

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Models 5300/5500/5600 Maintenance Manual

Lower Function

Intermittent Lower

Possible Cause Action

Bad load holding solenoid Run Test O11 - Toggle Load Holding Solenoid
(Page 6-120).
Binding proportional valve Check the proportional valve operation. Run Test
O12 - Proportional Solenoid PWM Ramp
(Page 6-121).
Plugged or malfunctioning flow control valve Open the emergency lower valve. If still slow,
remove and inspect. Check for contamination in
the hydraulic fluid. If contamination is present,
inspect and clean the relief valve, flush, fill, and
bleed the hydraulic system. If no contamination is
found, replace the flow control valves in the main
lift cylinders.

Load Drifting/Settling

Possible Cause Action

Incorrect lift pressure adjustment Check and adjust the lift pressure setting.
Load holding solenoid Run Test O11 - Toggle Load Holding Solenoid
(Page 6-120). Check for contamination in the
hydraulic fluid. If contamination is present,
inspect and clean the relief valve, flush, fill, and
bleed the hydraulic system.
Load too large for lift truck capacity Check load weight. Check lift pressure setting.
Emergency lower valve leaking Replace the emergency lower valve.

Publication: 1301126/001A, Issued: 12 Nov 2018 5-27

 Models 5300/5500/5600 Maintenance Manual

Symptom Tables: Travel Functions

Symptom Tables: Travel

Functions
Slow or Sluggish Acceleration

Possible Cause Action

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

Slow Travel

Possible Cause Action

Note: Determine if problem is mechanical or electrical.
Mechanical:
Dragging the brake Adjust the brake.
Debris in the wheel axle Remove debris.
Binding the drive unit Remove the drive motor and check drive unit
movement.
Binding in the control handle Run Test A22 - Traction Throttle Request
(Page 6-55) to determine if the controller is still
seeing a 100% request.
Electrical:
Bad mast speed limit switch (S10 or S11) or Run Test I02 - Lower Mast Reference (24 in.)
associated wiring Switch (Page 6-74), Test I69 - Upper Mast
Reference Switch (Page 6-103), or Test I03 - 60 in.
Limit Switch (Page 6-75).
Incorrect configuration Reconfigure the lift truck.
Drive motor or power amplifier temperature Run Test A08 - Traction Motor Temperature
(temperature icon illuminated) (Page 6-46) or Test A10 - Traction Power Amplifier
Temperature (Page 6-48)
Bad encoder pulses from the drive motor Run Test I19 - Traction Motor RPM (Page 6-79).
encoder

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Models 5300/5500/5600 Maintenance Manual

Symptom Tables: Electrical Symptoms

Symptom Tables:
Electrical Symptoms
NOTE: Use these symptom tables in
conjunction with the electrical and
hydraulic schematics.
NOTE: For intermittent issues with optional
devices such as RF units, check the
Fuse/Relay Card Capacitor and FGND.
Refer to Troubleshooting Aisle Exit Error
Code J2 on page 5-23.

Electrical Motors

Motor Arcing

Possible Cause Action

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

Motor Overheating

Possible Cause Action

Dragging brake Adjust the brake. See Brake on page 7-61.
Application exceeds designed workload -- Check with Raymond Sales and Service Center
short runs with plugging/acceleration or Service Manager to verify this is a correct
heavy duty lifting cycles application.
Using deadman pedal to stop all the time
Bad battery Check the battery voltage, both open circuit and
under load. Replace if necessary with fully-charged
good battery.
Incorrect BSOC Cutout value Check the battery specific gravity at cutout, after
the battery has stabilized. Compare to the battery
manufacturer specifications for discharged
battery. Adjust the BSOC Cutout as needed.
Cable, terminal, or wiring problems Replace the wiring or cables as necessary. See
Look for discolored terminals, loose or Power Cables on page 7-70.
damaged crimps Check the cable connection torque. See
Component Specific Service/Torque Chart on
page A-4.
Worn, damaged, or bad brushes or springs Inspect the motor brushes.
Check the brush spring tension.
Binding gearbox or pump Check the gearbox or pump for binding. Clean,
repair, or replace as necessary.
Hydraulic fluid viscosity too high or too low Replace the hydraulic fluid with the correct fluid.
See Lubrication Specification Chart on page A-2.
Pressure relief set too high Adjust the pressure relief.

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 Models 5300/5500/5600 Maintenance Manual

Symptom Tables: Electrical Symptoms

Operator Display Problems

Scrambled or Intermittent Display

Possible Cause Action

Loose JPC15 harness or Re-seat cards and harness connections.
card connectors
Intermittent wires or Test for continuity while flexing the harness. If discontinuity is found,
connectors in harness replace the wiring harness.
Electrical noise in Check the tightness of motor power cable connections (see page 7-70).
motors Check the motor brushes for arcing. Replace if necessary.
Bad key switch Replace the key switch.
Worn or missing static Replace as necessary.
straps

Dead Lift Truck

Display is Dark - No functions operate

Possible Cause Action

No LEDs illuminated Refer to Pin-Out Matrix on page 8-21 and the Electrical Schematics. Check
on circuit cards for B+ at the following locations wrt TP4:
• FU5
• JPF4-10
• JPC16-8
• JPC6-1
• JPC6-2
• JPC16-6
• JPF4-8
• JPF4-11
• JPT14-12
Check for B– at the following locations wrt TP1:
• FU6
• JPF3-3, 4, 5, 6, 7, 8 and 12
• JPT14-1, 2, 8, 9 and 10
• JPC16-4
• JPT14-3
• JPC11-6
If all of the above locations have the correct voltages, refer to the Diagnosis
and Repair table in Test A14 - VM +12V Power Supply (Page 6-51).

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Models 5300/5500/5600 Maintenance Manual

Symptom Tables: Electrical Symptoms

Auto Steer Center Problem

Intermittent Lift Truck Error Codes

Possible Cause Action

Noise, shorts to frame See “Shorts to Frame” on page 5-2.
Calculated position of Error Code G2 displayed, see CODE G2 Inform service on page 6-38.
the drive unit bad Check the adjustment of the home prox sensor.
Large correction to Steer motor encoder, steering amp, or VM may be bad. Check the home
steering prior to braking prox sensor adjustment.
Mechanical issue, worn Repair or replace as necessary.
radial ring

Lift Truck Codes After Deadman Pedal Pressed

Possible Cause Action

Steering will move in See “Test I25 - Steer Motor Encoder” on page 6-84.
both directions during
auto center
Steering only in one Check the home proximity sensor adjustment. See “Test I24 - Home
direction Position Proximity Sensor” on page 6-83. Run Test O44 - Steer Motor
(Page 6-134).
No movement in Run Test O44 - Steer Motor (Page 6-134). Repair or replace as
steering. Mechanical necessary.
issue, worn radial ring

Lift Truck Codes Before Deadman Pedal Pressed

Possible Cause Action

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

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 Models 5300/5500/5600 Maintenance Manual

Symptom Tables: Electrical Symptoms

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes, and Tests

Section 6. Messages, Codes, and Tests

Publication: 1301126/001A, Issued: 12 Nov 2018 6-1

Section 6. Messages, Codes, and Tests Models 5300/5500/5600 Maintenance Manual

Power Amp LED Diagnostics

Power Amp LED

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

The power amps also contain a Light Emitting

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

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes, and Tests

Summary List

Summary List
Messages
LPA Approaching Overtemperature (temp icon only). . . . . . . . . . . . . . . . . . . . . . 6-9
TPA Approaching Overtemperature (temp icon only) . . . . . . . . . . . . . . . . . . . . . 6-9
Aligning: Wire Is Sensed Truck Is Now Aligning . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Battery State-of-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
The height tracking system needs to recalibrate position. . . . . . . . . . . . . . . . . 6-10
End-of-Aisle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
EPO Pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
EPO has been pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Incorrect FlashWare Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Guidance Not Learned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
24 in. Limit Switch Not Sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Interlock activated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Truck will not pass SelfTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Scheduled Maintenance Reminder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Installed battery is too light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Truck Lift Speed Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Truck is disabled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
RDP has timed out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Load Coil Pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Tractor coil pair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Lost wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Lower Side Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Truck Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Platform Hung... Lift Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Press auto/manual switch to auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Switch (S24) Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Truck Lowering Inhibited. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Aux Buttons Pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Both Pendant Buttons Pressed Before Time-out. . . . . . . . . . . . . . . . . . . . . . . . 6-15
Truck Lift/Lower Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Control Handle Moved Before Deadman Pressed . . . . . . . . . . . . . . . . . . . . . . . 6-15
Release lift to resume operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Scheduled Maintenance Reminder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Seeking: AUTO/MAN Switch Is In Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
TPA not receiving Motor RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Speed Limited Due To Steer Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Truck Speed Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Truck Stalled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Truck Steering Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Truck Travel Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Truck Travel Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
View SWM Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 10: SelfTest Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 1H: TPA Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 1K: Platform Hung Lift Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 2A: Traction Motor Approaching Overtemperature. . . . . . . . . . . . . . . . . . 6-19

Publication: 1301126/001A, Issued: 12 Nov 2018 6-3

Section 6. Messages, Codes, and Tests Models 5300/5500/5600 Maintenance Manual

Messages

Code 2E: Traction Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . 6-19

Code 2G: Phase Open on Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 2H: Failure Detected in Traction Motor Speed Feedback Encoder . . . . . . . 6-20
Code 2M: TPA Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 2Q: Left TPA Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 2T: TPA Current Calibration Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 2U: TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 2V: High DC BUS Voltage – TPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 2X: TPA Power Supply Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 2Y: Incorrect Traction Power Amplifier Installed . . . . . . . . . . . . . . . . . . . . 6-21
Code 42: LPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . . . . 6-22
Code 43: LPC Detected Open When Commanded Closed . . . . . . . . . . . . . . . . . . 6-22
Code 4C: FU1 Sense Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 4F: TPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . . . . 6-22
Code 4G: TPC Detected Open After Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 4H: TPA, TPC Contactor Coil or Coil Driver Open or Shorted. . . . . . . . . . . 6-23
Code 4K: LPA, LPC Contactor Coil or Coil Driver Open or Shorted . . . . . . . . . . . 6-23
Code 50: No VM Communications Received by CCC . . . . . . . . . . . . . . . . . . . . . 6-23
Code 51: No CCC Communications Received by VM . . . . . . . . . . . . . . . . . . . . . 6-23
Code 56: Platform Hung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 59: CAN Transmission Buffer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code 5A: CAN BUS Error Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code 5B: Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code 5E: No Guidance Manager CAN Communications Received by the VM . . . 6-24
Code 5G: No Communications Received by VM from TPA. . . . . . . . . . . . . . . . . . 6-24
Code 5J: No communications Received by VM from LPA . . . . . . . . . . . . . . . . . . 6-25
Code 5M: No communications received by TPA from VM.. . . . . . . . . . . . . . . . . . 6-25
Code 5P: No communications received by LPA from VM. . . . . . . . . . . . . . . . . . . 6-25
Code 61: 24 in. Limit Switch Not Sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code 63: Upper and Lower Reference Switches Do Not Agree. . . . . . . . . . . . . . . 6-26
Code 64: No Flow Sensor Pulses When Lift/Lower Requested . . . . . . . . . . . . . . 6-26
Code 66: Calculated Height Does Not Match at Upper Reference Switch (150 in.) 6-26
Code 67: Calculated Height Does Not Match at Lower Reference Switch (24 in.). 6-26
Code 6D: Lift Pressure Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code 6F: Lift Motor Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code 6K: 60 in. Switch Does Not Agree with Lower Mast Reference . . . . . . . . . . 6-27
Code 6M: 60 in. and/or 24 in. Switch Disconnected . . . . . . . . . . . . . . . . . . . . . 6-27
Code 6N: Flow Sensor Temperature Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code 6P: 60 in. Limit Switch Out-of-Sequence with Upper
Reference Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code 7E: Lift Motor Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . 6-28
Code 7F: LPA Temp Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code 7G: LPA Motor Phase Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code 7H: Failure Detected in Lift Motor Feedback Encoder . . . . . . . . . . . . . . . . 6-28
Code 7M: LPA Failed to Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code 7Q: LPA Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code 7T: LPA Current Sensor Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code 7U: LPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code 7V: LPA High Voltage on DC BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code 7X: LPA Power Supply Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code 7Y: Incorrect Lift Power Amplifier Installed . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code 80: Throttle Potentiometer (VR1) Voltage Out-of-Range . . . . . . . . . . . . . . . 6-30

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes, and Tests

Messages

Code 81: Lift/Lower Potentiometer (VR2) Voltage Out-of-Range . . .. .. . .. . .. 6-30

Code 83: Throttle Potentiometer (VR1) Out-of-Neutral . . . . . . . . . .. .. . .. . .. 6-30
Code 84: Brake Inoperable; Not Applied. . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-31
Code 88: Lift and/or Travel Potentiometer Voltage Out-of-Range . .. .. . .. . .. 6-31
Code 8C: Deadman Switches Do Not Agree . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-31
Code 8F: Lift/Lower Potentiometer Out-of-Neutral . . . . . . . . . . . . .. .. . .. . .. 6-31
Code 8L: Electric Brake Feedback . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-31
Code 91: Drive Unit Turned >10° while Guiding on Wire . . . . . . . .. .. . .. . .. 6-32
Code 92: Tracking Limits Exceeded . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-32
Code 93: Not Near Wire; Tractor Coil Pair . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-32
Code 94: Not Near Wire; Load Coil Pair . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-32
Code 9A: Bad Wire Guidance Learn . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-33
Code 9B: Bad SDO (CAN - Service Data Object) Data Received. . . .. .. . .. . .. 6-33
Code 9E: Track And Hold Signal Failed . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-33
Code 9G: No Input; Load Antenna . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-34
Code 9H: No Input; Tractor Antenna . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-34
Code 9J: Load Antenna Input Too High . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-34
Code 9K: Tractor Antenna Input Too High . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-34
Code 9M: Tractor Antenna Input Too High. . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-35
Code A0: Incorrect Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-35
Code A2: Software Compatibility Issue with VM and TPA . . . . . . . .. .. . .. . .. 6-35
Code A4: Software Compatibility Issue with VM and LPA . . . . . . . .. .. . .. . .. 6-35
Code AH: Bad CCC Checksum. . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-35
Code AL: VM Battery Backed Up RAM Failed . . . . . . . . . . . . . . . . .. .. . .. . .. 6-36
Code AP: TPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-36
Code AT: LPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-36
Code F8: Microcontroller COP . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-36
Code FE: Internal VM Circuit for BSOC Not Calibrated . . . . . . . . .. .. . .. . .. 6-36
Code FG: +5V Reference Voltage and +12V Power Supply Failure. .. .. . .. . .. 6-37
Code FH: Battery Voltage Out-of-Range . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-37
Code FN: Relays Did Not Open at Power Off . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-37
Code FP: VM In-Circuit Hardware Failure . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-37
Code FT: VM Internal Software Error . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-38
Code G0: Steer Tiller Encoder 1 is Intermittent or Failed . . . . . . . .. .. . .. . .. 6-38
Code G2: Auto Steer Center Failed. . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-38
Code G3: Home Prox Switch Not Functioning Correctly . . . . . . . . .. .. . .. . .. 6-38
Code G4: Open Detected in Steer Control Circuit . . . . . . . . . . . . . .. .. . .. . .. 6-39
Code G5: Short Detected in Steer Power Circuit. . . . . . . . . . . . . . .. .. . .. . .. 6-39
Code G7: Steer Tiller Encoder 2 is Intermittent or Failed . . . . . . . .. .. . .. . .. 6-39
Code GD: No Steer Motor Encoder Pulses Seen . . . . . . . . . . . . . . .. .. . .. . .. 6-39
Code GE: Both Steer Tiller Encoders Failed . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-40
Code GF: Wire Guidance Position Out-of-Range. . . . . . . . . . . . . . .. .. . .. . .. 6-40
Code J2: Aisle Exit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-40
Code J4: Aisle Sensor Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-40
Code VC: The CAN Chip will not Reset. . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-41
Code X3: 180 in. Limit Switch Mismatch . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-41
Code X4: Lift Cutout Switch Mismatch . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-41
Code X5: Lift Inhibit Switch Mismatch. . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 6-41
Test A04 - Throttle Potentiometer Voltage . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-44
Test A05 - Lift/Lower Potentiometer Voltage . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-45
Test A08 - Traction Motor Temperature . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-46
Test A09 - Lift Motor Temperature . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-47

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Section 6. Messages, Codes, and Tests Models 5300/5500/5600 Maintenance Manual

Messages

Test A10 - Traction Power Amplifier Temperature . . . . . . . . . . . . . . . . . . . . . . . 6-48

Test A11 - Traction Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Test A13 - Pressure Sensor Voltage (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Test A14 - VM +12V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Test A15 - Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Test A19 - Lift Power Amplifier Temperature (AC lift only) . . . . . . . . . . . . . . . . . 6-53
Test A20 - Lift Motor Current (AC lift only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Test A22 - Traction Throttle Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Test A23 - Lift Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Test A26 - +5.3VDC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Test A34 - Lift/Lower Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Test A35 - Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Test A37 - Steer Power Amplifier Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Test A51 - Left Tractor Guidance Coil Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Test A52 - Right Tractor Guidance Coil Voltage . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Test A53 - Left Load Guidance Coil Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Test A54 - Right Load Guidance Coil Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Test A55 - Tractor Near Wire Coil Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
Test A56 - Load Near Wire Coil Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Tests A96 through A100 - iBATTERY Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
Test A101 - Guidance Manager 12V Power Supply Out-of-Range . . . . . . . . . . . 6-69
Test I00 - Carriage Deadman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Test I01 - Brake Deadman Switch (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Test I02 - Lower Mast Reference (24 in.) Switch . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Test I03 - 60 in. Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Test I04 - Lift/Lower Inhibit Bypass (optional) . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
Test I05 - Lift Inhibit Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Test I15 - Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Test I19 - Traction Motor RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Test I20 - Lift Motor RPM (AC lift only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Test I23 - CAN Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Test I24 - Home Position Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
Test I25 - Steer Motor Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Test I26 - Height Encoder - Main Lift (With Full Height Sensing) . . . . . . . . . . . 6-85
Test I26 - Flow Sensor Count (Without Full Height Sensing) . . . . . . . . . . . . . . . 6-86
Test I35 - Steer Tiller Encoder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Test I36 - Steer Tiller Encoder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
Test I38 - EPO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Test I39 - Neutral Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Test I41 - Aux Mast Lift Switch S32 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
Test I42 - Aux Mast Lower Switch S33 (Option) . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Test I43 - Slack Chain Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Test I44 - Aux Limit Switch S34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95
Test I45 - Slk S29 [Slack Chain 1 Switch (S29)] . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Test I46 - Slk Ch S30 [Slack Chain 2 Switch (S30)] . . . . . . . . . . . . . . . . . . . . . 6-97
Test I64 - Height Encoder - Free Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
Test I65 - Rail Guidance Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99
Test I66 - Auto/Manual Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100
Test I67 - Sidegate Switches (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
Test I68 - Travel Cutout/Battery Gate and PLS Switch (optional) . . . . . . . . . . 6-102
Test I69 - Upper Mast Reference Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
Test I72 - End-of-Aisle Sensor 2 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes, and Tests

Messages

Test I73 - End-of-Aisle Sensor 1 (optional) . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-106

Test I74 - Lower Inhibit Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-108
Test I75 - 180 in. Limit Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-109
Test I76 - Lift Cutout Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-110
Test I86 - Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-111
Test I91 - iPORT Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-112
Test I92 - iPORT Error Bitmap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-113
Test I93 - End-Of-Aisle EOA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-114
Test I120 - Height Reference Proximity Sensor Status . . . . . . . . . . . . . . .. . . . 6-115
Test O00 - Toggle the Traction Power Contactor . . . . . . . . . . . . . . . . . . .. . . . 6-118
Test O02 - Toggle the Lift Power Contactor . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-119
Test O11 - Toggle Load Holding Solenoid . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-120
Test O12 - Proportional Solenoid PWM Ramp . . . . . . . . . . . . . . . . . . . . .. . . . 6-121
Test O18 - Toggle Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-122
Test O19 - Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-123
Test O20 - Travel Alarm (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-124
Test O28 - Ramp Lift Motor (AC lift only) . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-125
Test O29 - Ramp Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-126
Test O30 - Toggle Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-127
Test O32 - Toggle Relay Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-128
Test O39 - Display Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-129
Test O40 - Lift/Lower Alarm (optional) . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-130
Test O41 - Aux Select Solenoid (optional) . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-131
Test O42 - Main Select Solenoid (optional) . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-132
Test O43 - Aux Load Hold Solenoid (optional) . . . . . . . . . . . . . . . . . . . . .. . . . 6-133
Test O44 - Steer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 6-134

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Section 6. Messages, Codes, and Tests Models 5300/5500/5600 Maintenance Manual

Messages

6-8 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Messages and Codes

Messages and Codes

Section 6. Messages, Codes and Tests

NOTE: Codes C46 and C47 are iPORT related

codes. Refer to iPORT Kit Installation Codes 64, 66, 67, D6, D7, D8, and D9 are
and Maintenance Instructions. Height Sensing Encoder related codes. Refer to
the Full Height Sensing System Kit Installation
All “M” Series codes are iBATTERY and Maintenance Instructions.
related error codes. Refer to iBATTERY
Battery Monitoring System Installation
and Maintenance Instructions.

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

None
LPA Approaching Overtemperature Test A19 - Lift Power Cycle the key switch
(temp icon only) Amplifier Temperature OFF/ON to clear after the lift
The VM senses the lift power amplifier (AC lift only) (Page 6-53) power amplifier has cooled.
temperature is approaching 185°F
(85°C). Lift performance is limited.

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

None
TPA Approaching Overtemperature Test A10 - Traction Power Cycle the key switch
(temp icon only) Amplifier Temperature OFF/ON to clear after the
The VM senses the traction power (Page 6-48) traction power amplifier has
amplifier temperature is approaching cooled.
185°F (85°C). Traction performance is
limited.

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

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

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

Battery low, no lift

Battery State-of-Charge If charging or changing the Lift is disabled. The battery
Lift interrupt has occurred due to the battery does not clear the needs to be charged or
battery state-of-charge. message, run Test A15 - changed.
Battery Voltage
(Page 6-52)

Publication: 1301126/001A, Issued: 12 Nov 2018 6-9

Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

EPO Rekey

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

Cross upper or lower limit switch

The height tracking system needs Test I02 - Lower Mast Move the forks past either
to recalibrate position. Reference (24 in.) Switch the 24 in. or 150 in. switch.
The 24 in. switch is open, indicating (Page 6-74)
the forks are elevated, and the system Test O12 - Proportional
has counted over 1024 in. of Solenoid PWM Ramp
accumulated fork up and down (Page 6-121)
movement without detection either Test I69 - Upper Mast
24 in. to 150 in. switches. Reference Switch
(Page 6-103)

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

End of aisle
End-of-Aisle Test I93 - End-Of-Aisle Not an error.
The message is displayed until the EOA (Page 6-114)
truck slows down or stops as it exits Test I72 - End-of-Aisle
the end of the aisle and the operator Sensor 2 (optional)
releases the travel control. (Page 6-104)
Test I73 - End-of-Aisle
Sensor 1 (optional)
(Page 6-106)

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

EPO Pressed
EPO Pressed Test I38 - EPO Switch Lift the EPO switch and cycle
CCC or VM senses the EPO switch is (Page 6-89) the key switch OFF/ON to
open (IN). clear.

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

EPO Rekey
EPO has been pressed Test I38 - EPO Switch Make sure the EPO switch is
CCC or VM senses the EPO switch was (Page 6-89) lifted and cycle the key
pressed, then lifted, without key switch OFF/ON to clear.
switch being cycled.

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

FlashWare options incorrectly configured

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

6-10 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Guidance not learned

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

Guidance not learned

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

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

Initialize to allow full speed travel

24 in. Limit Switch Not Sensed Test O12 - Proportional Travel is limited to
Too much time has passed without Solenoid PWM Ramp 2.5 mph (4 km/h). Make
crossing the 24 in. limit switch while (Page 6-121) sure the Emergency Lower
the lift request is above a certain Test I02 - Lower Mast Valve is closed. Cycle the key
threshold. Reference (24 in.) Switch switch OFF/ON to clear.
(Page 6-74)

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

Interlock activated, clear to resume

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

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

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

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

Lift cut-out pending ... low battey

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

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Lift cutout, Scheduled maintenance due

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

Lift cutout, Scheduled maintenance due

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

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

Lift limited...Installed battery is too light

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

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

Lift speed Limited

Truck Lift Speed Inhibited Test I20 - Lift Motor RPM Cycle the key switch
This code is generated by the Lift (AC lift only) (Page 6-80) OFF/ON to clear.
Power Amplifier after not receiving
encoder pulses.

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

Log in to enable truck

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

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

Loss of connection to the SWM

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

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Lost LCP

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

Lost LCP
Load Coil Pair Test A53 - Left Load Check that the truck did not
Not near wire. This is the antennae on Guidance Coil Voltage run off the wire. Re-run the
the fork end of the truck. (Page 6-64) Learn procedure. Travel is
Test A54 - Right Load not allowed while
Guidance Coil Voltage Auto/Manual switch is in
(Page 6-65) Auto. Set the Auto/Manual
Test A56 - Load Near Wire switch to Manual. Check the
Coil Voltage (Page 6-67) wiring between the Guidance
Manager and the VM.
Replace the Guidance
Manager. Cycle the key
switch OFF/ON to clear.

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

Lost TCP
Tractor coil pair Test A51 - Left Tractor Check truck did not run off
Not near wire. This is the antennae on Guidance Coil Voltage the wire. Re-run the Learn
the tractor end of the truck. (Page 6-62) procedure. Travel is not
Test A52 - Right Tractor allowed while Auto/Manual
Guidance Coil Voltage switch is in Auto. Set the
(Page 6-63) Auto/Manual switch to
Test A55 - Tractor Near Manual. Check the wiring
Wire Coil Voltage between the Guidance
(Page 6-66) Manager and the VM.
Replace the Guidance
Manager. Cycle the key
switch OFF/ON to clear.

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

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

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Lower sidegates to resume operation

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

Lower sidegates to resume operation

Lower Side Gate Test I67 - Sidegate Lower Sidegates to clear.
While standing on the deadman pedal, Switches (optional)
a sidegate is detected up when you (Page 6-101)
attempt to travel or lift.

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

Overheated, allow time to cool

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

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

Platform hung... lift slowly

Platform Hung... Lift Slowly Test I45 - Slk S29 [Slack Lift the platform slowly to
Slack chain switch has transitioned Chain 1 Switch (S29)] clear. Code 56 is logged. If
during operation. (Page 6-96), Test I46 - Slk lifted for too long, this
Ch S30 [Slack Chain 2 message will transition to
Switch (S30)] (Page 6-97) 1K.

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

Press auto/manual switch to auto

Press auto/manual switch to auto Test I66 - Auto/Manual The near coil has detected
This appears on wire guidance Switch (optional) the presence of the wire
equipped trucks when the system (Page 6-100) guidance floor signal, or the
senses the wire. It occurs on rail Test I65 - Rail Guidance guide rail switch input.
guidance system based on switch Switch (optional)
input. (Page 6-99)

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

Press bypass switch to continue lifting

Switch (S24) Activated Test I05 - Lift Inhibit Lift is disabled unless the
Lift Inhibit Switch (S24) has been Switch (optional) bypass switch is activated.
crossed or open. (Page 6-77) Lower the vehicle below the
lift inhibit switch.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Press bypass switch to continue lowering

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

Press bypass switch to continue lowering

Truck Lowering Inhibited Test I74 - Lower Inhibit Lower is disabled unless the
Lower Inhibit Switch (S25) has been Switch (optional) bypass switch is activated.
crossed. (Page 6-108) Lift above the lower inhibit
switch.

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

Release aux buttons to resume operation

Aux Buttons Pressed Test I41 - Aux Mast Lift Cycle the key switch
Auxiliary deadman and auxiliary lift or Switch S32 (Option) OFF/ON to clear.
lower switches are activated at (Page 6-91)
start-up. Test I42 - Aux Mast Lower
Switch S33 (Option)
(Page 6-92)

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

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

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

Release bypass switch

Truck Lift/Lower Inhibited Test I04 - Lift/Lower Release the switch.
Will happen with either lift or lower Inhibit Bypass (optional)
bypass switch (S7) activated for an (Page 6-76)
extended period of time.

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

Release control handle to resume operation

Control Handle Moved Before Test A04 - Throttle Release the throttle, step on
Deadman Pressed Potentiometer Voltage the deadman, and resume
(Page 6-44) travel.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Release lift to resume operation

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

Release lift to resume operation

Release lift to resume operation Test A05 - Lift/Lower Check for excessive
Control handle was moved before the Potentiometer Voltage mechanical play in the lift
deadman pedal was pressed at (Page 6-45) control knob. Release the lift
start-up. control knob, step on the
deadman, and resume
operation.

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

Scheduled maintenance due

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

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

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

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

Speed limited
TPA not receiving Motor RPM Test I19 - Traction Motor Travel speed is limited. Cycle
This code is generated by the Traction RPM (Page 6-79) the key switch OFF/ON to
Power Amplifier after not receiving clear.
encoder pulses.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Speed limited due to steer angle

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

Speed limited due to steer angle

Speed Limited Due To Steer Angle Test I02 - Lower Mast Straighten the drive unit to
A speed limiting condition due to a Reference (24 in.) Switch within 10° of straight ahead
combination of steering angle and (Page 6-74) or lower the carriage below
height is in effect. Test I03 - 60 in. Limit the 24 in. lower mast
Switch (Page 6-75) reference switch.
Test I69 - Upper Mast 1. If the operator platform
Reference Switch height is between 24 in.
(Page 6-103) (610 mm) and 60 in.
Test I75 - 180 in. Limit (1520 mm) and the
Switch (optional) steering angle is >10°,
(Page 6-109) max travel speed is
limited to 2.5 mph
(4 km/h).
2. If the operator platform
height is between 60 in.
(1520 mm) and 150 in.
(3810 mm) (with
intellispeed) or the
upper reference switch
(S10) (without
intellispeed) and the
steering angle is >10°
then max travel speed
is limited to 1 mph
(1.6 km/h).
3. If the height of the
operator platform is
greater than or equal to
150 in. (3810 mm) (with
intellispeed) or the
Upper Mast Reference
Switch (S10) (without
intellispeed) and
steering is greater than
10°, then travel is not
permitted.

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

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

Truck Speed Limited Test I02 - Lower Mast Lower the lift truck below the
Lift truck powered on when above 24 Reference (24 in.) Switch 24 in. limit switch.
inch limit switch. (Page 6-74)

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Stalled, release control handle to resume operation

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

Stalled, release control handle to resume operation

Truck Stalled Travel speed limited. Test Travel speed or lift speed is
No encoder pulses are received by the I19 - Traction Motor RPM limited depending on which
Power Amplifier. (Page 6-79). Lift speed amplifier is not receiving
limited. Test I20 - Lift encoder pulses. Cycle the
Motor RPM (AC lift only) key switch OFF/ON to clear.
(Page 6-80)

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

Steer limited due to height

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

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

Travel cutout
Truck Travel Inhibited Test I68 - Travel Travel is disabled. Lower the
Lift truck has been elevated above Cutout/Battery Gate and lift truck below the travel
travel cutout switch. PLS Switch (optional) cutout switch.
(Page 6-102) Travel Cutout is also used by
the battery gate switches
and for trucks with fuel cell
and the power warning
interrupt circuit.

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

Travel Interlock Activated

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

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

View SWM Display

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

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 10 Inform Service

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

CODE 10 Inform Service

Code 10: SelfTest Failed Test A35 - Brake All functions are disabled.
The brake test did not pass SelfTest. (Page 6-59) Make sure the EPO is not
Test O00 - Toggle the pressed. The TPC must close
Traction Power Contactor during SelfTest.
(Page 6-118) Check the battery voltage.
Check the brake wires.
Cycle the key switch
OFF/ON to clear.

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

CODE 1H Inform service

Code 1H: TPA Out-of-Range Test A10 - Traction Power Cycle the key switch
The Traction Power Amplifier has Amplifier Temperature OFF/ON to clear after the
reported its internal temperature is (Page 6-48) traction power amplifier has
less than –40°F (–40°C) or greater than returned to ambient
+203°F (+95°C). temperature.

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

CODE 1K Inform service

Code 1K: Platform Hung Lift Slowly Test I45 - Slk S29 [Slack Lift platform if it is hung up
Slack chain switch has transitioned Chain 1 Switch (S29)] to clear.
during operation. (Page 6-96), Test I46 - Slk
Ch S30 [Slack Chain 2
Switch (S30)] (Page 6-97)

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

CODE 2A Overheated Allow time to cool

Code 2A: Traction Motor Test A08 - Traction Motor Travel speed is linearly
Approaching Overtemperature Temperature (Page 6-46) derated starting at 266°F
The traction amplifier senses the (130°C). Travel speed is
traction motor is approaching limited to 1 mph (1.6 km/h)
overtemperature. Traction at 300°F (149°C). Cycle the
performance is limited. key switch OFF/ON to clear
after the traction motor has
cooled.

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

CODE 2E Inform service

Code 2E: Traction Motor Temp Test A08 - Traction Motor Travel is limited to 2.5 mph
Sensor Out-of-Range Temperature (Page 6-46) (4.0 km/h). Clears when the
The traction motor temperature sensor reason for the fault is
is open or shorted. corrected.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

CODE 2G Inform service

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

CODE 2G Inform service

Code 2G: Phase Open on Traction Test O29 - Ramp Traction Travel is disabled. Cycle the
Motor Motor (Page 6-126) key switch OFF/ON to clear.
The traction power amplifier has
detected no current draw in one of the
three phases of the motor.

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

CODE 2H Inform service

Code 2H: Failure Detected in Test I19 - Traction Motor Travel is limited to
Traction Motor Speed Feedback RPM (Page 6-79) 1 mph (1.6 km/h). If a single
Encoder channel is bad, this code is
displayed during Run. If one
or both channels are bad at
SelfTest, STALLED is
displayed. Cycle the key
switch OFF/ON to clear.

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

CODE 2M Inform service

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

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

CODE 2Q Inform service

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

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 2T Inform service

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

CODE 2T Inform service

Code 2T: TPA Current Calibration None Travel is limited to 2.5 mph
Error (4.0 km/h). Cycle the key
The traction power amplifier has switch OFF/ON to clear. If
sensed a current calibration error. the code will not clear,
replace traction power
amplifier. The VM cannot
cause this code.

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

CODE 2U Inform service

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

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

CODE 2V Inform service

Code 2V: High DC BUS Voltage – TPA Test A15 - Battery Voltage If the voltage is OK, replace
The traction power amplifier has (Page 6-52) the TPA. Cycle the key
detected an overvoltage condition at switch OFF/ON to clear. The
the (+) terminal. VM cannot cause this code.

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

CODE 2X Inform service

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

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

CODE 2Y Inform service

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

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

CODE 42 Inform service

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

CODE 42 Inform service

Code 42: LPC Detected Closed When Test O02 - Toggle the Lift Cycle the key switch
Commanded Open Power Contactor OFF/ON to clear.
AC Lift - the lift power amplifier has (Page 6-119)
detected an incorrect voltage at the B+
terminal on the amplifier.
DC Lift - the VM has detected an
incorrect voltage at JPT18-9.

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

CODE 43 Inform service

Code 43: LPC Detected Open When Test O02 - Toggle the Lift Cycle the key switch
Commanded Closed Power Contactor OFF/ON to clear.
AC Lift - the lift power amplifier has (Page 6-119)
detected an incorrect voltage at the B+
terminal on the amplifier.
DC Lift - the VM has detected an
incorrect voltage at JPT18-9.

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

CODE 4C Inform service

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

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

CODE 4F Inform service

Code 4F: TPC Detected Closed When Test O00 - Toggle the Travel is disabled.
Commanded Open Traction Power DC Lift - lift is also disabled.
The traction power amplifier has Contactor (Page 6-118) Cycle the key switch
detected an incorrect voltage at the B+ OFF/ON to clear.
terminal on the amplifier.

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

CODE 4G Inform service

Code 4G: TPC Detected Open After Test O00 - Toggle the Travel is disabled.
Power-Up Traction Power DC Lift - lift is also disabled.
The traction power amplifier has Contactor (Page 6-118) Cycle the key switch
detected the TPC open after power-up. OFF/ON to clear.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 4H Inform service

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

CODE 4H Inform service

Code 4H: TPA, TPC Contactor Coil Test O00 - Toggle the Cycle the key switch
or Coil Driver Open or Shorted Traction Power OFF/ON to clear.
Contactor (Page 6-118)

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

CODE 4K Inform service

Code 4K: LPA, LPC Contactor Coil or Test O02 - Toggle the Lift Lift is disabled. Cycle the key
Coil Driver Open or Shorted Power Contactor switch OFF/ON to clear.
AC lift only. (Page 6-119)

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

CODE 50 Inform service

Code 50: No VM Communications Test I23 - CAN Bus All functions are disabled.
Received by CCC (Page 6-81) See Communication Error
The Carriage Control Card has not Code Troubleshooting on
received correct communications from page 5-22.
the VM. Cycle the key switch
Note: This code is displayed during OFF/ON to clear.
FlashWare procedure.

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

CODE 51 Inform service

Code 51: No CCC Communications Test I23 - CAN Bus All functions are disabled.
Received by VM (Page 6-81) See Communication Error
The VM has not received correct Code Troubleshooting on
communications from the CCC. page 5-22. Cycle the key
switch OFF/ON to clear.

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

CODE 56 Inform service

Code 56: Platform Hung Test I43 - Slack Chain Lift platform slowly. Inspect
No switch input was seen during Switch (Page 6-93), Test wiring to slack chain
lower. I45 - Slk S29 [Slack switches.
Chain 1 Switch (S29)]
(Page 6-96), Test I46 -
Slk Ch S30 [Slack Chain
2 Switch (S30)]
(Page 6-97)

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

CODE 59 Inform Service

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

CODE 59 Inform Service

Code 59: CAN Transmission Buffer Test I23 - CAN Bus All functions are disabled.
Error (Page 6-81) See Communication Error
The VM has detected a CAN Code Troubleshooting on
transmission buffer error. page 5-22.

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

CODE 5A Inform service

Code 5A: CAN BUS Error Overflow Test I23 - CAN Bus All functions are disabled.
CAN Bus error overflow detected by (Page 6-81) See Communication Error
VM. Code Troubleshooting on
page 5-22. Cycle the key
switch OFF/ON to clear.

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

CODE 5B Inform service

Code 5B: Communication Error Test I23 - CAN Bus All functions are disabled.
There is no space in the CAN queue for (Page 6-81) Check for a short to frame or
the current message to be received. a bad connection in the bus
wiring. See Communication
Error Code Troubleshooting
on page 5-22.
Replace the VM, then the
CCC. Cycle the key switch
OFF/ON to clear.

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

CODE 5E Inform service

Code 5E: No Guidance Manager CAN Test I23 - CAN Bus Travel is disabled in AUTO
Communications Received by the (Page 6-81) mode. Travel is allowed in
VM MANUAL mode. Check to see
if something is dragging the
GM down, for example,
antenna. Cycle the key
switch OFF/ON to clear.

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

CODE 5G Inform service

Code 5G: No Communications Test I23 - CAN Bus Travel is disabled. Cycle the
Received by VM from TPA (Page 6-81) key switch OFF/ON to clear.
The VM has not received CAN
communications from the traction
power amplifier.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 5J Inform service

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

CODE 5J Inform service

Code 5J: No communications Test I23 - CAN Bus Lift is disabled. Cycle the key
Received by VM from LPA (Page 6-81) switch OFF/ON to clear.
AC Lift only - The VM has not
received CAN communications from
the lift power amplifier.

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

CODE 5M Inform service

Code 5M: No communications Check wiring, Replace the required part
received by TPA from VM. Maintenance Mode Test and cycle the key switch
The TPA has not received CAN I23 - CAN Bus OFF/ON to clear.
communications from the VM for over (Page 6-81)
one minute after power was applied to If the VM is not working,
pin 1 at the amp. you cannot get into
history. Troubleshoot
per general
communications
methods. If the lift truck
displays a code after
checking the wires,
replace the VM.

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

CODE 5P Inform service

Code 5P: No communications Check wiring, Test I23 - Replace the required part
received by LPA from VM. CAN Bus (Page 6-81) and cycle the key switch
The LPA has not received CAN If the VM is not working, OFF/ON to clear.
communications from the VM for over the code cannot get into
1 minute after power was applied to listing. Troubleshoot per
pin 1 at the amp. general communications
methods. If the lift truck
displays a code after
checking the wires,
replace the VM.

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

CODE 61 Inform service

Code 61: 24 in. Limit Switch Not Test I02 - Lower Mast Travel is limited to 2.5 mph
Sensed Reference (24 in.) Switch (4.0 km/h). Make sure the
Too much time has passed without (Page 6-74) Emergency Lower Valve is
crossing the 24 in. limit switch while Test O12 - Proportional closed. Cycle the key switch
lift request is above a certain Solenoid PWM Ramp OFF/ON to clear.
threshold. (Page 6-121)

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

CODE 63 Inform service

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

CODE 63 Inform service

Code 63: Upper and Lower Test I02 - Lower Mast Travel is limited to
Reference Switches Do Not Agree Reference (24 in.) Switch 1 mph (1.6 km/h). Cycle the
The VM has sensed that the positions (Page 6-74) key switch OFF/ON to clear.
of the upper (S10) and the lower (S11) Test I69 - Upper Mast
reference switches were out of Reference Switch
sequence. (Page 6-103)

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

CODE 64 Inform service

Code 64: No Flow Sensor Pulses Test I02 - Lower Mast Travel is limited to
When Lift/Lower Requested Reference (24 in.) Switch 1 mph (1.6 km/h). Lift or
No pulses were seen from the flow (Page 6-74) lower past one of the mast
sensor when lifting past one of the two Test I26 - Flow Sensor reference switches. Cycle the
mast reference switches (24 and 150 Count (Without Full key switch OFF/ON to clear.
in.). (intellispeed only) Height Sensing) Check the strain relief at
(Page 6-86) connector JPY-1.
Test I69 - Upper Mast
Reference Switch
(Page 6-103)

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

CODE 66 Inform service

Code 66: Calculated Height Does Test I26 - Flow Sensor Travel is limited to
Not Match at Upper Reference Count (Without Full 1 mph (1.6 km/h). Cycle the
Switch (150 in.) Height Sensing) key switch OFF/ON to clear.
intellispeed count and calculated (Page 6-86)
height of the upper reference switch Test I69 - Upper Mast
(S10) are out of tolerance. (intellispeed Reference Switch
only) (Page 6-103)

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

CODE 67 Inform service

Code 67: Calculated Height Does Test I02 - Lower Mast Travel is limited to
Not Match at Lower Reference Reference (24 in.) Switch 1 mph (1.6 km/h). Cycle the
Switch (24 in.) (Page 6-74) key switch OFF/ON to clear.
intellispeed count and calculated Test I26 - Flow Sensor
height of the lower reference switch Count (Without Full
(S11) are out of tolerance. (intellispeed Height Sensing)
only). (Page 6-86)

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 6D Inform service

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

CODE 6D Inform service

Code 6D: Lift Pressure Sensor Test A13 - Pressure The code is displayed for five
Out-of-Range Sensor Voltage (optional) seconds. Display will then
The VM has determined that the (Page 6-50) change to "----". Cycle the
pressure sensor voltage has exceeded key switch OFF/ON to clear.
the programmed limits.
(intellispeed only)

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

CODE 6F Overheated Allow time to cool

Code 6F: Lift Motor Overheated Test A09 - Lift Motor Lift is disabled. Allow time to
AC Lift only - Lift motor temperature Temperature (Page 6-47) cool. Cycle the key switch
has exceeded 300°F (149°C). OFF/ON to clear.

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

CODE 6K Inform service

Code 6K: 60 in. Switch Does Not Test I02 - Lower Mast Travel is limited to 2.5 mph
Agree with Lower Mast Reference Reference (24 in.) Switch (4.0 km/h). Lower, then lift
The 60 in. switch (S28) is out of (Page 6-74) past the first mast limit
sequence with the lower reference Test I03 - 60 in. Limit switch (S11). Cycle the key
switch (S11). Switch (Page 6-75) switch OFF/ON to clear.
(non-intellispeed only)

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

CODE 6M Inform service

Code 6M: 60 in. and/or 24 in. Test I02 - Lower Mast Lower, then lift past the
Switch Disconnected Reference (24 in.) Switch lower reference switch (S11).
The system detected that the 60 in. (Page 6-74) Cycle the key switch
(S28) and/or the 24 in. (S11) switch is Test I03 - 60 in. Limit OFF/ON to clear.
disconnected. Switch (Page 6-75)

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

CODE 6N Inform service

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

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

CODE 6P Inform service

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

CODE 6P Inform service

Code 6P: 60 in. Limit Switch Test I03 - 60 in. Limit Travel is limited to 1 mph
Out-of-Sequence with Upper Switch (Page 6-75) (1.6 km/h). Cycle the key
Reference Switch Test I69 - Upper Mast switch OFF/ON to clear.
The system senses that the 60 in. limit Reference Switch
switch and the upper reference switch (Page 6-103)
are out of sequence.
(non-intellispeed only)

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

CODE 7E Inform service

Code 7E: Lift Motor Temperature Test A09 - Lift Motor Lift performance is disabled
Sensor Out-of-Range Temperature (Page 6-47) by the power amplifier. Cycle
Lift motor temperature sensor voltage the key switch OFF/ON to
is out-of-range. clear.

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

CODE 7F Inform service

Code 7F: LPA Temp Out-of-Range Test A19 - Lift Power Lift is disabled. Cycle the key
The lift power amplifier has reported Amplifier Temperature switch OFF/ON to clear.
its internal temperature is less than (AC lift only) (Page 6-53)
–40°F (–40°C) or greater than +203°F
(+95°C).

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

CODE 7G Inform service

Code 7G: LPA Motor Phase Open Test O28 - Ramp Lift Lift is disabled. Cycle the key
The lift power amplifier has detected Motor (AC lift only) switch OFF/ON to clear.
no current draw in one of the three (Page 6-125)
phases of the motor.

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

CODE 7H Inform service

Code 7H: Failure Detected in Lift Test A20 - Lift Motor Lift is limited to approx. 10
Motor Feedback Encoder Current (AC lift only) feet per minute (approx. 3
The lift power amplifier has detected (Page 6-54) meters per minute). Cycle
incorrect pulses from the lift motor the key switch OFF/ON to
encoder. clear.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 7M Inform service

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

CODE 7M Inform service

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

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

CODE 7Q Inform service

Code 7Q: LPA Low Voltage None. Lift performance may be
The LPA has detected less than 17V at limited. Cycle the key switch
the + terminal. ON/OFF to clear. Check
wiring and contactor tips.
Replace the battery with a
fully charged battery.

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

CODE 7T Inform service

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

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

CODE 7U Inform service

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

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

CODE 7V Inform service

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

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

CODE 7X Inform service

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

CODE 7X Inform service

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

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

CODE 7Y Inform service

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

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

CODE 80 Inform service

Code 80: Throttle Potentiometer Test A04 - Throttle Travel is disabled. Cycle the
(VR1) Voltage Out-of-Range Potentiometer Voltage key switch OFF/ON to clear.
(Page 6-44)

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

CODE 81 Inform service

Code 81: Lift/Lower Potentiometer Test A05 - Lift/Lower Lift is disabled. Cycle the key
(VR2) Voltage Out-of-Range Potentiometer Voltage switch OFF/ON to clear.
(Page 6-45)

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

CODE 83 Inform service

Code 83: Throttle Potentiometer Test A04 - Throttle Travel is disabled. Cycle the
(VR1) Out-of-Neutral Potentiometer Voltage key switch OFF/ON to clear.
Throttle potentiometer (VR1) out of (Page 6-44)
learned neutral value.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 84 Inform service

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

CODE 84 Inform service

Code 84: Brake Inoperable; Not Test O30 - Toggle Brake Travel is disabled at
Applied Solenoid (Page 6-127) start-up. Make sure the
The drive motor bearing encoder brake release bolts are
indicated movement during SelfTest. removed from the brake
assembly. Cycle the key
switch OFF/ON to clear.

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

CODE 88 +5VDC Power Supply Out-of-Range

Code 88: Lift and/or Travel Test A26 - +5.3VDC Power Cycle the key switch to clear.
Potentiometer Voltage Supply (Page 6-57)
Out-of-Range
Control Handle +5.3VDC power supply
(located on the CCC) is out-of-range.

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

CODE 8C Inform service

Code 8C: Deadman Switches Do Not Test I00 - Carriage Travel, lift, lower, and brake
Agree Deadman (Page 6-72) are disabled. Cycle the key
Deadman switches S2 and S23 do not Test I01 - Brake Deadman switch OFF/ON to clear.
agree or the steering encoder is Switch (S2) (Page 6-73)
disconnected.

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

CODE 8F Inform service

Code 8F: Lift/Lower Potentiometer Test A05 - Lift/Lower Lift and lower are disabled.
Out-of-Neutral Potentiometer Voltage Cycle the key switch
Lift/Lower potentiometer (VR2) out of (Page 6-45) OFF/ON to clear.
learned neutral value.

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

CODE 8L Inform service

Code 8L: Electric Brake Feedback Test A35 - Brake Travel is limited to 1 mph
The VM senses the brake coil current (Page 6-59) (1.6 km/h). Cycle the key
is incorrect. switch OFF/ON to clear.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

CODE 91 Inform service

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

CODE 91 Inform service

Code 91: Drive Unit Turned >10° Test I25 - Steer Motor Lift truck plugs to 0 mph.
while Guiding on Wire Encoder (Page 6-84) Set the Auto/Manual switch
to Manual. Cycle the key
switch OFF/ON to clear.

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

CODE 92 Inform service

Code 92: Tracking Limits Exceeded Test A51 - Left Tractor Lift truck plugs to 0 mph.
Guidance Coil Voltage Set the Auto/Manual switch
(Page 6-62) to Manual. Cycle the key
Test A52 - Right Tractor switch OFF/ON to clear.
Guidance Coil Voltage
(Page 6-63)
Test A53 - Left Load
Guidance Coil Voltage
(Page 6-64)
Test A54 - Right Load
Guidance Coil Voltage
(Page 6-65)

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

CODE 93 Lost TCP Lost Wire

Code 93: Not Near Wire; Tractor Coil Test A51 - Left Tractor Lift truck plugs to 0 mph.
Pair Guidance Coil Voltage Set the Auto/Manual switch
(Page 6-62) to Manual. Cycle the key
Test A52 - Right Tractor switch OFF/ON to clear.
Guidance Coil Voltage
(Page 6-63)
Test A55 - Tractor Near
Wire Coil Voltage
(Page 6-66)

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

CODE 94 Lost LCP Lost Wire

Code 94: Not Near Wire; Load Coil Test A53 - Left Load Truck plugs to 0 mph. Set
Pair Guidance Coil Voltage the Auto/Manual switch to
(Page 6-64) Manual. Cycle the key
Test A54 - Right Load switch OFF/ON to clear.
Guidance Coil Voltage
(Page 6-65)
Test A56 - Load Near Wire
Coil Voltage (Page 6-67)

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 9A Inform Service

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

CODE 9A Inform Service

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

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

CODE 9B Inform Service

Code 9B: Bad SDO (CAN - Service If the error occurred while Travel is limited to 1 mph
Data Object) Data Received learning Wire Guidance, (1.6 km/h). Set the
VM received bad data from the re-run the Learn Auto/Manual switch to
Guidance Manager. procedure. Manual. Check the wiring
between the Guidance
Manager and the VM.
Re-learn Guidance. Replace
the Guidance Manager.
Cycle the key switch
OFF/ON to clear.

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

CODE 9E Inform service

Code 9E: Track And Hold Signal Test A51 - Left Tractor Lift truck plugs to 0 mph.
Failed Guidance Coil Voltage Set the Auto/Manual switch
The lift truck is moving on the wire (Page 6-62) to Manual. Cycle the key
and the guidance signals are not Test A52 - Right Tractor switch OFF/ON to clear.
fluctuating at all. Guidance Coil Voltage
(Page 6-63)
Test A53 - Left Load
Guidance Coil Voltage
(Page 6-64)
Test A54 - Right Load
Guidance Coil Voltage
(Page 6-65)

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

CODE 9G Inform service

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

CODE 9G Inform service

Code 9G: No Input; Load Antenna Test A53 - Left Load Lift truck plugs to 0 mph.
The signal from the load antenna is Guidance Coil Voltage Set the Auto/Manual switch
not being received by the Guidance (Page 6-64) to Manual. Cycle the key
Manager. Test A54 - Right Load switch OFF/ON to clear.
Guidance Coil Voltage
(Page 6-65)

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

CODE 9H Inform service

Code 9H: No Input; Tractor Antenna Test A51 - Left Tractor Lift truck plugs to 0 mph.
The signal from the tractor antenna is Guidance Coil Voltage Set the Auto/Manual switch
not being received by the Guidance (Page 6-62) to Manual. Cycle the key
Manager. Test A52 - Right Tractor switch OFF/ON to clear.
Guidance Coil Voltage
(Page 6-63)

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

CODE 9J Inform service

Code 9J: Load Antenna Input Too Test A53 - Left Load Lift truck plugs to 0 mph.
High Guidance Coil Voltage Set the Auto/Manual switch
Can be triggered by a checksum error (Page 6-64) to Manual. Cycle the key
calculated by the Guidance Manager. Test A54 - Right Load switch OFF/ON to clear.
Guidance Coil Voltage Complete Tests A53 and
(Page 6-65) A54, then re-run the Learn
Procedure.

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

CODE 9K Inform service

Code 9K: Tractor Antenna Input Too Test A51 - Left Tractor Lift truck plugs to 0 mph.
High Guidance Coil Voltage Set the Auto/Manual switch
Can be triggered by a checksum error (Page 6-62) to Manual. Cycle the key
calculated by the Guidance Manager. Test A52 - Right Tractor switch OFF/ON to clear.
Guidance Coil Voltage Complete Tests A53 and
(Page 6-63) A54, then re-run the Learn
Procedure.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE 9M Inform service

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

CODE 9M Inform service

Code 9M: Tractor Antenna Input Test A101 - Guidance Wire guidance will not
Too High Manager 12V Power function. Measure power
Guidance Manager Voltage is Supply Out-of-Range being supplied to antenna
Out-of-Range (Page 6-69) boards. Acceptable range is
11-13 volts.

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

CODE A0 Inform service

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

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

CODE A2 Inform service

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

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

CODE A4 Inform service

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

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

CODE AH Inform service

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

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

CODE AL Inform service

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

CODE AL Inform service

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

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

CODE AP Inform service

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

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

CODE AT Inform service

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

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

CODE F8 Inform service

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

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

CODE FE Inform service

Code FE: Internal VM Circuit for None Code is displayed for 30
BSOC Not Calibrated seconds. Replace the VM.
If intermittent, test the
Inrush Protection circuit.
See “Inrush Protection” on
page 5-20.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE FG Inform service

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

CODE FG Inform service

Code FG: +5V Reference Voltage and Test A14 - VM +12V Power Travel, lift, and lower are
+12V Power Supply Failure Supply (Page 6-51) disabled. Brake will engage.
Cycle the key switch
OFF/ON to clear.
If intermittent, test the
Inrush Protection circuit.
See “Inrush Protection” on
page 5-20.

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

CODE FH Inform service

Code FH: Battery Voltage Test A15 - Battery Voltage Travel, lift, and lower are
Out-of-Range (Page 6-52) disabled. Brake will remain
Wrong voltage battery or voltage engaged. Cycle the key
out-of-range. switch OFF/ON to clear.
If intermittent, test the
Inrush Protection circuit.
See “Inrush Protection” on
page 5-20.

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

CODE FN Inform service

Code FN: Relays Did Not Open at Test O32 - Toggle Relay Travel, lift, and lower are
Power Off Enable (Page 6-128) disabled. Brake remains
engaged. Cycle the key
switch OFF/ON to clear.

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

CODE FP Inform service

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

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

CODE FT Inform service

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

CODE FT Inform service

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

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

CODE G0 Inform service

Code G0: Steer Tiller Encoder 1 is See “Test I35 - Steer Tiller Coasts to 2.5 mph (4.0
Intermittent or Failed Encoder 1” on km/h). Travel is limited to
Determined by channel A and/or B page 6-87. 2.5 mph (4.0 km/h). Cycle
not functioning correctly when the key switch OFF/ON to
compared with Steer Tiller Encoder 2. clear.

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

CODE G2 Inform service

Code G2: Auto Steer Center Failed See “Test O44 - Steer Moderate plug to 0 mph.
1. Home switch is more than 10° from Motor” on page 6-134. Step off, then back on the
the initial value saved during a See “Auto Steer Center deadman pedal to allow
successful auto steer center. Problem” on page 5-31. travel again. Max travel
2. Auto steer center time-out is speed is limited to 1.0 mph
greater than two seconds. (1.6 km/h). Cycle the key
3. No encoder pulses sensed during switch OFF/ON to clear.
auto steer center.

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

CODE G3 Inform service

Code G3: Home Prox Switch Not See “Test O44 - Steer All steer indicator lights will
Functioning Correctly Motor” on page 6-134. flash. Travel speed is limited
See “Auto Steer Center to 1.0 mph (1.6 km/h). Cycle
Problem” on page 5-31. the key switch OFF/ON to
clear.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE G4 Inform service

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

CODE G4 Inform service

Code G4: Open Detected in Steer See “Test O44 - Steer Aggressive plug to 0.0 mph.
Control Circuit Motor” on page 6-134. Step off, then back on the
No neutral pulses detected when the See “Auto Steer Center deadman pedal to allow
lift truck is not moving and the Problem” on page 5-31. travel again. Max travel
operator is on the deadman pedal. speed is set to 1.0 mph (1.6
km/h).
Cycle the key switch
OFF/ON to clear.

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

CODE G5 Inform service

Code G5: Short Detected in Steer Test A37 - Steer Power Moderate plug to 0.0 mph.
Power Circuit Amplifier Current Step off, then back on the
Steer motor encoder pulses or (Page 6-60) deadman pedal to allow
command detected and no steer tiller See “Test O44 - Steer travel again. Max travel
encoder pulses detected. Motor” on page 6-134. speed is set to 1.0 mph (1.6
Test I25 - Steer Motor km/h).
Encoder (Page 6-84) Cycle the key switch
OFF/ON to clear.

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

CODE G7 Inform service

Code G7: Steer Tiller Encoder 2 is Test I36 - Steer Tiller Coasts to 2.5 mph (4.0
Intermittent or Failed Encoder 2 (Page 6-88) km/h). Travel is limited to
Determined by the connect detect 2.5 mph (4.0 km/h). Cycle
circuit for the CD Supply and Gnd the key switch OFF/ON to
connections or by channel A and/or B clear.
not functioning correctly when
compared with Steer Tiller Encoder
One.

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

CODE GD Inform service

Code GD: No Steer Motor Encoder Test I25 - Steer Motor Lift truck plugs to 0 mph.
Pulses Seen Encoder (Page 6-84) Travel is limited to 1 mph
No steer motor encoder pulses seen See “Test O44 - Steer (1.6 km/h). More steer tiller
when requesting a steer correction, Motor” on page 6-134. rotations are required to
travel is >0.1 mph or during auto steer turn the drive unit. Cycle the
center. key switch OFF/ON to clear.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

CODE GE Inform service

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

CODE GE Inform service

Code GE: Both Steer Tiller Encoders Test I35 - Steer Tiller Lift truck plugs to 0 mph.
Failed Encoder 1 (Page 6-87) Travel is limited to 1 mph
Determined by the connect detect Test I36 - Steer Tiller (1.6 km/h). Cycle the key
circuit. Encoder 2 (Page 6-88) switch OFF/ON to clear.

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

CODE GF Inform service

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

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

CODE J2 Inform service

Code J2: Aisle Exit Error Test I72 - End-of-Aisle Plugs to stop, speed is
Only one magnet was sensed when the Sensor 2 (optional) limited to 1 mph (1.6 km/h).
guided aisle was exited. (Page 6-104) While out of the aisle, switch
Test I73 - End-of-Aisle the Auto/Manual switch to
Sensor 1 (optional) Manual. Turn the drive unit
(Page 6-106) >10° and travel until the
code clears.
Go into lift truck history and
see what subcode was
thrown. See Table 5-5 on
page 5-23

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

CODE J4 Inform service

Code J4: Aisle Sensor Error Test I72 - End-of-Aisle Travel is limited to 1 mph
Sensor 2 (optional) (1.6 km/h).
(Page 6-104)
Test I73 - End-of-Aisle
Sensor 1 (optional)
(Page 6-106)

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

CODE VC Inform service

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

CODE VC Inform service

Code VC: The CAN Chip will not Test I23 - CAN Bus All functions are disabled.
Reset (Page 6-81) See Communication Error
Most likely this is due to an internal Code Troubleshooting on
fault in the VM. page 5-22.
Replace the VM. Cycle the
key switch OFF/ON to clear.

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

CODE X3 Inform service

Code X3: 180 in. Limit Switch Test I75 - 180 in. Limit Travel is limited to 1 mph
Mismatch Switch (optional) (1.6 km/h). Cycle the key
The 180 in. Switch (S100) is out of (Page 6-109) switch OFF/ON to clear.
sequence with a standard mast
switch.

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

CODE X4 Inform service

Code X4: Lift Cutout Switch Test I76 - Lift Cutout Cycle the key switch
Mismatch Switch (optional) OFF/ON to clear.
Lift Cutout Switch (S124) mismatch (Page 6-110) Up arrow icon flashes and
with standard mast switch. message lift cutout - max ht
reached.

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

CODE X5 Inform service

Code X5: Lift Inhibit Switch Test I05 - Lift Inhibit Cycle the key switch
Mismatch Switch (optional) OFF/ON to clear.
Lift Inhibit Switch (S24) mismatch (Page 6-77)
with standard mast switch.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

CODE X5 Inform service

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Analog Input Tests

Section 6. Messages, Codes and Tests

Analog Input Tests

A Diagnosis and Repair table is provided for
most tests. If a test fails, refer to the Diagnosis
and Repair table. Through the process of
elimination, these tables provide the technician
with a step-by-step approach to diagnosing a
problem and the necessary corrective action.
See the table below.
Example Diagnosis and Repair Table
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

This column
identifies the
action(s) required
(if any) before
testing the
circuit. If no
instructions are
given, all circuits
must be
The next
connected. The next
This is the Connection Connection action to be
Note: If action to be
order that point for point for The reading performed if
something was performed if
the testing the Positive the required to consider the
disconnected in the Expected
must be (+) meter Negative (–) the step a success. Expected
the prior step, Results are
performed. lead. meter lead. Results are
reconnect it met.
not met.
before
performing the
next step.

This column also

identifies the
required setting
on the meter for
this step.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test A04 - Throttle Potentiometer Voltage

Test A04 - Throttle Run Test:

Potentiometer Voltage The test is a success if the voltage displayed is
within these limits:
This test displays the voltage the CCC produces Throttle Position Voltage Displayed
based on input from the throttle potentiometer
(VR1). Full forward position
0.30 to 1.21V
Tractor-first (TF)
NOTE: Learn must be run whenever the throttle
assembly is replaced, repaired, or Neutral position 1.23 to 1.83V
adjusted. See Learn Controls on
Full reverse position
page 3-19. 1.85 to 2.80V
Forks-first (FF)

For information on using Maintenance Mode,

refer to page 3-9. If the voltage reading is outside these limits or
does not change in a smooth linear fashion, the
test has failed. Any voltage fluctuation indicates
a bad cable or VR1.

The voltage reading should decrease when the

throttle is moved from the reverse to the
forward position. If these results are not
observed, the test has failed. Perform diagnosis
and repair.

Diagnosis and Repair

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

1 JPC9 PC9-7 Perform step 2

disconnected/ PC9-8 5.3V Replace CCC
2 DCV PC9-9 Perform step 3

Neutral: 1.23-1.83V
Replace pot
3 DCV JPC9-9 JPC9-7 FF: increase Replace CCC
(VR1)
TF: decrease

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test A05 - Lift/Lower Potentiometer Voltage

Test A05 - Lift/Lower Run Test:

Potentiometer Voltage The test is a success if the voltage displayed is
within these limits:
This test displays the voltage the CCC produces Lift/Lower
based on input from the lift/lower pot (VR2). Voltage Displayed
Control Position
NOTE: Run this test if the voltage output by the Full lift position 0.15 to 0.95V
lift/lower potentiometer (pot) exhibits
problems. Neutral position 0.97 to 1.46V

NOTE: Learn must be run when the lift/lower Full lower position 1.48 to 2.40V
pot is replaced, repaired, or adjusted.
See Learn Mode on page 3-9. If the voltage reading is outside these limits or
does not change in a smooth linear fashion, the
For information on using Maintenance Mode, test has failed. Any voltage fluctuation indicates
refer to page 3-9. a bad cable or VR2.

The voltage reading should decrease when the

lift/lower knob is moved from lower to lift. If
these results are not observed, the test has
failed. Perform diagnosis and repair.

Diagnosis and Repair

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

1 JPC9 PC9-4 Perform step 2

PC9-5 5.3V Replace CCC
2 disconnected/DCV PC9-6 Perform step 3

Neutral: 0.97-1.46V
Replace pot
3 DCV JPC9-6 JPC9-4 Lower: increase Replace CCC
(VR2)
Lift: decrease

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test A08 - Traction Motor Temperature

Test A08 - Traction Motor the lift truck up by driving it hard for
approximately 30 minutes. As the motor heats,
Temperature the temperature will increase.

For information on how to use Maintenance

This test displays the temperature of the Mode, refer to page 3-9.
traction motor.

Limits Run Test:

• Normal operation: ambient to 258°F 1. With the lift truck at rest and at ambient
(125°C) temperature, compare the temperatures
• Between 266°F (130°C) and 300°F (149°C), obtained from those obtained using
speed is linearly reduced to 1.0 mph Maintenance Mode to the ambient
(1.6 km/h). temperature.
• Temperature icon lights at 275°F (135°C) 2. If the temperatures are not within several
degrees, the test has failed.
• Fault Code 2A and travel disabled at 300°F
(149°C) 3. If the lift truck is not at ambient
temperature, use the diagnosis and repair
While operating, the VM continually monitors chart to isolate the cause.
the temperature of the traction motor. If the
temperature gets too high, performance is
reduced until the motor cools down.

Use Active Maintenance to see the actual

temperature from the temperature sensor. Heat
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPTA1
1 disconnected/ JTA1-8 JTA1-7 <1200 ohms if Replace TPA Perform step 2
ohms motor is cool
JPTA3 >1200 ohms if T/S traction
motor is hot Replace traction
2 disconnected/ JTA3-2 JTA3-1 motor temp
motor temp sensor
ohms sensor

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test A09 - Lift Motor Temperature

Test A09 - Lift Motor

Temperature
This test displays the temperature of the AC lift
motor.

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

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
As lift is operated, the readings should increase
evenly over time. If not, the test has failed.
Perform diagnosis and repair.

Diagnosis and Repair

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

JPLA1
1 disconnected/ JLA1-8 JLA1-7 <1200 ohms if Replace LPA Perform step 2
ohms motor is cool
JPLA3 >1200 ohms if
motor is hot T/S lift motor Replace lift motor
2 disconnected/ JLA3-2 JLA3-1
temp sensor temp sensor
ohms

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test A10 - Traction Power Amplifier Temperature

Test A10 - Traction

Power Amplifier
Temperature
This test displays the temperature of the
Traction Power Amplifier (TPA).

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

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
The OD shows the heatsink temperature that
the traction power amplifier reads.

As drive is operated, the readings should

increase evenly over time. If not, the test has
failed. Perform diagnosis and repair.

Diagnosis and Repair

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

Is TPA heatsink If not hot, replace

1 Hot to touch Perform step 2
hot to touch? TPA
N/A N/A
Allow time to Not hot to touch, no Return to
2 Replace TPA
cool. code service

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test A11 - Traction Motor Current

Test A11 - Traction Motor Diagnosis and Repair

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

This test displays the current in the traction Check individual phase currents with a
motor power circuits. clamping ammeter. The current should ramp
evenly as the lift truck accelerates and
Limits: decelerates. Phase currents must be
approximately equal. Gross differences indicate
• Above 266°F (130°C) current is reduced
a problem.
linearly
• Maximum current up to 540A when If readings are not within reference limits, the
deadman pedal is released, unaffected and test has failed.
unreduced by temperature
1. If any one phase differs significantly from
the other two, check power cable
For information on using Maintenance Mode,
continuity. Replace cables as necessary.
refer to page 3-9.
See Power Cables on page 7-70.
NOTE: This test shows best results in Active • If power cable continuity is OK,
Maintenance. troubleshoot the traction motor. See AC
Motors on page 5-15.
Run Test: • If all phases give high readings, the
drive unit may be binding. Check the
The OD shows the current that the traction drive unit.
power amplifier reads from the traction motor.
2. The power amplifier may be bad. Run Test
O29 - Ramp Traction Motor (Page 6-126).
System Condition Current Displayed

Static at Rest <20A

Travel at Full Speed <150A

Because Test A11 measures only one phase, the

test may not always reveal a problem.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test A13 - Pressure Sensor Voltage (optional)

Test A13 - Pressure

Sensor Voltage
(optional)
This test displays the voltage from the pressure
sensor used for load weight sensing.

For information on using Maintenance Mode,

refer to page 3-9.

Limits

The OD shows the voltage present with various

load weights.

Load Weight Voltage

0 (no load) Approx. 1V

3000 lbs. Approx. 3V

If the weight sensor is disconnected at the VM,

the OD shows 0V.

Run Test:
The voltage shown on the OD should increase
and decrease in a linear fashion as the load
weight is either increased or decreased. If it
does not, the test has failed. If the weight
display is inaccurate, the test has failed.
Perform diagnosis and repair.

Diagnosis and Repair

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

1 JPT20-5 JPT24-10 Perform step 2 Replace VM

DCV 10.5 to 13V
2 JPS50-1 Perform step 3 T/S harness

JPS50-3 Replace
3 Attach pressure JPS50-2 1V at 0 psi: 1V Perform step 4 Pressure
gauge to G1/DCV increase per 1000 psi Transducer

4 JPT24-18 JPT24-10 Replace VM T/S harness

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test A14 - VM +12V Power Supply

Test A14 - VM +12V

Power Supply
This test displays the output of the internal
+12V power supply of the VM.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
The display should read 10.8-13V. If the voltage
fluctuates more than 0.8V in 10 seconds, the
test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

Remove wire from PT14-5

1 Perform step 2 Perform step 4
JPT14-5/DCV (VM side)

JPC11 Replace mast

2 Perform step 3
disconnected/DCV cable

Disconnect all wires

supplying 12 or
5.3V from the Plug in wires
3 connectors at the TP4 10.5 to 13V Replace CCC
and connectors
CCC. Disconnect JPT14-5 one at a time.
JPC15 and Troubleshoot
JPC2/DCV the circuit that
Disconnect all wires pulls down the
supplying 12V from 12V.
4 Replace the VM
the connectors at
the VM/DCV

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test A15 - Battery Voltage

Test A15 - Battery Run Test:

Voltage The test is a success if the voltage displayed is
within these limits:
This test displays the voltage the VM is reading PC must be closed.
from the battery sense line.
Nominal Battery
Voltage Displayed
A successful test proves the VM is correctly Voltage
reading BATTERY_SENSE_IN at JPT24-24.
24V 22.0 to 26.0V
NOTE: This voltage is used by the VM to
36V 33.0 to 39.0V
calculate the battery state-of-charge.

For information on using Maintenance Mode, If the reading fluctuates by more than 0.8V in
refer to page 3-9. 10 seconds with the lift truck not moving or
lifting, the test has failed. Perform diagnosis
and repair.
NOTE: If FH Code occurs, verify that the model
number viewed in FlashWare matches
the vehicle model before replacing the
VM.

Diagnosis and Repair

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

Check battery
voltage/ specific
1 TP1 Perform step 2
gravity. T/S battery
cables.

24V truck: 16 to 32V T/S harness TP1 to

2 DCV JPF4-1 TP4 Perform step 3
36V truck: 28 to 44V TP4.

3 JPF4-7 Perform step 4 T/S Fuse Relay Card.

T/S harness from

4 JPT24-24 Replace VM Fuse Relay Card to
VM.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test A19 - Lift Power Amplifier Temperature (AC lift only)

Test A19 - Lift Power

Amplifier Temperature
(AC lift only)
This test displays the temperature of the Lift
Power Amplifier (LPA) heatsink.

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

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
The OD shows the heatsink temperature that
the lift power amplifier reads.

As the lift is operated, the readings should

increase evenly over time. If not, the test has
failed. Perform diagnosis and repair.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

Is LPA heatsink If not hot, replace

1 Hot to touch Perform step 2
hot to touch? LPA
N/A N/A
Allow time to Not hot to touch, no Return to
2 Replace LPA
cool. code service

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test A20 - Lift Motor Current (AC lift only)

Test A20 - Lift Motor 1. If any one phase differs significantly from
the other two, check power cable
Current (AC lift only) continuity. Replace cables as necessary.
See Power Cables on page 7-70.

This test displays the lift motor current through • If power cable continuity is OK,
the lift power amplifier. troubleshoot the lift motor. See AC
Motors on page 5-15.
• If all phases give high readings, the lift
pump may be binding.
The lift carriage and forks will move 2. The power amplifier may be bad. Run Test
during this test. O28 - Ramp Lift Motor (AC lift only)
(Page 6-125).

The area around the forks must be clear.

The ceiling clearance should allow for
the highest lift.

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

Test requires the use of Active Maintenance to

see correct test results.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
The OD shows the current that the lift power
amplifier reads from one phase of the lift motor.
NOTE: Because only one phase is measured, a
current problem may not be revealed.

Diagnosis and Repair

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

Check individual phase currents with a

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

If readings are not within reference limits, the

test has failed.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test A22 - Traction Throttle Request

Test A22 - Traction

Throttle Request
This test displays the percentage of traction
throttle request from VR1 being read by the VM.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
NOTE: Run Learn after you replace, repair, or
adjust the throttle assembly. See Learn
Controls on page 3-19.

The OD shows the percentage of throttle

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

Acceptable values are:

Throttle Position Percentage Displayed

Full Tractor-First 0 to +100

Neutral 0

Full Forks-First 0 to –100

The values must change smoothly and evenly

as the handle moves from full tractor-first to
full forks-first.

If percentages are not within reference limits,

the test has failed. Perform diagnosis and
repair.
NOTE: Any speed limiting conditions will result
in less than 100 shown on the display.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

Test should pass. Check traction

Run Test A04 -
Compare Test A04 system for speed
Throttle
results with the limits due to motor
1 Potentiometer N/A N/A Replace the TPA
results from A22. temperature, limit
Voltage
Max throw should switches, or
(Page 6-44)
show max values. configured speed.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test A23 - Lift Request

Test A23 - Lift Request

This test displays the percentage of lift throttle
request from VR2 being read by the VM.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
NOTE: Run Learn after you replace, repair, or
adjust the Lift/Lower potentiometer
(VR2). See Learn Controls on page 3-19.

The OD shows the percentage of lift request

that the VM reads from the lift potentiometer
(VR2).

Acceptable values are:

Throttle Position Percentage Displayed

Full Lower 0 to –100

Neutral 0

Full Lift 0 to +100

The values must change smoothly and evenly

as the handle moves from full lower to full lift.

If percentages are not within reference limits,

the test has failed. Perform diagnosis and
repair.
NOTE: Any lift limiting conditions will result in
less than 100% shown on display.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

Test should pass.

Run Test A05 -
Compare Test A05 Check lift system
Lift/Lower
results with the for limits due to
1 Potentiometer N/A N/A Replace the LPA
results from A23. motor temperature
Voltage
Max throw should or switches.
(Page 6-45)
show max values.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test A26 - +5.3VDC Power Supply

Test A26 - +5.3VDC

Power Supply
This test measures the +5.3VDC Power Supply
voltage used for the control handle switches
and potentiometers.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
If the Operator Display does not show +5.3VDC,
the test has failed. Refer to Diagnosis and
Repair after verifying that the CCC does not
have a firmware chip installed and that the
software version is 2.0 or higher.

Diagnosis and Repair

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

Disconnect
1 PC9-8 PC9-7 Perform step 2 Replace CCC
JPC9/DCV
5.05 to 5.55VDC Inspect control Repair or replace
Connect JPC9-8 JPC9-7
2 handle harness control handle or
JPC9/DCV
for damage. harness.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test A34 - Lift/Lower Current

Test A34 - Lift/Lower

Current
This test displays the current the proportional
lift/lower solenoid coil is drawing.

Test requires the use of Active Maintenance to

see correct test results.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
Acceptable values are:

State Current

Neutral Approx. 0.70A

Full Lower Approx. 1.3A

If results do not match the preceding table. the

test has failed. Perform diagnosis and repair.

Diagnosis and Repair

Perform Test O12 - Proportional Solenoid PWM

Ramp (Page 6-121).

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test A35 - Brake

Test A35 - Brake

The brake coil is activated by a coil driver
located inside the VM. This test displays the
voltage measured across that coil driver.

For information on using Maintenance Mode,

refer to page 3-9.
NOTE: This test can only be run in Active
Maintenance.

Run Test:
When the test is run, observe the following
results:

State of Brake Display

Brake deactivated B+

Deadman Pedal
Approx. 12V (36V trucks)
Pressed/Travel
Approx. 0V (24V trucks)
Requested

If results do not match the preceding table, the

test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPT20 and
JPF2 T/S wires and
1 JT20-14 JF2-2 Approx. 13 ohms Perform step 2
disconnected/ coil
ohms

If no B+, T/S
Brake de-energized: B+ Fuse Relay Card.
Inspect brake
Brake energized: If voltage does
2 DCV JP20-14 TP4 assembly for
36V truck = approx. 12V not drop when
binding
24V truck = 0V energized,
replace the VM

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test A37 - Steer Power Amplifier Current

Test A37 - Steer Power report something higher than zero

current in Maintenance Mode.
Amplifier Current If the results do not match the preceding table,
the test has failed. Perform diagnosis and
This test displays the current that the steer repair.
motor is drawing.

Test requires the use of Active Maintenance to

see correct test results.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
You should see:

State of Motor Display

At rest <2A

Clockwise (CW) Steering –30 to –50A

Counterclockwise (CCW) Steering 30 to 50A

NOTE: CW and CCW is drive unit direction.

NOTE: On a fully functional truck, this test

reports OA in Maintenance Mode
because the steer is not being moved in
Maintenance Mode. If the steer amp is
unplugged or other errors in steer
current feedback occur, the test will

Diagnosis and Repair

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

At rest: approx. 2.5V

Replace Steer
1 DCV JPT6-3 TP4 Steering CCW: <V at rest Replace VM
Amplifier
Steering CW: >V at rest

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Run Test:

Tractor Near Wire -

Test A55 - Tractor
Tractor Left - Test A51 Near Wire Coil
- Left Tractor Voltage (Page 6-66)
Guidance Coil Voltage Tractor Right - Test
(Page 6-62) A52 - Right Tractor
Guidance Coil Voltage
(Page 6-63)

Load Near Wire - Test

A56 - Load Near Wire
Coil Voltage
(Page 6-67)

Load Left - Test A53 - Load Right - Test A54

Left Load Guidance - Right Load Guidance
Coil Voltage Coil Voltage
(Page 6-64) (Page 6-65)

6
Figure 6-1. Location of Wire Guidance Coils and Related Tests

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test A51 - Left Tractor Guidance Coil Voltage

Test A51 - Left Tractor For information on using Maintenance Mode,

refer to page 3-9.
Guidance Coil Voltage
Run Test:
This test displays the percentage of the left
NOTE: Center the lift truck over the wire prior
tractor guidance coil voltage sensed by the
to running the test. If it will not track, it
Guidance Manager.
may not be centered and voltages will
fail the test.
Refer to Figure 6-1 on page 6-61 to determine
what coil this test checks.
The test is a success if the percentage displayed
is between 40 and 70%. If the reading is outside
Make sure the lift truck has been through the
these limits, the test has failed. Perform
learn process before testing. Make sure the
diagnosis and repair.
software is up to date. Inspect all motor cables.
Test for shorts to frame. See Shorts to Frame on
page 5-2.

Test line driver output. Refer to the applicable

Raymond Wire Guidance Maintenance Manual.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPW2 and PW2-1, 2, 3, J1T-1, 2, 3,

1 JP1T cables 4, 5, 6, 7, 8, 4, 5, 6, 7, 8, 0 ohms Perform step 2 Replace cable
disconnected 14, 15 14, 15

JPW2
2 disconnected/ JW2-15 JW2-14 Perform step 3 Replace GM
DCV
Approx. 11.5V
JP1T
3 disconnected/ J1T-15 J1T-14 Replace sensor Replace cable
DCV

NOTE: Steps 2 and 3 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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Test A52 - Right Tractor Guidance Coil Voltage

Test A52 - Right Tractor Run Test:

Guidance Coil Voltage NOTE: Center the lift truck over the wire prior
to running the test. If it will not track, it
may not be centered and voltages will
This test displays the percentage of the right fail the test.
tractor guidance coil voltage sensed by the
Guidance Manager. The test is a success if the voltage percentage
displayed is between 40 and 70%.
Refer to Figure 6-1 on page 6-61 to determine
what coil this test checks. If the reading is outside these limits, the test
has failed. Perform diagnosis and repair.
Make sure the lift truck has been through the
learn process before testing. Make sure the
software is up to date. Inspect all motor cables.
Test for shorts to frame. See Shorts to Frame on
page 5-2.

Test line driver output. Refer to the applicable

Raymond Wire Guidance Maintenance Manual.

For information on using Maintenance Mode,

refer to page 3-9.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead ExpectedResults Step Passed Step Failed
Setting

JPW2 and JP1T PW2-1, 2, 3, J1T-1, 2, 3,

1 cable 4, 5, 6, 7, 8, 4, 5, 6, 7, 8, 0 ohms Perform step 2 Replace cable
disconnected 14, 15 14, 15

JPW2
2 disconnected/ JW2-15 JW2-14 Perform step 3 Replace GM
DCV
Approx. 11.5V
JP1T
3 disconnected/ J1T-15 J1T-14 Replace sensor Replace cable
DCV

NOTE: Steps 2 and 3 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test A53 - Left Load Guidance Coil Voltage

Test A53 - Left Load Run Test:

Guidance Coil Voltage NOTE: Center the lift truck over the wire prior
to running the test. If it will not track, it
may not be centered and voltages will
This test displays the percentage of the left load fail the test.
guidance coil voltage sensed by the Guidance
Manager. The test is a success if the voltage percentage
displayed is between 40 and 70%.
Refer to Figure 6-1 on page 6-61 to determine
what coil this test checks. If the reading is outside these limits, the test
has failed. Perform diagnosis and repair.
Make sure the lift truck has been through the
learn process before testing. Make sure the
software is up to date. Inspect all motor cables.
Test for shorts to frame. See Shorts to Frame on
page 5-2.

Test line driver output. Refer to the applicable

Raymond Wire Guidance Maintenance Manual.

For information on using Maintenance Mode,

refer to page 3-9.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPW1 and PW1-1, 2, 3, J1L-1, 2, 3,

1 JP1L cable 4, 5, 6, 7, 8, 4, 5, 6, 7, 8, 0 ohms perform step 2 Replace cable
disconnected 14, 15 14, 15

JPW1
2 disconnected/ JW1-15 JW1-14 perform step 3 Replace GM
DCV
Approx. 11.5V
JP1L
3 disconnected/ J1L-15 J1L-14 Replace sensor Replace cable
DCV

NOTE: Steps 2 and 3 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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Test A54 - Right Load Guidance Coil Voltage

Test A54 - Right Load For information on using Maintenance Mode,

refer to page 3-9.
Guidance Coil Voltage
Run Test:
This test displays the percentage of the right
NOTE: Center the lift truck over the wire prior
load guidance coil voltage sensed by the
to running the test. If it will not track, it
Guidance Manager.
may not be centered and voltages will
fail the test.
Refer to Figure 6-1 on page 6-61 to determine
what coil this test checks.
The test is a success if the voltage percentage
displayed is between 40 and 70%.
Make sure the lift truck has been through the
learn process before testing. Make sure the
If the reading is outside these limits, the test
software is up to date. Inspect all motor cables.
has failed. Perform diagnosis and repair.
Test for shorts to frame. See Shorts to Frame on
page 5-2.

Test line driver output. Refer to the applicable

Raymond Wire Guidance Maintenance Manual.

Diagnosis and Repair

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

J1L-1, 2,
JPW1 and PW1-1, 2, 3,
3, 4, 5, 6,
1 JP1L cable 4, 5, 6, 7, 8, 0 ohms Perform step 2 Replace cable
7, 8, 14,
disconnected 14, 15
15

JPW1
2 disconnected/ JW1-15 JW1-14 Perform step 3 Replace GM
DCV
Approx. 11.5V
JP1L
3 disconnected/ J1L-15 J1L-14 Replace sensor Replace cable
DCV

NOTE: Steps 2 and 3 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test A55 - Tractor Near Wire Coil Voltage

Test A55 - Tractor Near Run Test:

Wire Coil Voltage NOTE: Center the lift truck over the wire prior
to running the test. If it will not track, it
may not be centered and voltages will
This test displays the percentage of the tractor fail the test.
near wire guidance coil voltage sensed by the
Guidance Manager. The test is a success if the percentage displayed
is between 80 and 110%.
Refer to Figure 6-1 on page 6-61 to determine
what coil this test checks. If the reading is outside these limits, the test
has failed. Perform diagnosis and repair.
Make sure the lift truck has been through the
learn process before testing. Make sure the
software is up to date. Inspect all motor cables.
Test for shorts to frame. See Shorts to Frame on
page 5-2.

Test line driver output. Refer to the applicable

Raymond Wire Guidance Maintenance Manual.

For information on using Maintenance Mode,

refer to page 3-9.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPW2 and PW2-1, 2, 3, J1T-1, 2, 3,

1 JP1T cable 4, 5, 6, 7, 8, 4, 5, 6, 7, 8, 0 ohms Perform step 2 Replace cable
disconnected 14, 15 14, 15

JPW2
2 disconnected/ JW2-15 JW2-14 Perform step 3 Replace GM
DCV
Approx. 11.5V
JP1T
3 disconnected/ J1T-15 J1T-14 Replace sensor Replace cable
DCV

NOTE: Steps 2 and 3 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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Test A56 - Load Near Wire Coil Voltage

Test A56 - Load Near Run Test:

Wire Coil Voltage NOTE: Center the lift truck over the wire prior
to running the test. If it will not track, it
may not be centered and voltages will
This test displays the percentage of the load fail the test.
near wire guidance coil voltage sensed by the
Guidance Manager. The test is a success if the voltage percentage
displayed is between 80 and 110%.
Refer to Figure 6-1 on page 6-61 to determine
what coil this test checks. If the reading is outside these limits, the test
has failed. Perform diagnosis and repair.
Make sure the lift truck has been through the
learn process before testing. Make sure the
software is up to date. Inspect all motor cables.
Test for shorts to frame. See Shorts to Frame on
page 5-2.

Test line driver output. Refer to the applicable

Raymond Wire Guidance Maintenance Manual.

For information on using Maintenance Mode,

refer to page 3-9.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

J1L-1, 2,
JPW1 and PW1-1, 2, 3,
3, 4, 5, 6,
1 JP1L cable 4, 5, 6, 7, 8, 0 ohms Perform step 2 Replace cable
7, 8, 14,
disconnected 14, 15
15

JPW1
2 disconnected/ JW1-15 JW1-14 Perform step 3 Replace GM
DCV
Approx. 11.5V
JP1L
3 disconnected/ J1L-15 J1L-14 Replace sensor Replace cable
DCV

NOTE: Steps 2 and 3 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Tests A96 through A100 - iBATTERY Tests

Tests A96 through A100

- iBATTERY Tests
Tests A96 through A100 are iBATTERY related
tests. Refer to iBATTERY Monitoring System
Installation and Maintenance Instructions.

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test A101 - Guidance Manager 12V Power Supply Out-of-Range

Test A101 - Guidance Run Test:

Manager 12V Power The Guidance Manager is equipped with a 2
amp fuse (F1). It is located internal to the fuse
Supply Out-of-Range holder on the bottom left corner. Cover removal
is required in order to remove and check the
This test displays the 12V power supply from fuse. Check the fuse prior to proceeding with
the Guidance Manager to the antenna card. the testing below.
The display should read between 11 and 13
For information on using Maintenance Mode, volts. If the voltage is outside this range the test
refer to page 3-9. has failed. Perform diagnosis and repair

Diagnosis and Repair

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

JPW2
Guidance Replace
1 Manager JW2-15 JW2-14 Perform step 2 Guidance
disconnected/ Manager
DCV

JPW1
Guidance Replace
2 Manager JW1-15 JW1-14 Perform step 3 Guidance
disconnected/ Manager
DCV 11 to 13V
JP1T Tractor Perform step 4
TS wiring from
Sensor before you
3 P1T-15 P1T-14 Guidance
disconnected/ replace the
Manager
DCV Tractor Sensor

Perform step 3
JP1L Load
before you TS wiring from
Sensor
4 P1L-15 P1L-14 replace the Guidance
disconnected/
Load Sensor Manager
DCV

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Run Test:

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Input Tests
Section 6. Messages, Codes and Tests

Input Tests
A Diagnosis and Repair table is provided for
most tests. If a test fails, refer to the Diagnosis
and Repair table. Through the process of
elimination, these tables provide the technician
with a step-by-step approach to diagnosing a
problem and the necessary corrective action.
See the table below.
Example Diagnosis and Repair Table
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

This column
identifies the
action(s) required
(if any) before
testing the
circuit. If no
instructions are
given, all circuits
must be
The next
connected. The next
This is the Connection Connection action to be
Note: If action to be
order that point for point for The reading performed if
something was performed if
the testing the Positive the required to consider the
disconnected in the Expected
must be (+) meter Negative (–) the step a success. Expected
the prior step, Results are
performed. lead. meter lead. Results are
reconnect it met.
not met.
before
performing the
next step.

This column also

identifies the
required setting
on the meter for
this step.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test I00 - Carriage Deadman

Test I00 - Carriage

Deadman
This test shows what the VM is reading from
S23. The switch is hard wired through the CCC
to the VM.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
The state of the switch is displayed:

Deadman Pedal Operator Display

Up Up

Down Down

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPC7
1 disconnected PC7-5 PC7-6 Perform Step 2 Replace CCC
/DCV
10.7 to 13V
2 JPC7-5 Perform Step 3
S23-3 Repair/replace wire
3 Perform Step 4
S23-1
4 S23-2 Pedal down: Perform Step 5 Adjust/replace S23
10.7 to 13V
5 JPC7-5 JPC7-4 Pedal up: 0V Perform Step 6 Repair/replace wires
DCV
6 JPC11-6 Perform Step 7 Replace CCC

Pedal down: B+ Repair/replace

7 B+ JPS25-5 Perform Step 8
Pedal up: 0V over-the-mast cable

8 JPT22-8 Replace VM Repair/replace cable

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Test I01 - Brake Deadman Switch (S2)

Test I01 - Brake

Deadman Switch (S2)
This test shows what the VM is reading from
S2. The switch is hard wired through the CCC
to the VM.
NOTE: Make sure jumper from JPC1-8 to
JPC1-9 is in place before running the
test.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
The state of the switch is displayed:

Deadman Pedal Operator Display

Up Up

Down Down

If these results are not observed, the test has

failed. Perform diagnosis and repair.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPC7
1 disconnected/ PC7-2 PC7-3 Perform Step 2 Replace CCC
DCV
10.7 to 13V
2 JPC7-2 Perform Step 3 Repair/replace
S2-3
3 Perform Step 4 wire
S2-1
4 S2-2 Perform Step 5 Adjust/replace S2
Pedal down: 10.7 to 13V
Pedal up: 0V Repair/replace
5 DCV JPC7-2 JPC7-1 Perform Step 6
wires

6 JPC11-4 Perform Step 7 Replace CCC

7 JPS25-4 Pedal down: 0V Perform Step 8 Replace

B–
Pedal up: 10V over-the-mast
8 JPT22-7 Replace VM cable

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test I02 - Lower Mast Reference (24 in.) Switch

Test I02 - Lower Mast Run Test:

Reference (24 in.) Switch When the test is run, observe the following
results:
This test monitors the state of the lower mast Carriage Switch Operator
reference switch (S11). This test displays what Height Actuator Display
the CCC is reading from the switch.
Below 24 in.
Pressed Belw
For information on using Maintenance Mode, (61 cm)
refer to page 3-9. Above 24 in.
Released Abve
(61 cm)

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Use Active Maintenance to check that the

display indicates the lower mast reference
switch is Belw at all positions below 24 in.
(61 cm). Check that the display indicates the
24 in. (61 cm) switch is Abve at all positions
above 24 in. (61 cm).

Diagnosis and Repair

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

JPC8
1 disconnected PC8-2 PC8-3 Perform Step 2 Replace CCC
/DCV
6 to 13V
2 JPC8-2 Perform Step 3
S11-3 Repair/replace wires
3 Perform Step 4
DCV S11-1
4 S11-2 S11 Perform Step 5 Adjust/replace S11
Closed (below): 6-13V
5 JPC8-2 JPC8-1 Open (above): 0V Replace CCC Repair/replace wires

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Test I03 - 60 in. Limit Switch

Test I03 - 60 in. Limit If these results are not observed, the test has
failed.
Switch Using Active Maintenance, check that the
display indicates the 60 in. switch is Belw at all
Using this test, the state of the 60 in. limit positions below 60 in. Check that the display
switch (S28) can be monitored. This test indicates Abve for all positions above the 60 in.
displays what the CCC is reading from the switch.
switch.
NOTE: This switch is not used with the Lift trucks without S28 require a jumper
intellispeed option. (P/N 114-008-958/002) between JPC3-3 and
JPC3-1.
For information on using Maintenance Mode,
refer to page 3-9.

Run Test:
When the test is run, observe the following
results:

Operator
Carriage Height Switch
Display

Below 60 in. Pressed Belw

Above 60 in. Extended Abve

Diagnosis and Repair

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

JPC3
1 disconnected PC3-2 PC3-3 Perform Step 2 Replace CCC
/DCV
6 to 13V
2 JPC3-2 Perform Step 3
S28-3
3 Perform Step 4
DCV S28-1 Repair/replace wires
4 S28-2 S28 Perform Step 5
Closed (below): 6-13V
5 JPC3-2 JPC3-1 Open (above): 0V Replace CCC

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test I04 - Lift/Lower Inhibit Bypass (optional)

Test I04 - Lift/Lower

Inhibit Bypass (optional)
Using this test, the state of the lift inhibit
bypass switch (S7) can be tested. This test
displays what the CCC is reading from the
switch. This test is only visible on lift trucks
equipped with the Lift/Lower Inhibit Bypass
option.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
When the test is run, observe the following
results.

Lift Inhibit Switch (S7) Operator Display

Up Out

Pressed In

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPC6 Verify option Repair/replace wires

Released: open circuit
1 disconnected/ JC6-6 JC6-5 is turned on. and/or switch S7
Pressed: 0 ohms
ohms Replace CCC

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test I05 - Lift Inhibit Switch (optional)

Test I05 - Lift Inhibit

Switch (optional)
Using this test, the state of the lift inhibit
switch (S24) can be monitored. This test
displays what the VM is reading from the
switch. This test only works on lift trucks
equipped with the Lift/Lower Inhibit Bypass
option.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
When the test is run, observe the following
results:

Operator Carriage Operator Display

Below Switch (closed) Belw

Above Switch (open) Abve

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Diagnosis and Repair

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

Pull pin from

JPT20-10.
1 JPT24-3 Perform Step 2 Replace VM
Backprobe
connection. 10.7 to 13V
2 JPT20-10 Perform Step 3 Repair/replace
S24-1
3 DCV Perform Step 4 harness
S24-3 Adjust or replace
4 S24-2 Perform Step 5
S24 S24
Closed: 10.7 to 13V Verify option is
Open: approx. 0V Repair/replace
5 JPT20-10 JPT22-2 turned on.
harness
Replace VM

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test I15 - Horn Switch

Test I15 - Horn Switch

This test checks the input from the horn switch
(S3) to the CCC at JPC9-3 and JPC9-4.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
When the test is run, observe the following
results:

Horn Switch Position Operator Display

Out Out

Pressed In

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Diagnosis and Repair

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

S3 Repair/replace
1 DCV JPC9-3 JPC9-4 Closed: < 0.6V Replace CCC wires and/or
Open: Approx. 5.35V switch S3

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test I19 - Traction Motor RPM

Test I19 - Traction Motor

RPM
This test displays the output from the speed
encoder on the traction motor as seen by the
traction power amplifier.

Do this test in an area free of

obstructions with ample room for
maneuvering.

For information on using Maintenance Mode,

refer to page 3-9.

This test requires the use of Active Maintenance

to see correct test results.

Run Test:
NOTE: The OD shows RPM as measured by the
traction power amplifier. The RPM
reading should show a linear increase to
maximum RPM.

You should see:

Lift Truck Type Maximum RPM

Standard Duty 5532

Heavy Duty 4424

If these results are not observed, the test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

1 JPTA1-26 Perform Step 2 Replace TPA

JPTA1-7
2 4.5 to 5.5V Perform Step 3 Troubleshoot/replace
JPTA2-1
3 JPTA2-4 Perform Step 4 harness

4 DCV JPTA1-31 Perform Step 5 Perform Step 6

Stationary: >3.5V
5 JPTA1-32 or <0.5V Replace TPA Perform Step 7
JPTA1-7
6 JPTA2-3 Running: approx.
2V Repair/replace Replace traction motor
7 JPTA2-2 harness speed encoder

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test I20 - Lift Motor RPM (AC lift only)

Test I20 - Lift Motor RPM

(AC lift only)
This test displays the input from the speed
encoder on the lift motor as seen by the lift
power amplifier.

Do this test in an area free of

obstructions with ample room for lifting.

For information on using Maintenance Mode,

refer to page 3-9.

This test requires the use of Active Maintenance

to see correct test results.

Run Test:
NOTE: The OD shows RPM as measured by the
lift power amplifier. The RPM reading
should show a linear increase to
maximum RPM.

During lift, 2400 rpm max must be displayed.

Diagnosis and Repair

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

1 JPLA1-26 Perform Step 2 Replace LPA

JPLA1-7
2 4.5 to 5.5V Perform Step 3 Troubleshoot/replace
JPLA2-1
3 JPLA2-4 Perform Step 4 harness

4 DCV JPLA1-31 Perform Step 5 Perform Step 6

Stationary: >3.5V or
5 JPLA1-32 <0.5V Replace LPA Perform Step 7
JPLA1-7
6 JPLA2-3 Running: approx.
2V Repair/replace Replace lift motor
7 JPLA2-2 harness speed encoder

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test I23 - CAN Bus

Test I23 - CAN Bus

This test verifies the VM is communicating with
the Traction Power Amplifier, Lift Power
Amplifier, and Guidance Manager.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
NOTE: To enter this test, press and hold
both the UP and DOWN buttons and
turn the key switch ON.

The OD shows:
• V if the Vehicle Manager is communicating
with the Carriage Control Card
• T if the Traction Power Amplifier is
communicating with the Carriage Control
Card
• L if the Lift Power Amplifier is
communicating with the Carriage Control
Card (AC lift only)
• W if the Guidance Manager is
communicating with the Carriage Control
Card (Wire Guidance only)
NOTE: Wait at least 60 seconds after the test
shows on the display for letters to be
displayed.

If V, T, L, or W are not displayed, the test has

failed. Perform diagnosis and repair.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Run Test:

Diagnosis and Repair

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

If letter V is missing:

1 DCV JPTA1-1 B– B+ Perform Step 2 T/S B+ from K3 Relay

2 JPT14 and JPT14-11 JPSC1-2

JPSC1 Repair/replace
JPT14-4 JPSC1-1 0 ohms Replace VM
3 disconnected/ harness
ohms

If letter L is missing (AC Lift only):

1 DCV JPLA1-1 B– (on amp) B+ Perform Step 2 T/S B+ from K3 Relay

2 JPLA1 and JPLA1-23 JPSC2-2

JPSC2 Replace Lift Repair/replace
JPLA1-35 JPSC2-1 0 ohms
3 disconnected/ Amplifier harness
ohms

If letter T is missing:

1 DCV JPTA1-1 B– (on amp) B+ Perform Step 2 T/S B+ from K3 Relay

2 JPTA1 and JPTA1-23 JPSC1-2

Replace
JPSC1 Repair/replace
JPTA1-35 JPSC1-1 0 ohms Traction
3 disconnected/ harness
Amplifier
ohms

If letter W is missing (Wire Guidance only):

1 JPS2-11 JPS2-24 Perform Step 4 Perform Step 2

2 JPT20-19 TP4 Perform Step 3 Replace VM

DCV B+
Perform Step 1 Replace Fuse/Relay
3 TP1 JPF3-9
Card

Disconnect T/S wires and Replace Guidance

JPW1 and 2 at W shows on Antenna Cards. Manager
4 N/A N/A
Guidance display
Manager

If no letters are displayed:

Perform Step 2 Repair/replace shorted

1 JPLA1, JPTA1, JT14-4 Open
Bus +/– cable
JPT14, JPS4
and JPC11 JT14-11 JTA1-23,
disconnected/ JLA1-23, Repair/replace
2 0 ohms Perform Step 3
ohms JS4-6, harness
JC11-3

One at a time, Letters for the Replace

disconnect all other devices disconnected
3 N/A N/A Replace CCC
devices on the come back on component
Bus display

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test I24 - Home Position Proximity Sensor

Test I24 - Home Position

Proximity Sensor
This test displays what the VM sees from the
Home Proximity Sensor.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
When the test is run, observe the following
results:

Home
Operator Red LED on
Proximity
Display Sensor
Sensor

Over metal On On

Away from
Off Off
metal

If these results are not observed, the test has

failed. Perform diagnosis and repair.
NOTE: If the test fails in Active Maintenance,
pass a screwdriver or metal ruler under
the sensor to activate it. If the test
passes, adjust the switch. See Home
Proximity Sensor Adjustment on
page 7-18.

Diagnosis and Repair

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

1 JPA7-3 JPA7-2 Perform Step 3 Perform Step 2

10.5 to 13V Replace/replace
2 JPT20-9 JPT22-11 Replace VM
harness
DCV Adjust/replace
3 JPA7-3 JPA7-1 Sensor over metal: Perform Step 4
approx. 10V sensor
Sensor not over Replace/replace
4 JPT22-3 JPT20-9 metal: approx. 6V Replace VM
harness

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test I25 - Steer Motor Encoder

Test I25 - Steer Motor

Encoder
This test displays the counts from the steer
motor encoder.

For information on using Maintenance Mode,

refer to page 3-9.

This test requires the use of Active Maintenance

to see correct test results.

Run Test:
A three digit number is displayed representing
the number of steer motor encoder counts.
When the count exceeds 255, it starts over at 0.
If the count goes below 0, it starts over at 255.
NOTE: Turn the steering slowly to make sure
that the display shows the encoder
counting correctly.

If these results are not seen, perform diagnosis

and repair.

Diagnosis and Repair

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

1 JPE4-1 10.5 to 13V Perform Step 2 Perform Step 6

2 JPE4-3 JPE4-4 Perform Step 3 Replace steer motor

Stationary: encoder
3 JPE4-2 >4V or <0.5V Perform Step 4

4 DCV JPT22-9 Turning: Perform Step 5

approx. 2.5V Repair/replace
5 JPT22-10 Replace VM harness
JPT10-9
Repair/replace
6 JPT20-7 10.5 to 13V Replace VM
harness

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Test I26 - Height Encoder - Main Lift (With Full Height Sensing)

Test I26 - Height Encoder

- Main Lift (With Full
Height Sensing)
Test I26 is a Height Sensing Encoder related
test. Refer to the Full Height Sensing System Kit
Installation and Maintenance Instructions.

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Test I26 - Flow Sensor Count (Without Full Height Sensing)

Test I26 - Flow Sensor

Count (Without Full Run Test:
Height Sensing) A three digit number is displayed representing
the number of flow pulses counted. When the
NOTE: This test applies to lift trucks equipped count exceeds 255, it starts over at 0. If the
with the intellispeed option. count goes below 0, it starts over at 255.

This test displays the flow sensor pulses that Place test in Active Maintenance. The count
the VM reads. A successful test proves the VM should increase during lift and decrease during
is correctly reading pulses from the flow sensor. lower. If these results are not observed, the test
has failed. Perform diagnosis and repair.
For information on using Maintenance Mode,
refer to page 3-9. This test must be run from
Active Maintenance.

Diagnosis and Repair

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

1 JPY7-1 J21-A Perform Step 2

2 JPY7-2 J21-B Perform Step 3 Repair/replace

ohms 0 ohms
3 JPY6-1 J22-A Perform Step 4 wires

4 JPY6-2 J22-B Perform Step 5

5 JPY1 JPT20-2 JPY24-11 Perform Step 6 Replace VM

disconnected/ 12V Repair/replace
6 DCV JPY1-5 JPY1-3 Perform Step 7
wires

7 JPY7-1 JPY7-3 Perform Step 8 Replace cable

DCV 2.6V
8 JPY6-1 JPY6-3 Perform Step 9 and sensor

9 JPY7-2 JPY7-3 At rest: <2mV Perform Step 10

Lift/Lower: Ramps from
Lift or Lower/ Clean flow
approx 0 to between 200
10 mVAC JPY6-2 JPY6-3 Perform Step 11 sensor turbine
and 300mV as speed
increases

11 JPY1-1 Perform Step 12 Replace cable

12 JPY1-2 Perform Step 13 and sensor
Lift or Lower/ At rest: 0 to 5V
B–
13 DCV JPT22-13 Lift/Lower: approx 2.8V Perform Step 14 Repair/replace
14 JPT22-14 Replace VM wires

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Test I35 - Steer Tiller Encoder 1

Test I35 - Steer Tiller

Encoder 1
This test displays the value that the CCC sees
from the Steer Tiller Encoder at JPC1. A
successful test proves the CCC is reading the
encoder correctly.

The VM uses the input from the CCC to

determine the rate and direction of steering.
The displayed number varies between 0 and
255. The value has little correlation to the
actual steering angle. The displayed value
should change as the drive unit is steered.

This test requires the use of Active Maintenance

to see correct test results.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
If the number displayed does not vary or the
count only changes from 0 to 1 or 0 to 255, the
test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

1 PC1-1 PC1-2 Perform Step 2

JPC1at CCC
2 disconnected/ PC1-3 PC1-2 5.3V Perform Step 3 Replace CCC
DCV
3 PC1-4 PC1-2 Perform Step 4

Will be either approx.

5.3V or approx. 0V
when the tiller is
JPC1-3 (CHB-E2) JPC1-2 Replace Steer
4 DCV stationary. Replace CCC
JPC1-4 (CHA-E2) JPC1-2 Encoder
Somewhere between
0 and 5V when tiller
is moving.

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Test I36 - Steer Tiller Encoder 2

Test I36 - Steer Tiller Run Test:

Encoder 2 If the number displayed does not vary or the
count only changes from 0 to 1 or 0 to 255, the
This test displays the value that the CCC sees test has failed. Perform diagnosis and repair.
from the Steer Tiller Encoder at JPC21. A
successful test proves the CCC is reading the
encoder correctly.

The VM uses the input from the CCC to

determine the rate and direction of steering.
The displayed number varies between 0 and
255. The value has little correlation to the
actual steering angle. The displayed value
should change as the drive unit is steered.

This test requires the use of Active Maintenance

to see correct test results.

For information on using Maintenance Mode,

refer to page 3-9.

Diagnosis and Repair

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

1 JPC21 at PC21-1 PC21-2 Perform Step 2

CCC
2 PC21-3 PC21-2 5.3V Perform Step 3 Replace CCC
disconnected
3 /DCV PC21-4 PC21-2 Perform Step 4

Will be either approx.

5.3V or approx. 0V
when the tiller is Replace
JPC21-3 (CHB-E2) JPC21-2
4 DCV stationary. Replace CCC Steer
JPC21-4 (CHA-E2) JPC21-2
Somewhere between Encoder
0 and 5V when the
tiller is moving.

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Test I38 - EPO Switch

Test I38 - EPO Switch

This test monitors the state of the Emergency
Power Off (EPO) switch. A successful test proves
the CCC is correctly reading the EPO switch.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
When the test is run, observe the following
results:

Emergency Off Switch Operator Display

Out Out

In In

If these results are not observed, the test has

failed. Perform diagnosis and repair.
NOTE: After activating the EPO switch, cycle
the key switch OFF/ON.

Diagnosis and Repair

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

1 JPC6-4 Perform Step 2 Replace CCC

Repair/replace wires or
2 JPC6-3 Perform Step 3
switch

3 JPC16-1 Perform Step 4 Replace CCC

DCV B– B+ Replace over-the-mast
4 JPF4-5 Perform Step 5
cable

5 JPF4-6 Perform Step 6 Replace Fuse Relay Card

Repair or replace wire

6 JPT22-21 Replace VM
from Fuse Relay Card

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Test I39 - Neutral Pulses

Test I39 - Neutral Pulses

This test displays the neutral pulses seen by
the VM from the Steer Power Amplifier.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
This test requires use of Active Maintenance to
see correct test results.

You should see:

Off Deadman On Deadman

Quickly toggles
ON
between ON and OFF

If results do not match the preceding table, the

test has failed. Perform diagnosis and repair.
NOTE: If an error code exists, Active
Maintenance will not work. Refer to
“Test O44 - Steer Motor” on page 6-134
for troubleshooting.

Diagnosis and Repair

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

1 JPT6-6 10.5 to 13V Perform Step 2 Replace VM

DCV JPT6-4 Repair wiring or

2 JPT6-1 Deadman pedal up: >4V Replace VM replace Steer Power
Amplifier

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Test I41 - Aux Mast Lift Switch S32 (Option)

Test I41 - Aux Mast Lift Run Test:

Switch S32 (Option) You should see:

This test monitors the state of the auxiliary lift Aux Mast Lift Switch Operator Display
switch (S32). This switch causes the auxiliary
Out Off
mast to lift. This test displays what the CCC is
reading from the switch. Pressed On
NOTE: S31 (Aux lift left-hand deadman) must
also be pressed during this test. The S31 If results do not match the preceding table, the
switch circuit must be functional. test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPC19
1 Disconnected PC19-1 PC19-3 6-13V Perform Step 2 Replace CCC
/DCV

JPC19
Connected/
2 DCV/S31 JPC19-1 JPC19-3 Approx. 0.0V Replace CCC Perform Step 3
and S32
Activated

S32
3 Activated/ S32-1 S32-2 .1 ohm Perform Step 4 Replace S32
ohms

Troubleshoot wiring
4 ohms S32-2 S31-1 .1 ohm Perform Step 5
from S31 to S32

S31 Troubleshoot
5 Activated/ S31-2 S31-1 .1 ohm wiring from Replace S31
ohms CCC to S31

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Test I42 - Aux Mast Lower Switch S33 (Option)

Test I42 - Aux Mast Run Test:

Lower Switch S33 You should see:

(Option) Aux Mast Lower

Operator Display
Switch
This test monitors the state of the auxiliary
Out Off
lower switch (S33). This switch causes the
auxiliary mast to lower. This test displays what Pressed On
the CCC is reading from the switch.
NOTE: S31 (Aux lift left-hand deadman) must If results do not match the preceding table, the
also be pressed during this test.The S31 test has failed. Perform diagnosis and repair.
switch circuit must be functional.

Diagnosis and Repair

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

JPC19
1 disconnected/ PC19-2 PC19-3 6-13V Perform Step 2 Replace CCC
DCV

JPC19
Connected/
2 JPC19-2 JPC19-3 Approx. 0.0V Replace CCC Perform Step 3
DCV/S31 and
S33 Activated

S33 Activated/
3 S33-1 S33-2 .1 ohm Perform Step 4 Replace S33
ohms

Troubleshoot wiring
4 ohms S33-2 S31-1 .1 ohm Perform Step 5
from S31 to S33

S31 Troubleshoot
5 Activated/ S31-2 S31-1 .1 ohm wiring from Replace S31
ohms CCC to S31

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Test I43 - Slack Chain Switch

Test I43 - Slack Chain Run Test:

Switch You should see:

This test monitors the state of the auxiliary Switch Operator Display
slack chain switches, S36 and S37. These
Activated In
switches cause the auxiliary mast to lift. This
test displays what the CCC is reading from the Deactivated Out
switches.
NOTE: Either switch listed below can cause an If results do not match the preceding table, the
error. Run the tests below on both the test has failed. Perform diagnosis and repair.
S36 and S37 switches.

Diagnosis and Repair

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

JPC24
1 Disconnected JC24-2 JC24-3 Perform step 2 Replace CCC.
/DCV 12V
Troubleshoot wiring
2 S36/DCV S36-3 S36-1 Perform step 3
from S36 to CCC

Switch engaged-
Troubleshoot
0.1 ohm
3 S36/ohm S36-2 S36-1 wiring from Replace S36
Switch disengaged -
S36-2 to CCC
open

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Run Test:

Run Test: If results do not match the preceding table, the

test has failed. Perform diagnosis and repair.
You should see:

Switch Operator Display

Activated In

Deactivated Out

Diagnosis and Repair

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

JPC22
1 Disconnected JC22-2 JC22-3 Perform step 2 Replace CCC
/DCV 12V
TS wiring from S37 to
2 S37/DCV S37-3 S37-1 Perform step 3
CCC

Switch engaged - 0.1

TS wiring from
ohm
3 S37/ohm S37-2 S37-1 S37-2 and Replace S37
Switch disengaged -
S37-1 to CCC
open

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Test I44 - Aux Limit Switch S34

Test I44 - Aux Limit

Switch S34
This test monitors the state of the auxiliary
limit switch (S34). This switch causes the
auxiliary mast lift to decelerate before reaching
the stops. This test displays what the CCC is
reading from the switch.

Run Test:
You should see:

Aux Limit Switch Operator Display

Switch Activated Belw

Switch Not Activated Abve

If results do not match the preceding table, the

test has failed. Perform diagnosis and repair.

Diagnosis and Repair

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

JPC20
1 disconnected PC20-2 PC20-3 Perform step 2 Replace CCC
/DCV 12V
Troubleshoot wiring
2 S34/DCV S34-3 S34-1 Perform step 3
from S34 to CCC

Switch engaged Troubleshoot

3 S34/ohms S34-2 S34-1 0.1ohm\ wiring from Replace S34
Disengaged Open S34-2 to CCC

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Test I45 - Slk S29 [Slack Chain 1 Switch (S29)]

Test I45 - Slk S29 [Slack

Chain 1 Switch (S29)]
The state of the Slack Chain Switch (S29).

Run Test:
The state of the switch is displayed:

Deadman Pedal Operator Display

Activated In

Deactivated Out

If these results are not observed, the test has

failed. Perform diagnosis and repair. Check lift
chain tension.

Diagnosis and Repair

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

JPT20 and
JPT4 are
1 JT20-3 JT4-2 Perform step 2 Replace VM
Disconnected
/DCV

12V Troubleshoot wiring

2 JPS58/DCV JPS58-1 JPS58-3 Perform step 3 from JPS58 to
JPT20-3/JPT4-2

Troubleshoot wiring
3 S29/DCV S29-3 S29-1 Perform step 4
from JPS58 to S29

Troubleshoot
Switch disengaged -
4 S29/ohm S29-2 S29-1 wiring from S29 Replace S29
open
to VM

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Test I46 - Slk Ch S30 [Slack Chain 2 Switch (S30)]

Test I46 - Slk Ch S30

[Slack Chain 2 Switch
(S30)]
The state of the Slack Chain Switch S30 is
displayed.

Run Test:
The state of the switch is displayed:

Switch Operator Display

Activated In

Deactivated Out

If these results are not observed, the test has

failed. Perform diagnosis and repair. Check lift
chain tension.

Diagnosis and Repair

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

JPT20 and
JPT4
1 JT20-4 JT4-2 Perform step 2 Replace VM
Disconnected
/DCV

12V Troubleshoot wiring

2 JPS59/DCV JPS59-1 JPS59-3 Perform step 3 from JPS59 to JPT20-4
and JPT4-2

Troubleshoot wiring
3 S30/DCV S30-3 S30-1 Perform step 4
from JPS59 to S30

Switch engaged - 0.1

Troubleshoot
ohm
4 S30/ohm S30-2 S30-1 wiring from S30 Replace S30
Switch disengaged -
to VM
open

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Test I64 - Height Encoder - Free Lift

Test I64 - Height Encoder

- Free Lift
Test I64 is a Height Sensing Encoder related
test. Refer to the Full Height Sensing System Kit
Installation and Maintenance Instructions.

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Test I65 - Rail Guidance Switch (optional)

Test I65 - Rail Guidance

Switch (optional)
NOTE: This test applies to lift trucks equipped
with rail guidance.

Using this test, the state of the rail guidance

switch (S15) can be verified.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
When the test is run, observe the following
results:

Rail Guidance Switch

Operator Display
(S15)

Pressed In

Released Out

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Diagnosis and Repair

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

Pull pin from

JPT18-4.
1 JPT24-5 Perform Step 2 Replace VM
Backprobe
connection. 10.5 to 13V
2 JPT18-4 Perform Step 3 Repair/replace
DCV S15-1
3 Perform Step 4 harness
S15-3
4 S15-2 S15 Perform Step 5 Adjust or replace S15
Closed: 10.7 to 13V Repair/replace
5 JPT18-4 JPT22-22 Open: <1V Replace VM
harness

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Test I66 - Auto/Manual Switch (optional)

Test I66 - Auto/Manual

Switch (optional)
This test displays the position of the Auto/
Manual switch (S4). A successful test proves
the CCC is correctly reading the Auto/Manual
switch.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
When the test is run, observe the following
results:

Switch Position Operator Display

O (open) Auto

| (closed) Manu

If these results are not observed, the test has

failed. Perform diagnosis and repair.
NOTE: If the wire between the Auto/Manual
switch and the CCC becomes
disconnected, the system defaults to
Auto.

Operation of the Auto/Manual switch and CCC

can also be checked by observing the green
triangles on the display. The green triangles
should illuminate when the switch is in Auto
and extinguish when the switch is in Manual.

Diagnosis and Repair

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

JPC9 Verify option is

Auto: open circuit Troubleshoot wires
1 disconnected JC9-1 JC9-2 turned on.
Manual: 0 ohms and switch
/ohms Replace CCC

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Test I67 - Sidegate Switches (optional)

Test I67 - Sidegate Run Test:

Switches (optional) The state of the sidegate switch is displayed.
Both sidegates must be down for the display to
Use this test to test the state of the sidegate change states.
switches (S60, S61). This test displays what the Sidegates Operator Display
CCC is reading from the switch. This test only
works on lift trucks equipped with the sidegate One sidegate up Up
switch option.
Both sidegates up Up

For information on using Maintenance Mode, Both sidegates down Down

refer to page 3-9.
If these results are not observed, the test has
failed. Perform diagnosis and repair.

Diagnosis and Repair

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

Right Sidegate - Switch S60

JPC14
1 disconnected PC14-2 PC14-3 Perform Step 2 Replace CCC
/DCV
10.7 to 13V
2 JPC14-2 Perform Step 3 Repair/replace
S60-3
3 Perform Step 4 harness
S60-1
4 DCV S60-2 Perform Step 5 Adjust or replace S60
S60
Closed: 6 to 12V Repair/replace
5 JPC14-2 JPC14-1 Open: 1V Replace CCC
harness

Left Sidegate - Switch S61

JPC13
1 disconnected PC13-2 PC13-3 Perform Step 2 Replace CCC
/DCV
10.7 to 13V
2 JPC13-2 Perform Step 3 Repair/replace
S61-3
3 Perform Step 4 harness
S61-1
4 DCV S61-2 Perform Step 5 Adjust or replace S61
S61
Closed: 10.7 to 13V Repair/replace
5 JPC13-2 JPC13-1 Open: <1V Replace CCC
harness

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Test I68 - Travel Cutout/Battery Gate and PLS Switch (optional)

Test I68 - Travel If these results are not observed, the test has
failed. Perform diagnosis and repair.
Cutout/Battery Gate and
PLS Switch (optional)
This test monitors the state of the travel cutout
switch (S27). This test displays what the VM is
reading from the switch.

This test is also used for trucks equipped with

battery gates and PLS. This test monitors your
battery gate switches.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
When the test is run, observe the following
results.

Carriage Position
Operator Display
(wrt S27)

Below Belw

Above Abve

Diagnosis and Repair

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

Pull pin from

JPT20-6.
1 JPT24-6 Perform Step 2 Replace VM
Backprobe
connection. 10.5 to 13V
2 JPT20-6 Perform Step 3 Repair/replace
DCV S27-1
3 Perform Step 4 harness
S27-3
4 S27-2 S27 Perform Step 5 Adjust or replace S27
Closed: 6 to 12V Repair/replace
5 JPT20-6 JPT22-6 Open: <1.5V Replace VM
harness

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Test I69 - Upper Mast Reference Switch

Test I69 - Upper Mast Run Test:

Reference Switch When the test is run, observe the following
results:
This test monitors the state of the upper mast Switch Operator
reference switch (S10). This test shows what the Carriage Height
Actuator Display
VM is reading from the upper mast reference
switch at JPT20-1 wrt JPT22-1. A successful Below Upper
Pressed Belw
test proves the VM is correctly reading the Reference Switch
upper mast reference switch. Above Upper
Released Abve
Reference Switch
For information on using Maintenance Mode,
refer to page 3-9.
If these results are not observed, the test has
failed. Perform diagnosis and repair.

Use Active Maintenance to check that the

display indicates the upper reference switch is
closed at all positions below the upper reference
switch. Check that the display indicates the
upper reference switch is not closed at all
positions above upper reference switch.

Diagnosis and Repair

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

Pull pin from JPF3-8

JPT20-1. (Fuse
1 Perform Step 2 Replace VM
Backprobe Relay
connection. Card) 10.5 to 13V
2 JPT20-1 Perform Step 3 Repair/replace
DCV S10-1
3 Perform Step 4 harness
S10-3
4 S10-2 S10 Perform Step 5 Adjust or replace S10
Closed: 10.5 to 13V Repair/replace
5 JPT20-1 JPT22-1 Open: <6.5V Replace VM
harness

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Test I72 - End-of-Aisle Sensor 2 (optional)

Test I72 - End-of-Aisle

Sensor 2 (optional)
NOTE: This test applies to lift trucks equipped
with End-of-Aisle Detect.

This test displays what the VM sees from Aisle

Detect Sensor 2. Sensor 2 (S47A and B) is
located on the left side of the Antenna Card
bracket as you stand on the platform facing the
tractor.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
You have two choices when running this test:

Statically: If this test is to be run statically,

park the lift truck away from any magnets in
the floor. Obtain a magnet (P/N 591-552/002)
and pass the magnet under the sensor.
Remember that this is a transitional state.

The sensor reverts to its original position even if

the magnet remains under the sensor. It may be
helpful if two people are available for this test.
When a magnet is placed under the sensor, the
OD shows On briefly. Even if the magnet
remains under the sensor, the display changes
back to Off.

Active Maintenance: To run this test in Active

Maintenance, position the lift truck away from
any floor magnets. Select this test for Active
Maintenance. Have this test on the OD. While
observing the display, drive the lift truck so the
sensor passes over a floor magnet. The OD
shows On briefly. Even if the magnet remains
under the sensor, the display changes back to
Off.

If these results are not observed, the test has

failed. Perform diagnosis and repair.

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Run Test:

Diagnosis and Repair

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

Pull pin
JPT10-7.
1 Approx. 10.5V Perform Step 2 Replace VM
Backprobe
connection
JPT24-9 T/S harness for
opens and shorts.
2 JPT10-7 Approx. 7.9V Perform Step 3 If OK, replace
sensor S47A or
S47B

If <4V, replace
3 S47B-5 Perform Step 4
S47A or S47B
DCV
S47B-8 Approx. 4V If <4V,
repair/replace
4 S47A-6 Perform Step 5
harness from
S47B-5 to S47A-6

If approx. 10.5V,
5 JPT10-7 Approx. 7.9V Perform Step 6 replace sensor
S47A
JPT24-9 S47A or S47B T/S harness for
Closed (sees magnet): 3.7V opens and shorts.
6 JPT10-8 Replace VM
Open (no magnet): approx If OK, replace bad
7.8V sensor

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test I73 - End-of-Aisle Sensor 1 (optional)

Test I73 - End-of-Aisle Run Test:

Sensor 1 (optional) The state of the switch is displayed:

Switch Operator Display

This test applies to lift trucks equipped with
End-of-Aisle Detect or Auto Steer Center. Activated On

Deactivated Off
This test displays what the VM sees from Aisle
Detect Sensor 1. Sensor 1 (S46A and B) is
located on the right side of the Antenna Card While observing the display, drive the truck so
bracket as you stand on the platform facing the the sensor passes over a floor magnet. The
tractor. display should change from off to on.

For information on using Maintenance Mode, If these results are not observed, the test has
refer to page 3-9. failed. Perform diagnosis and repair.

Run Test:
You have two choices when running this test:

Statically: If this test is to be run statically,

park the lift truck away from any magnets in
the floor. Obtain a magnet (P/N 591-552/002)
and pass the magnet under the sensor.
Remember that this is a transitional state.

The sensor will revert to its original position

even if the magnet remains under the sensor. It
may be helpful if two people are available for
this test. When a magnet is placed under the
sensor, the OD shows On briefly. Even if the
magnet remains under the sensor, the display
changes back to Off.

Active Maintenance: To run this test in Active

Maintenance, position the lift truck away from
any floor magnets. Select this test for Active
Maintenance. Have this test on the OD. While
observing the display, drive the lift truck so the
sensor passes over a floor magnet. The OD
shows On briefly. Even if the magnet remains
under the sensor, the display changes back to
Off.

NOTE: If these results are not observed, the test

has failed. Perform diagnosis and repair.

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Run Test:

Diagnosis and Repair

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

Pull pin
JPT10-6.
1 Approx. 10.5V Perform Step 2 Replace VM
Backprobe
connection JPT24-8
T/S harness for opens
and shorts. If OK,
2 JPT10-6 Approx. 7.9V Perform Step 3
replace sensor S46A or
S46B

3 S46B-5 Perform Step 4 If <4V, replace S46B

DCV S46B-8 If <4V, repair/ replace
Approx. 4V
4 S46A-6 Perform Step 5 harness from S46B-5 to
S46A-6

If approx. 10.5V,
5 JPT10-6 Approx. 7.9V Perform Step 6
replace sensor S46A

S46A or S46B
JPT24-8 Closed (sees T/S harness for opens
6 JPT10-2 magnet): 3.7V Replace VM and shorts. If OK,
Open (no magnet): replace bad sensor
approx 7.8V

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test I74 - Lower Inhibit Switch (optional)

Test I74 - Lower Inhibit

Switch (optional)
This test monitors the state of the lower inhibit
switch (S25). This test displays what the CCC is
reading from the switch.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
The state of the lower inhibit switch (S25) is
displayed.

Carriage Position
Operator Display
(wrt S25)

Below Belw

Above Abve

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Using Active Maintenance, check that the

display indicates the carriage is Belw at all
positions below the lower inhibit switch. Check
that the display indicates Abve for all positions
above the lower inhibit switch.

Diagnosis and Repair

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

JPC4
1 disconnected PC4-2 PC4-3 Perform Step 2 Replace CCC
/DCV
10.7 to 13V
2 JPC4-2 Perform Step 3 Repair/replace
S25-3
3 Perform Step 4 harness
S25-1
4 DCV S25-2 S25 Perform Step 5 Adjust or replace S25
Closed: 10.5 to
13V Repair/replace
5 JPC4-2 JPC4-1 Replace CCC
Open: 0V harness

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Test I75 - 180 in. Limit Switch (optional)

Test I75 - 180 in. Limit

Switch (optional)
This test monitors the state of the 180 in. limit
switch (S100). This test displays what the CCC
is reading from the switch.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
The state of the 180 in. limit switch (S100) is
displayed.

Carriage Position
Operator Display
(wrt S100)

Below Belw

Above Abve

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Using Active Maintenance, check that the

display indicates the carriage is Belw at all
positions below the lower inhibit switch. Check
that the display indicates Abve for all positions
above the lower inhibit switch.

Diagnosis and Repair

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

Pull pin from

JPT24-1.
1 JPT24-7 Perform Step 2 Replace VM
Backprobe 10.5 to 13V
connection.

2 JPT24-1 Perform Step 3 Repair/replace

DCV S100-1
3 10.7 to 13V Perform Step 4 harness
S100-3
4 S100-2 S100 Perform Step 5 Adjust or replace S100
Closed: 10.7 to 13V Repair/replace
5 JPT24-1 JPT22-4 Open: <1V Replace VM
harness

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test I76 - Lift Cutout Switch (optional)

Test I76 - Lift Cutout

Switch (optional)
This test monitors the state of the lift cutout
switch (S124). This test displays what the CCC
is reading from the switch.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
The state of the lift cutout switch (S124) is
displayed.

Carriage Position
Operator Display
(wrt S124)

Below Belw

Above Abve

If these results are not observed, the test has

failed. Perform diagnosis and repair.

Using Active Maintenance, check that the

display indicates the carriage is Belw at all
positions below the lower inhibit switch. Check
that the display indicates Abve for all positions
above the lower inhibit switch.

Diagnosis and Repair

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

Pull pin from

JPT20-8.
1 JPT18-7 10.5 to 13V Perform Step 2 Replace VM
Backprobe
connection.

2 JPT20-8 Perform Step 3 Repair/replace

DCV S124-1 10.7 to 13V
3 Perform Step 4 harness
S124-3
4 S124-2 S124 Perform Step 5 Adjust or replace S124
Closed: 10.5 to 13V Repair/replace
5 JPT20-8 JPT4-3 Open: <1V Replace VM
harness

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Test I86 - Lift Height

Test I86 - Lift Height

Test I86 is a Height Sensing Encoder related
test. Refer to the Full Height Sensing System Kit
Installation and Maintenance Instructions.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test I91 - iPORT Communication

Test I91 - iPORT

Communication
Test I91 is an iPORT related code. Refer to
iPORT Kit Installation and Maintenance
Instructions.

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Test I92 - iPORT Error Bitmap

Test I92 - iPORT Error

Bitmap
This test is for factory use only.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test I93 - End-Of-Aisle EOA

Test I93 - End-Of-Aisle

EOA
This test displays position status used by the
EOA software. It displays either 0 or 1 to
indicate whether the program currently
considers the truck in or out of aisle.

For information on using Maintenance Mode,

refer to page 3-9.

Run Test:
This test requires use of Active Maintenance to
see correct test results.

You should see:

Truck Position Operator Display

Truck is in the aisle 0

Truck is out of the aisle 1

If results do not match the preceding table, the

test has failed.
NOTE: One of the magnets could have been
inadvertently tripped or the truck is in
the aisle. Refer to tests “Test I72 -
End-of-Aisle Sensor 2 (optional)” and
“Test I73 - End-of-Aisle Sensor 1
(optional)”

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Test I120 - Height Reference Proximity Sensor Status

Test I120 - Height

Reference Proximity
Sensor Status
Test I120 is a Height Sensing Encoder related
test. Refer to the Full Height Sensing System Kit
Installation and Maintenance Instructions.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test I120 - Height Reference Proximity Sensor Status

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Output Tests
Section 6. Messages, Codes and Tests

Output Tests
A Diagnosis and Repair table is provided for
most tests. If a test fails, refer to the Diagnosis
and Repair table. Through the process of
elimination, these tables provide the technician
with a step-by-step approach to diagnosing a
problem and the necessary corrective action.
See the table below.
Example Diagnosis and Repair Table
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

This column
identifies the
action(s) required
(if any) before
testing the
circuit. If no
instructions are
given, all circuits
must be
The next
connected. The next
This is the Connection Connection action to be
Note: If action to be
order that point for point for The reading performed if
something was performed if
the testing the Positive the required to consider the
disconnected in the Expected
must be (+) meter Negative (–) the step a success. Expected
the prior step, Results are
performed. lead. meter lead. Results are
reconnect it met.
not met.
before
performing the
next step.

This column also

identifies the
required setting
on the meter for
this step.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test O00 - Toggle the Traction Power Contactor

Test O00 - Toggle the

Traction Power
Contactor
This test toggles the TPC on and off.

For information on how to use Maintenance

Mode, refer to page 3-9.

Run Test:
PC Contactor Operator Display

Closed In

Open Out

The test is a success if the TPC contactor tracks

the In/Out shown on the display. If these results
are not observed, the test has failed.

Diagnosis and Repair

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

JPTA1
1 disconnected JPTA1-6 JPTA1-13 Approx. 38 ohms Perform Step 2 T/S wires and coil
/ohms

2 JPTA1-13 TP4 B+ Perform Step 3

Replace Traction
DCV Test on: B+ Test contactor
3 B+ JPTA1-6 Power Amplifier
Test off: 0V for binding

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Test O02 - Toggle the Lift Power Contactor

Test O02 - Toggle the Lift Run Test:

Power Contactor LPC Contactor Operator Display

Closed In
This test toggles the LPC on and off.
Open Out
For information on how to use Maintenance
Mode, refer to page 3-9. The test is a success if the LPC contactor tracks
the In/Out shown on the display. If these results
are not observed, the test has failed. Perform
diagnosis and repair.
Open the emergency lowering valve
before starting this test.

Diagnosis and Repair

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

AC Lift

JPLA1
T/S wires and
1 disconnected JPLA1-6 JPLA1-13 Approx. 18 ohms Perform Step 2
coil
/ohms

2 JPLA1-13 TP4 B+ Perform Step 3

Replace Lift
DCV Test on: B+ Test contactor
3 B+ JPLA1-6 Power Amplifier
Test off: 0V for binding

DC Lift

JPT18 and
JPF2 T/S wires and
1 JPF2-1 Approx. 38 ohms Perform Step 2
disconnected coil
/ohms

If B+ is not
present, T/S
JPT18-9 JPF2-1 on the
Contactor Test contactor Relay Fuse Card.
2 DCV TP4 Energized: approx. -0V for mechanical If voltage does
De-energized: B+ binding not change when
the test is
toggled, replace
the VM

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test O11 - Toggle Load Holding Solenoid

Test O11 - Toggle Load

Holding Solenoid
This test turns the Load Holding (L/H) Solenoid
(SOL1) on and off.

Make sure the operator platform is fully

lowered before performing this test.

Turning the Load Holding Solenoid on

during this test causes the operator
platform to lower because the
proportional lift/lower valve is open in
Maintenance Mode.

For information on how to use Maintenance

Mode, refer to page page 3-9.

Run Test:
1. Lower the operator platform to the floor.
2. Disconnect the wire from the Load Holding
solenoid L/H-1.
3. Connect an ammeter in series with the
L/H solenoid as follows:
• (–) lead to terminal of L/H-1
• (+) lead to wire removed from L/H-1

Ammeter Operator
L/H Solenoid
Reading Display

Open 0.5 to 1.0A On

Closed 0.0 to 0.02A Off

If these results are not observed, the test has

failed. Reconnect the wire to L/H-1.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPT18 and JPF2

T/S wires and
1 disconnected/ JPT18-10 JPF2-5 Approx. 38 ohms Perform Step 2
coil
ohms

T/S relays and

2 DCV JPF2-5 TP4 B+ Replace VM
Fuse Relay Card

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Test O12 - Proportional Solenoid PWM Ramp

Test O12 - Proportional 5. Reconnect the connector.

6. Connect the (–) lead of a DVM to L/L-2 and
Solenoid PWM Ramp the (+) lead to L/L-1.
7. Turn the key switch ON and run this test.
This test ramps the proportional Lift/Lower
(L/L) solenoid from 0% to 90%. Voltmeter
Operator Display
Reading
A successful test proves the wiring, related 0 to 24V Ramp (15% increments)
circuitry in the VM, and proportional L/L
solenoid coil driver are all functioning correctly. 0 to 1V 0%
It also proves the harness is electrically
functional. It does not prove the L/L solenoid The percentage shown on the display starts at
itself is mechanically functional. 0%. Use the Up button to increase the
percentage up to 90% in 15% increments.
Ramping the proportional L/L solenoid should
not allow the operator platform to lower, since If the voltage ramps proportionally, the wiring
the Load Holding (L/H) valve must be closed. If and related circuitry are functional. (It does not
there is a fault in the L/H circuit or a fault in prove the L/L solenoid itself is mechanically
L/H solenoid itself, the operator platform may functional.)
lower. To guard against unexpected motion of
the operator platform, fully lower the operator If these results are not observed, the test has
platform before entering this test. failed.

For information on how to use Maintenance

Mode, refer to page page 3-9.

Run Test:
1. Turn the key switch OFF.
2. Loosen the screw that secures the 90°
connector to the L/L solenoid.
3. Unplug the connector from the solenoid.
4. Remove the cover to expose the connector
terminals.
Diagnosis and Repair
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting

JPT20 dis-
T/S wires and
1 connected/ JPT20-16 JPT20-15 Approx. 25 ohms Perform Step 2
coil
ohms

2 DCV JPT20-15 B+ Perform Step 3

Check valve for

Test on B– 24V truck: ramp B+ to 0V mechanical Replace VM
3 JPT20-16
/DCV 36V truck: ramp B+ to 12V binding or
contamination

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test O18 - Toggle Horn

Test O18 - Toggle Horn

This test toggles the horn on and off.

For information on how to use Maintenance

Mode, refer to page 3-9.

Run Test:
The horn should sound when the test is
activated. If these results are not observed, the
test has failed.

Diagnosis and Repair

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

T/S wires and

1 H2 TP4 B+ Perform Step 2
Fuse Relay Card

2 DCV H1 Replace horn Perform Step 3

Horn off: <0.5V
TP1 T/S wires to
3 JPT18-16 Horn on: B+ Replace VM
horn

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Test O19 - Audible Alarm

Test O19 - Audible

Alarm
Using this test, the operation of the audible
alarm in the CCC can be verified.

A successful test proves the audible alarm is

functioning.

For information on how to use Maintenance

Mode, refer to page 3-9.

Run Test:
Operator
Alarm
Display

Sounding Ramp

Off Off

This test generates a sound on the audible

alarm in the CCC.

If these results are not observed, the test has

failed.

Diagnosis and Repair

Replace the Carriage Control Card.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test O20 - Travel Alarm (optional)

Test O20 - Travel Alarm Run Test:

(optional) Connect a voltmeter at JPT20-17 wrt JPT18-18.

Operator
This test verifies the operation of the travel Voltage Output
Display
alarm.
0.0 to 1.0V Off
A successful test proves the wiring and related
22.0V On
circuitry in the VM are functioning correctly.

For information on how to use Maintenance When the display shows On, the optional device
Mode, refer to page page 3-9. must be activated.

NOTE: In order to test the output portion of the If these results are not observed, the test has
VM, a device that causes a load in the failed.
circuit is required. The load holding coil
on the hydraulic manifold can be used
for testing purposes. Remove the load
holding coil and carefully connect wires
into the circuit. Use extreme caution
and make sure that the wires do not
short to any components.

Diagnosis and Repair

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

1 AL– Approx. 22V Replace alarm Perform Step 2

AL+
2 B+ Perform Step 3 Test wire to AL+
DCV
TP4 24V truck: approx. 2V
Repair/replace
3 JPT18-18 36V truck: approx. Replace VM
wire to AL–
14V

Connect Load
4 Holding JPT20-17 JPT18-18 Approx. 22V Replace alarm Replace VM
Coil/DCV

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Test O28 - Ramp Lift Motor (AC lift only)

Test O28 - Ramp Lift

Motor (AC lift only) Run Test:
This test ramps the lift motor by gradually The requested rpm is displayed. Use the Up
increasing the command to the lift power button to increase the rpm in increments of 25,
amplifier via the CAN Bus. This test verifies that from a minimum of 775 rpm to a maximum of
the lift power amplifier can drive the lift motor. 1500 rpm.
NOTE: To prevent lift pump damage due to very
low rpm, the minimum lift motor speed
Running this test for an extended period request is 775 rpm.
of time can cause damage to the motor,
power amplifier, or wiring. When the maximum requested rpm is reached,
press Down to reset the request to 0. Press the
Enter button to exit the test.

Open the emergency lowering valve

before performing this test. See
“Emergency Lower Valve” on
page 2-11.

For information on how to use Maintenance

Mode, refer to page 3-9.

Diagnosis and Repair

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

If current does not ramp to

one or two phases, test the
Current cables to the motor. If OK,
probe Current must be replace the motor. If phases
(amp even on all phases Replace Lift are low or unequal, replace
1 N/A N/A
clamp) on and ramp up as the Amplifier the Lift Amplifier. If phases
phases U, percentage increases. are equal and high but the
V, and W motor runs slow, check for
binding. If no binding,
replace the lift motor.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test O29 - Ramp Traction Motor

Test O29 - Ramp Traction When the maximum requested rpm is reached,
press Down to reset the request to 0. Press the
Motor Enter button to exit the test.

This test ramps the traction motor by gradually

increasing the command to the traction power
amplifier via the CAN Bus. This test verifies that
the traction power amplifier can generate
current and drive the traction motor.

Running this test for an extended period

of time can cause damage to the traction
motor, power amplifier, or wiring.

The traction motor will rotate during this

test. Jack the drive wheel off the floor.

Use extreme care when the lift truck is

jacked up. Never block the lift truck
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an
overhead hoist to stabilize the mast if
jacking higher than described in the
Jacking Safety section. Keep hands and
feet clear while jacking the lift truck.
After the lift truck is jacked, place solid
blocks or jack stands beneath it to
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the
jack or jack stand alone to support the
lift truck. See Jacking on page 2-9.

For information on how to use

Maintenance Mode, refer to page 3-9.

Run Test:
Step on the deadman pedal and run the test.

The requested rpm is displayed. Use the Up

button to increase the rpm in increments of 25,
from 0 to a maximum of 1500 rpm.

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Test O30 - Toggle Brake Solenoid

Test O30 - Toggle Brake

Solenoid
This test checks for correct brake coil operation.

For information on how to use Maintenance

Mode, refer to page 3-9.

Run Test:
Observe the following results:

Operator Display Brake

Up Applied

Down Released

NOTE: Deadman pedal must be pressed while

performing this test. Use the Enter
button to cycle the test.

If these results are not observed, the test has

failed.
If this test passes, check brake adjustment. See
“Brake Adjustment” on page 7-61.

Diagnosis and Repair

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

JPT20 and
JPF2
1 JT20-14 JF2-2 Approx. 13 ohms Perform Step 2 T/S wires and coil
disconnected/
ohms

If no B+, T/S Fuse

Brake de-energized: B+ Relay Card. If
Inspect brake
Brake energized: voltage does not
2 DCV JP20-14 TP4 assembly for
36V truck = approx. 12V drop when
binding
24V truck = 0V energized, replace
the VM

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test O32 - Toggle Relay Enable

Test O32 - Toggle Relay

Enable
This test toggles Fuse/Relay Card relays K1,
K2, K3, and K4 on and off.

Run Test:
NOTE: Off is displayed when entering the test,
even if the relays are closed.

Press the Enter button to toggle the test.

The following table gives the expected value at

each relay test point during the test.

Expected Values
Relay Lead Toggled Key
(+) (–) On Off OFF
K1 JPF2-9 or *TP1
K2 JPF2-1 or *TP2 <1V
TP4 B+ <1V
K3 JPF1-5 or *TP3
K4 JPF2-4 or *TP4 <1V
* TPs located on Fuse/Relay Card

If results do not match the preceding table, the

test has failed. Refer to diagnosis and repair.

Diagnosis and Repair

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

T/S Fuse
1 JF4-13 Perform Step 2
Relay Card

Check diodes on
the Fuse/Relay
Test off: B+ Card (refer to
DCV TP4 T/S wire to
Test on: <1V Section 5). If bad,
2 JPC14-6 Fuse Relay
replace the
Card
Fuse/Relay Card
and VM. If OK,
replace the VM.

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Test O39 - Display Lights

Test O39 - Display Lights Run Test:

When the test is turned on, 13 LEDs on the
This test verifies all the lights operate correctly
display should light. See Figure 6-2. If all the
on the OD.
LED’s do not light, the test has failed.
For information on how to use Maintenance
Mode, refer to page page 3-9.

Yellow LED Yellow LED Red LED

Green LED

Red LED

Yellow LED

Green LED

6
Figure 6-2. Operator Display LED Identification

Diagnosis and Repair

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

Display not
1 JPD15-16 JPD15-15 illuminated. Perform Step 2
Perform Step 3
DCV Approx. 5.3V
Display not
2 JPC15-16 JPC15-15 illuminated. Replace CCC
Replace display

Disconnect Display not

JC15-1 JD15-1
JPC15 from illuminated,
3 through through Continuity Replace display
CCC and repair/replace
JC15-24 JD15-24
Display /ohms cable

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test O40 - Lift/Lower Alarm (optional)

Test O40 - Lift/Lower Run Test:

Alarm (optional) Use the Enter button to toggle the test on and
off. The OD shows on or off.
This test toggles the Lift/Lower Alarm on and
off. Connect a voltmeter at JPT20-17 wrt JPT20-18.

Operator
For information on how to use Maintenance Voltage Output
Display
Mode, refer to page 3-9.
0.0 to 1.0V Off
NOTE: In order to test the output portion of the
VM, a device that causes a load in the 22.0V On
circuit is required. The load holding coil
on the hydraulic manifold can be used
for testing purposes. Remove the load
holding coil and carefully connect wires
into the circuit. Use extreme caution
and make sure that the wires do not
short to any components.

Diagnosis and Repair

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

Lift/Lower
1 Approx. 22V Replace alarm Perform Step 2
Alarm (–)
Lift/Lower
DCV Test wire to
Alarm (+)
2 TP4 B+ Perform Step 3 Lift/Lower
Alarm (+)

Disconnect Lift/Lower Repair/replace

3 JPT20-18 0 ohms Perform Step 4
JPT20/ohms Alarm (–) wire

Connect Load
4 Holding JPT20-17 JPT20-18 Approx. 22V Replace alarm Replace VM
Coil/DCV

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test O41 - Aux Select Solenoid (optional)

Test O41 - Aux Select 4. Reconnect the battery connector and turn
the key switch ON. Run the test and
Solenoid (optional) observe the following results.

Ammeter Operator
This test toggles the Aux Select Solenoid off and Reading Display
on, verifying its correct operation electrically.
0.0 to 0.02A Off

A successful test proves that the Aux Select 1.0 to 2.0A On

Solenoid coil, coil driver, wiring, and related
circuitry in the VM are functioning correctly.
If the above results are not observed, the
NOTE: This test does not prove that the Aux test has failed.
Select Solenoid valve is mechanically 5. Turn the key switch OFF and disconnect
functional. the battery connector. Remove the
For information on how to use ammeter from the circuit and reconnect
Maintenance Mode, refer to page 3-9. the wire.

Run Test:
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from the Aux Select
Solenoid coil at AUX SEL SOL-X.
3. Connect a digital ammeter in series with
the Aux Select Solenoid: (–) lead to AUX
SEL SOL-X terminal, (+) lead to the
removed wire.

Diagnosis and Repair

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

JPT18 and
JPF2 T/S wires and
1 JPT18-15 JPF2-3 Approx. 38 ohms Perform Step 2
disconnected coil
/ohms

T/S relays and

2 DCV JPF2-3 TP4 B+ Replace VM Fuse Relay
Card

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test O42 - Main Select Solenoid (optional)

Test O42 - Main Select SEL SOL-X terminal, (+) lead to the
removed wire.
Solenoid (optional) 4. Reconnect the battery connector and turn
the key switch ON. Run the test and
This test toggles the Main Select Solenoid off observe the following results.
and on, verifying its correct operation
Ammeter Operator
electrically. Reading Display

A successful test proves that the Main Select 0.0 to 0.02A Off
Solenoid coil, coil driver, wiring, and related
1.0 to 2.0A On
circuitry in the VM are functioning correctly.
NOTE: This test does not prove that the Main If the above results are not observed, the
Select Solenoid valve is mechanically test has failed.
functional.
5. Turn the key switch OFF and disconnect
For information on how to use Maintenance the battery connector. Remove the
Mode, refer to page 3-9. ammeter from the circuit and reconnect
the wire.

Run Test:
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from the Main Select
Solenoid coil at MAIN SEL SOL-X.
3. Connect a digital ammeter in series with
the Main Select Solenoid: (–) lead to MAIN

Diagnosis and Repair

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

JPT18 and
JPF2 T/S wires and
1 JPT18-14 JPF2-3 Approx. 38 ohms Perform Step 2
disconnected coil
/ohms

T/S relays and

2 DCV JPF2-3 TP4 B+ Replace VM Fuse Relay
Card

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Models 5300/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests

Test O43 - Aux Load Hold Solenoid (optional)

Test O43 - Aux Load 4. Reconnect the battery connector and turn
the key switch ON. Run the test and
Hold Solenoid (optional) observe the following results.

Ammeter Operator
This test toggles the Aux Load Hold Solenoid off Reading Display
and on, verifying its correct operation
0.0 to 0.02A Off
electrically.
1.0 to 2.0A On
A successful test proves that the Aux Load Hold
Solenoid coil, coil driver, wiring, and related
If the above results are not observed, the
circuitry in the VM are functioning correctly.
test has failed.
NOTE: This test does not prove that the Aux 5. Turn the key switch OFF and disconnect
Load Hold Solenoid valve is the battery connector. Remove the
mechanically functional. ammeter from the circuit and reconnect
the wire.
For information on how to use Maintenance
Mode, refer to page 3-9.

Run Test:
1. Turn the key switch OFF and disconnect
the battery connector.
2. Disconnect the wire from the Aux Load
Hold Solenoid coil at AUX L/H SOL-X.
3. Connect a digital ammeter in series with
the Aux Load Hold Solenoid: (–) lead to
AUX L/H SOL-X terminal, (+) lead to the
removed wire.

Diagnosis and Repair

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

JPT18 and
JPF2 T/S wires and
1 JPT18-12 JPF2-3 Approx. 38 ohms Perform Step 2
disconnected coil
/ohms

T/S relays and

2 DCV JPF2-3 TP4 B+ Replace VM Fuse Relay
Card

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Test O44 - Steer Motor

Test O44 - Steer Motor

This test ramps the steer motor by gradually
increasing the command to the steer amplifier.
This test verifies that the steer amplifier can
generate current and cause steering to occur in
both the clockwise and counterclockwise
directions. The value ranges from -50 to +50 in
increments of five and is an approximate
percentage of full steer command. To prevent
damage to the steer amplifier, this test limits
the steer current to 100A for about 10 seconds.
Running the test for an extended period of time
can cause damage to the steer motor or steer
amplifier. Normal current while steering on a
smooth floor, lift truck not traveling, is
approximately 50 amps. If it is considerably
higher, check for binding.

Run Test:
1. The requested% of on-time is displayed.
Use the Up and Down buttons to increase
or decrease the steer request in
increments of 5%, from 0 to 50% and 0 to
-50%. Press the Enter button to exit the
test. Negative values cause the lift truck to
steer to the left and positive values cause
the lift truck to steer to the right.

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

While changing the

value from 5 to 50 Check
MS+ cable removed and -5 to -50, the brushes.
MS+
1 from motor MS- voltage should ramp Replace steer Perform Step 2
cable
steer/DCV from 0 to approx. motor if
11.5 volts positive necessary
and negative.

While changing the

DCV/Motor lead values from 5 to 50,
Perform Step
2 removed to prevent JPT6-5 JPT6-4 voltage should ramp Replace VM
3
movement. from approx. 11.5
to 8.00 volts.

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Run Test:

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

While changing the

DCV/Motor lead value from -5 to Replace
3 removed to prevent JPT6-2 JPT6-4 -50, voltage should Steering Replace VM
movement. ramp from approx. Amplifier
11.5 to 8.00 volts.

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Section 6. Messages, Codes and Tests Models 5300/5500/5600 Maintenance Manual

Run Test:

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Section 7. Component Procedures

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

List of Component Procedures

List of Component Procedures

Steering and Controls . . . . . . . . . . . . . 7-15 Main Cover Installation . . . . . . . . . 7-59
Encoder Bearing Replacement . . . . . . . 7-16 Pivot Ring Assembly . . . . . . . . . . . . 7-59
Removal . . . . . . . . . . . . . . . . . . . . . . . 7-19 Brake Adjustment. . . . . . . . . . . . . . . . 7-61
Disassembly . . . . . . . . . . . . . . . . . . . . 7-19 Removal/Disassembly . . . . . . . . . . 7-62
Lift/Lower Pot and Assembly/Installation . . . . . . . . . . 7-62
Spring Replacement . . . . . . . . . . . . 7-20 Removal . . . . . . . . . . . . . . . . . . . . . . . 7-65
Horn Switch Replacement . . . . . . . . 7-20 Installation . . . . . . . . . . . . . . . . . . . . . 7-65
Assembly. . . . . . . . . . . . . . . . . . . . . . . 7-20 Drive Tire Replacement. . . . . . . . . . . . 7-65
Travel Spring and Pinion . . . . . . . . . . . 7-22 AC Motor Temperature Sensor . . . . . . 7-75
Disassembly . . . . . . . . . . . . . . . . . . 7-22 Traction Motor Replacement: . . . . . 7-75
Assembly . . . . . . . . . . . . . . . . . . . . 7-22 Lift Motor Replacement: . . . . . . . . . 7-75
Cleaning and Inspection . . . . . . . . . . . 7-23 AC Motor Bearing Encoder . . . . . . . . . 7-76
Installation . . . . . . . . . . . . . . . . . . . . . 7-24 Traction Motor Replacement: . . . . . 7-76
Switch Replacement . . . . . . . . . . . . . . 7-25 Lift Motor Replacement: . . . . . . . . . 7-77
Drive and Brake . . . . . . . . . . . . . . . . . 7-27 Installation . . . . . . . . . . . . . . . . . . . . . 7-78
Removal . . . . . . . . . . . . . . . . . . . . . . . 7-28 O-Ring Replacement . . . . . . . . . . . . . . 7-90
Installation . . . . . . . . . . . . . . . . . . . . . 7-28 Main Lift Cylinders . . . . . . . . . . . . . . . 7-95
Pivot Ring Inspection . . . . . . . . . . . . . . 7-29 Free Lift Cylinder . . . . . . . . . . . . . . . . 7-95
Drive Unit Removal . . . . . . . . . . . . . . . 7-29 Removal . . . . . . . . . . . . . . . . . . . . . . . 7-96
Radial Ring Removal . . . . . . . . . . . . 7-32 Installation . . . . . . . . . . . . . . . . . . . . . 7-96
Axle Shaft and Bevel Gear Removal . 7-32 Remove. . . . . . . . . . . . . . . . . . . . . . . . 7-97
Spiral Gear and Installation . . . . . . . . . . . . . . . . . . . . . 7-97
Helical Gear Removal . . . . . . . . . . . 7-33 Removal . . . . . . . . . . . . . . . . . . . . . . 7-101
Bearing Cup and Shim Removal . . . 7-34 Installation . . . . . . . . . . . . . . . . . . . . 7-101
Spur Gear Removal . . . . . . . . . . . . . 7-35 Service of Cylinder with Cushions. . . 7-101
Housing Cleaning and Inspection . . 7-35 Cushion Replacement . . . . . . . . . 7-101
Axle Shaft Disassembly. . . . . . . . . . 7-35 Removal . . . . . . . . . . . . . . . . . . . . . . 7-106
Bevel Gear Disassembly . . . . . . . . . 7-36 Installation . . . . . . . . . . . . . . . . . . . . 7-107
Spiral Gear Disassembly . . . . . . . . . 7-36 Shimming Main Frame to
Gear Set Assembly . . . . . . . . . . . . . 7-38 Outer Telescopic . . . . . . . . . . . . . 7-112
Calculate Shim Formulas . . . . . . . . 7-38 Shimming Outer Telescopic to
Spiral Pinion Gear Shim Inner Telescopic . . . . . . . . . . . . . . 7-113
Calculation: . . . . . . . . . . . . . . . . . . 7-38 Shimming Inner Telescopic to
Bevel Gear Shim Calculation: . . . . . 7-39 Carriage . . . . . . . . . . . . . . . . . . . . 7-114
Housing Bearing Cup and Inspection . . . . . . . . . . . . . . . . . . . . 7-118
Shim Assembly . . . . . . . . . . . . . . . . 7-40 Removal . . . . . . . . . . . . . . . . . . . . . . 7-119
Helical Gear/Spiral Pinion Gear Installation . . . . . . . . . . . . . . . . . . . . 7-119
Assembly . . . . . . . . . . . . . . . . . . . . 7-41 Installation . . . . . . . . . . . . . . . . . . . . 7-120
Axle Assembly. . . . . . . . . . . . . . . . . 7-42 Installation . . . . . . . . . . . . . . . . . . . . 7-121
Measuring Backlash . . . . . . . . . . . . 7-44 Lift Chain Adjustment . . . . . . . . . . . 7-122
Pivot Ring Assembly . . . . . . . . . . . . 7-45 Lift Chain Maintenance . . . . . . . . . . 7-122
Housing Cover Installation . . . . . . . 7-48
Pivot Ring Inspection . . . . . . . . . . . . . . 7-49
Drive Unit Removal . . . . . . . . . . . . . . . 7-49
Spiral Pinion Assembly . . . . . . . . . . 7-54
Main Cover and
Output Shaft Assembly . . . . . . . . . . 7-54
Calculate Shim Formulas . . . . . . . . 7-57
Installing and Testing Shims. . . . . . 7-57
Measuring Backlash . . . . . . . . . . . . 7-59

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Component Locator Photos

Component Locator Photos

Section 7. Component Procedures

Tether Attachment Point

Dome Light

Working Lights

Battery
Compartment
Sidegate

Storage
Compartment

Pallet Clamp Release

Skid Pads

Pallet Clamp

Deadman Pedal

Load Wheels
Forks

78C04050S.TIF
Figure 7-1. Model 5600 - Overall View

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Component Locator Photos

Steering Indicator Lights Operator Display Key Switch

(Electronic Steering/Wire Guidance) Emergency
Guidance Indicator Lights Key Pad Power Off

Steer Tiller Lift/Lower Horn Switch Direction/Speed

Control Control

78C11036H.TIF
Figure 7-2. Operator Console

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Component Locator Photos

Reservoir

Lift Motor

Lift Pump Lift/Lower

Solenoid

Lift/Lower
Manifold
High Pressure
Relief Valve

Load Holding
Solenoid (SOL2)

Pressure Test
Connection

Emergency
Lower Valve

7
Figure 7-3. Hydraulic Compartment Components

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Component Locator Photos

Fuse/Relay
Card

Vehicle
Manager

Pendant
Steer Motor Connection

Contactor
Brake Panel
Assembly

Lift Power
Drive Motor
Amplifier

Guidance
Manager

Home Horn
Proximity
Sensor

7
Figure 7-4. Electrical Compartment Components

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Component Locator Photos

Traction Power Steer

Amplifier Amplifier

TP4 Fuse/Relay
Card
7
Figure 7-5. Electrical Compartment Components (located on Upper Deck of Tractor)

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Component Locator Photos

Steering Encoder Assembly

(behind steer tiller)

Carriage
Control Card

Pallet Clamp
Release

7
Figure 7-6. Platform Components

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Special Tools and Decals

Special Tools and Decals

Section 7. Component Procedures

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Special Tools Special Tools and Decals

Special Tools
The following tools are available from your local
authorized Raymond Sales and Service Center.

Table 7-1. Special Tools

Tool Part Number Purpose

Anti-static Field Kit 1-187-059

Anti-static Wrist Straps 1-187-059 ESD protection

Anti-static Wrist Strap Tester 1-187-060/100

Free Lift Cylinder Service 401-000-058 Prevents damage to packing at the top of cylinder
Driver

Free Lift Cylinder Service 401-000-059 Prevents damage to packing at the top of cylinder
Guide

Chain Gauge 939-10606 Lift chain inspection

Connector Unlatching 950-042 Separate AMP connectors

Crimp Tool 1069861 Crimp power cable lugs

1090761/002 Center Lift Cylinder with decel and staging end cap
End Cap
removal and installation

Fork Wear Caliper 922-369 Fork inspection

Lift/Lower Pendant 114-020-848 Lift and Lower platform for service

Lock Nut Wrench 761-870/T03 Removing end play in drive unit bearings

Magnet 591-552/002 Testing EOA sensor

Nut Driver Tool 761-870/T04 Removing end play in drive unit bearings

Nut Driver Tool 761-870/T07 Removing end play in drive unit bearings

Pin Extraction Tool 950-009 AMP connector pin extraction

Pin Extraction Tool 950-026 MOLEX connector pin extraction

Seal Pressing Ring 828-004-901 Prevents damage to seals during installation

Main Cylinder Service Driver 401-000-050 Prevents damage to packing at the top of cylinder

Main Cylinder Service Guide 401-000-051 Prevents damage to packing at the top of cylinder

Snap Ring Pliers MI-Snapplier Removing and installing snap rings

610-809/W7P FlashWare connection to lift truck for devices that do

USB to Serial Adapter Cable
not have a serial port

5-Ton Jack 990-807 Jacking lift truck

9-Pin Serial Cable 610-809/201 FlashWare connection to lift truck

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Special Tools and Decals Decals and Tags

Decals and Tags

Table 7-2. Decal and Tag Location Chart

Decal and Specification Tag Locations

Identifier Description

1 Raymond 21 in. (two places)

2 Raymond 11 in.

3 ACR (two places)

4 Emergency Lower (inside of the tractor)

5 Emergency Lower (top of the tractor)

6 Main Specification Tag

7 Attachment Tag

8 Mast Specification Tag

9 Battery Removal Warning (two places)

10 Driver Operating

11 Overhead Guard (ANSI/ITSDF

conformance)

12 Operator General Safety Decal

13 Bumper (optional)

14 Drive Unit Warning

15 EE Compliance (optional)

Note: Items in italics are safety decals.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Decals and Tags Special Tools and Decals

11

15

14

Figure 7-7. Decal and Specification Tag Locations

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Special Tools and Decals Decals and Tags

12
7
6

10
4

13

Figure 7-7 (Cont.). Decal and Specification Tag Locations

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Decals and Tags Special Tools and Decals

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Steering and Controls

Section 7. Component Procedures

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Steer Motor/Gearbox

Steer Motor/Gearbox 9. Torque the bolts holding the motor to the

gear reducer to approx. 85 in. lb. (9.9 Nm).

B Side End
Encoder Bearing Replacement Bell
NOTE: Replace the shaft seal, the B side
bearing, and the brushes while the
motor is apart.
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the steer motor and gearbox.
3. Remove the B side end bell and brush A Side
retainers. See Figure 7-8. End Bell
4. Remove the A side end bell bolts and pull
the end bell and rotor from the motor
housing. Push the wires and rubber
grommet out of the housing slot.
5. Loosen the two phillips head screws that
are used with the small clips to retain the
bearing in the A side end bell.
6. Remove the A side end bell from the rotor.
7. Use a press to remove the old bearing.
7

Figure 7-8. Steer Motor and Gearbox

New encoder bearings are mounted like
regular bearings except induction
heaters must not be used because they
demagnetize the encoder. Also, care
must be taken against ESD. See
page 2-8.

NOTE: When pressing a bearing onto a shaft,

press on the inner race, never the outer
race.
8. Press on the new bearing and reassemble
the motor. Place a small amount of good
quality grease between the new bearing
and the shaft seal. Take care to not
damage the pinion gear in the end of the
motor shaft.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Spur Gear Orientation

Spur Gear Orientation

Install the spur gear as shown in Figure 7-9.
7

Figure 7-9. Spur Gear Orientation

NOTE: Make sure that the spur gear teeth

mesh fully with the teeth of the gear on
the drive unit.

Radial Rings
Make sure that the radial rings on the drive
unit do not bind any time the steering motor is
repaired or replaced. Rotate the drive unit full
left and full right while pumping grease into the
radial rings at both grease fittings.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Home Proximity Sensor Adjustment

Home Proximity Sensor

Adjustment
1. Turn the key switch OFF and disconnect
the battery connector.
2. Loosen the two lock nuts that secure the
sensor to the bracket. See Figure 7-10.

Figure 7-10. Home Proximity Sensor

3. Adjust the vertical gap between the sensor

and the sensor rail to 0.060 +0.010/
–0.040 in. (1.5 +0.254/–1.016 mm).
4. Tighten the lock nuts.
5. Reconnect the battery connector and turn
the key switch ON.
6. Center the drive wheel. The sensor must
be located horizontally just over the end of
the sensor rail.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Control Handle

Control Handle NOTE: Carefully slide the two fiber washers,

lift/lower spring, and third fiber washer
off the lift pot shaft. See Figure 7-11.
Removal
1. Turn the key switch OFF and disconnect
the battery connector. Fiber
Washer
2. Disconnect JPC9 and remove the control
handle from the lift truck.
NOTE: Observe the orientation of switches,
potentiometers (pot), and the routing of Lift/Lower
cables and wires as the handle is Spring
disassembled to make reassembly
easier.
7

Figure 7-11. Spacer Washer and L/L Spring Removal

3. Remove the three 3 mm socket head cap

Observe correct ESD precautions. See screws from the handle assembly. See
“Static Precautions” on page 2-8. Figures 7-12 and 7-13. Separate the cover
from the handle.
Before disassembly, determine what
components require replacement such as:
• Lift/Lower Pot, Spring, and/or Horn
Switch
• Travel Pot
• Travel Spring and/or Pinion
• Lift/Lower Knob

Disassembly
1. Remove the two 3/32 socket head nylon
7
set screws in the lift/lower knob (thumb Figure 7-12. Cover Retaining Screws - Bottom
lever). Use a small 1/8 in. (3.2 mm) blade
flat-head screwdriver to carefully back out
a stripped set screw.
2. Loosen the two metal set screws in the
lift/lower knob two full turns and remove
the lift/lower knob.

Figure 7-13. Cover Retaining Screw - Top

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Control Handle

Lift/Lower Pot and Spring Horn Switch Replacement

Replacement 1. Disconnect the horn switch connector. See
NOTE: Before sliding the pot bracket off the pot Figure 7-15.
shaft, identify what slot in the pot
bracket is used to hold the pot
anti-rotate tab. The anti-rotate tab must Plastic Nut
be located in the slot furthest from the
pin in the pot bracket.
1. Remove the lift/lower pot and bracket
from the cover. See Figure 7-14.

Tab
Slot
Cable Tie Connector

Figure 7-15. Horn Switch Removal

2. Remove the plastic nut and external tooth

washer securing the horn switch. Remove
the cable tie.

Bracket
3. Install the new horn switch assembly into
the handle cover. Install the external tooth
7
washer and plastic nut. Cable tie all wires
Figure 7-14. Anti-Rotate Tab together.
NOTE: The button, pin, and spring can easily
slide apart. Identify the correct position Assembly
of these components before
1. Make sure all wires are routed correctly.
disassembly.
Tuck the common ground wire into the
2. If replacing the pot, carefully remove heat handle between the bottom of the pot and
shrink tubing from the terminals. Identify the screw boss to prevent the wire from
the wires so they can be installed in the being pinched or interfering with the horn
same location on the new pot. button.
3. Carefully unsolder the harness wires from 2. Install the cover onto the handle assembly
the lift/lower pot. with the three socket head cap screws.
4. Carefully solder harness wires to the Torque to 15 to 20 in. lb. (1.7 to 2.25 Nm).
correct terminals on the new lift/lower 3. Install a fiber washer and lift/lower spring
pot. Refer to Hand Soldering Procedures (lightly greased with P/N 990-635) on the
on page 7-24. lift/lower pot shaft. Install the spring with
5. Slide the lift/lower pot bracket onto the the tangs straddling the pot bracket pin.
shaft. Make sure the anti-rotation tab is See Figure 7-11 on page 7-19.
inserted into the correct slot on the NOTE: Replace the spring if the tangs are not
bracket. See Figure 7-14. parallel. Do not bend the spring.
6. Press the lift/lower pot and bracket into 4. Install the two remaining fiber washers.
the handle cover. Make sure the key on the
bracket engages the keyway in the handle 5. Install the lift/lower knob. See “Lift/Lower
cover. Knob Installation/Adjustment” on
page 7-23.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Travel Pot (VR1) Replacement

Travel Pot (VR1) Replacement 3. Loosen the set screw on the gear two full
turns and slide the gear off the shaft. See
1. Remove the four hex head cap screws from Figure 7-19.
the front of the travel pot enclosure and
4. Remove the retaining nut and lock washer
remove the cover. See Figure 7-16.
from the pot and separate from the
bracket. See Figure 7-19.
Hex Head Cap
Screws Set Screw

Retaining Nut and

Lock Washer
7 7

Figure 7-16. Travel Pot Cover Removal Figure 7-19. Travel Pot/Bracket Disassembly

2. Remove the two pan head machine screws 5. Carefully remove the heat shrink tubing
from the back of the enclosure. Carefully from the terminals and identify the wires
pull the travel pot/bracket assembly from so they can be installed in the same
the enclosure. See Figures 7-17 and 7-18. location on the new pot.
6. Carefully unsolder the harness wires.
7. Slide 3/8 in. (9.5 mm) long shrink sleeving
over previously sleeved wires.
8. Solder all electrical components to the
harness. See “Hand Soldering Procedures”
on page 7-24.
9. Shrink sleeving as necessary.
10. Assemble the pot and bracket. Install the
Pan Head retaining nut and lock washer. When
Machine Screws installing the travel pot into the bracket,
7
leave the mounting nut finger tight. See
Figure 7-17. Travel Pot Bracket Screws Figure 7-19.
11. Install the gear on the pot shaft, aligning
the set screw with the flat portion of the
Travel Spring shaft.
12. Install the travel pot/bracket assembly
into the enclosure. Engage the travel pot
Button
Head Screw
gear with the shaft gear (there is one large
tooth that is used to align the gears).
Tighten the pot gear set screw and torque
to 3 to 4 in. lb. (0.3 to 0.4 Nm).

Figure 7-18. Travel Pot Enclosure (Cover Removed)

It is very easy to over torque and ruin
the gear.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Travel Pot (VR1) Replacement

13. Tighten the two pan head machine screws such that when the spring is installed,
on the back of the enclosure while moving the spring sits on an even edge of the
the handle to make sure there is no pin and not on the gap.
binding. See Figure 7-17 on page 7-21.
NOTE: Replace the spring if the tangs are not
14. Install the handle in the lift truck. parallel. Do not bend the spring.
15. Adjust the travel pot. Run Test A04 - b. Make sure the washer and shims are
Throttle Potentiometer Voltage (Page 6-44) correctly aligned to allow the handle
and adjust the travel pot voltages to the shaft to slide easily through the
values given. enclosure. See Figure 7-20.
16. Tighten the retaining nut.
17. Install the cover on the travel pot
enclosure with the four hex head cap
screws. See Figure 7-16 on page 7-21.
18. Run Learn. See “Learn Mode” on page 3-9.

Travel Spring and Pinion

Disassembly
1. Remove the four hex head cap screws from
the front of the travel pot enclosure and Washers/Shims
remove the cover. See Figure 7-16 on 7

page 7-21. Figure 7-20. Travel Pot/Bracket Assembly Installation

2. Use a pin extraction tool and pull pins 3
through 6 from JC-9. These wires pass 2. Route the lift/lower pot and horn wires
through the shaft to the lift/lower pot and through the enclosure. Carefully slide the
horn switch. shaft through the enclosure, passing
through the shaft gear assembly, washer,
NOTE: The washer and shims can easily slip off and shims.
the shaft gear. Observe the correct 3. Align the screw hole in the handle shaft
position of these components before with the hole in the shaft gear. Apply
disassembling them. thread-locking compound (P/N 990-412)
to the threads in the shaft and on the
3. Remove the button head screw from the
button head screw. Install the screw and
shaft gear and slide the shaft out of the
torque to 8 to 12 in. lb. (0.9 to 1.3 Nm).
enclosure. See Figure 7-18 on page 7-21.
4. Reinstall the wire pins into the connector.
4. Carefully rotate the shaft gear assembly to
disengage the spring tangs from the pin. 5. Inspect the tab on the plate ground to
Remove the shaft gear assembly from the make sure that it is in contact with the
enclosure. bronze handle shaft bushing. See
Figure 7-21.
Assembly
1. Slide the shaft gear assembly back into the
enclosure. Engage the travel pot gear with
the shaft gear (there is one large tooth that
is used to align the gears).
a. Make sure that the spring tangs
straddle the pin, keeping the tangs
parallel. If the spiral pins were
replaced, make sure they are installed

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Lift/Lower Knob Installation/Adjustment

3. Rotate the lift/lower knob fully

counterclockwise and tighten the metal set
screws to 6 to 8 in. lb. (0.7 to 0.9 Nm).
Plate Ground 4. Check the pot for correct operation and
spring return to neutral. Correct any
binding.
5. Install and tighten the two nylon set
screws on top of the metal set screws.
6. Verify the pot reference voltages. Refer to
Test A05 - Lift/Lower Potentiometer
Voltage on page 6-45.
7. Run Learn. See “Learn Mode” on page 3-9.

Figure 7-21. Plate Ground

7
Cleaning and Inspection
6. Install the cover on the travel pot
enclosure with the four hex head cap
screws. See Figure 7-16 on page 7-21. When cleaning plastic parts, use a dry
rag or a cleaner that is safe on plastics.
Most chemicals can damage plastic.
Lift/Lower Knob
Installation/Adjustment While performing a repair on the control
handle, clean and inspect the parts listed in
1. Rotate the lift/lower pot shaft fully
Table 7-3.
counterclockwise.
2. Install the lift knob on the pot shaft. The
pin on the knob must fit between the tangs
of the pot return spring.
Table 7-3. Control Handle Checks

Part Check for:

Horn Button Assembly Cracks or deformation

Lift/Lower Pot Bracket Cracks, deformation, loose dowel pin, over round or oversized shaft hole

Travel Pot Gear Cracks, gear deformation, or stripped threads

Travel Shaft Gear Assembly Cracks, gear deformation, or loose spiral pin

Travel Pot Enclosure Cracks, loose spiral pin, stripped threads, deformation, or indents on external
stops

Handle Halves Cracks, damage, or deformation/indents on external stops

Lift/Lower Knob Cracks, deformation, stripped threads, loose dowel pin

Plate Ground Check for continuity between the control handle shaft and the lift truck frame

Other Hardware Stripped threads

All screw threads must be cleaned

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Hand Soldering Procedures

Hand Soldering Procedures

When hand soldering is performed on solid
state potentiometers, the following is
recommended:
• Flux - rosin base
• Solder - 60/40 rosin core or equivalent
• Solder Iron - 55 watt max.
• Tip Size - 0.118 in. (3 mm) diameter x
1.182 in. (30 mm) long screwdriver
• Tip Temperature - 500°F (260°C) max.
• Terminal Contact Time - 6 seconds max.
NOTE: Apply light soldering iron pressure on
the terminal. Make sure the tip is clean.
A dirty tip does not transfer heat well,
therefore requiring longer dwell time
and greater tip pressure.

Contact contamination can occur if

cleaning solvent is allowed to enter
switches or potentiometers.

After soldering, clean terminals with a brush

dampened with an alcohol based cleaner. Make
sure cleaner does not seep into the electrical
component.
NOTE: Components damaged due to solvent
saturation will not be covered under
warranty.

Installation
1. Install the control handle on the lift truck.
Connect JPC9.
2. Connect the ground wire to the lift truck
frame.
3. Reconnect the battery connector and turn
the key switch ON.
4. Perform Learn Controls and test lift truck
operation before returning to service. See
“Learn Mode” on page 3-9.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Deadman Pedal

Deadman Pedal 9. Install the springs and washers on the

deadman assembly. See Figure 7-23.

Switch Replacement
Spring
There are two deadman switches (S2 and S23).
1. Raise the operator platform high enough
(at least 3 feet [91.44 cm]) to access the Washers
bottom of the deadman pedal from under
the platform.
2. Block the operator platform with a Washer
4 x 4 in. (100 x 100 mm) wooden block. Post Stop
M8 Nut
3. Turn the key switch OFF and disconnect
the battery connector.
Figure 7-23. Deadman Pedal Springs and Washers
4. Remove the deadman assembly by
removing the three retaining nuts under 10. Install the deadman assembly on the
the carriage, and disconnecting the deadman weldment. See Figure 7-22.
harness. See Figure 7-22.
11. Install the nut and washers on the center
post.
12. Torque the M8 nut against the shoulder of
the center post. Refer to “Torque Chart -
Metric (Ferrous)” on page A-9.
13. Attach the deadman assembly to the
carriage with the three retaining nuts and
connect the harness.
14. Reconnect the battery connector and turn
the key switch ON.
77k10131s
15. Remove the block and lower the carriage.
Figure 7-22. Deadman Lock Nuts and Washers 16. Test the lift truck operation before
returning to service.
5. Remove the M8 nut and washers from the
bottom of the center post.
6. Separate the deadman assembly from the
deadman weldment.
NOTE: Do not lose the springs or washers.
7. Replace bad switch(es).
8. Reconnect wires.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Deadman Pedal

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive and Brake

Section 7. Component Procedures

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Traction Motor

Traction Motor Installation

1. Clean the motor mounting flange and drive
Refer to AC Motor Service on page 7-75 for unit. Install a new gasket.
traction motor temperature sensor and encoder 2. Install the pinion in the drive motor, if
bearing replacement procedures. required, by following these steps:
a. Clean the threads using thread-locking
Removal compound primer (P/N 990-666).
1. Turn the key switch OFF and disconnect b. Install the key and gear.
the battery connector.
c. Apply thread-locking compound
2. Remove the brake assembly including the (P/N 990-669) to the threads of the
rotor hub nut and rotor hub. See motor and nut.
Figure 7-24. Note the number of spacers
d. Torque the nut to 45 ft. lb. (61 Nm).
used.
3. Mount the motor to the drive unit.
4. Install the drive motor retaining screws.
Refer to the Component Specific
Brake Assembly
Service/Torque Chart on page A-4.
5. Install the power cables on the traction
motor.
6. Torque the power cable nuts to 18 ft. lb.
(24.4 Nm). See Power Cable Terminals on
page 7-72.
7. Install the brake assembly, including the
rotor hub nut and rotor hub.
8. Check brake adjustment. See Brake
Adjustment on page 7-61.

Figure 7-24. Drive Motor

3. Identify and remove the power cables from

the traction motor.
4. Remove the drive motor retaining screws.
5. Remove the traction motor.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit - Standard

Drive Unit - Standard Drive Unit Removal

1. Turn the key switch OFF and disconnect
the battery connector.
Pivot Ring Inspection
2. Remove the bumper gate. See Figure 7-25.
Some play is expected between the pivot ring
bearings and the drive unit. As the rings wear,
the play may increase. If the play is permitted to
become extreme, it will become noticeable in
the drive unit.
Inspect the drive housing if worn rings are
suspected as the cause of excessive play in the
drive unit. Determine if the bearing radial rings
must be replaced:
1. Jack the tractor of the lift truck up just
enough to permit the drive tire to clear the
floor.
Bumper Gate

7
Figure 7-25. Removing Drive Unit
Use extreme care when the lift truck is
3. If the lift truck is wire guided, remove the
jacked up. Never block the lift truck
sensor mounted on the backside of the
between the telescopic and the floor.
bumper gate.
Attach an appropriately rated rigging
device to the top of the mast, and an 4. If the drive tire is to be removed, loosen the
overhead hoist to stabilize the mast if lug nuts.
jacking higher than described in the 5. Remove the proximity sensor and
Jacking Safety section. Keep hands and associated hardware on the drive unit
feet clear while jacking the lift truck. casting.
After the lift truck is jacked, place solid
6. Remove the traction motor. See Traction
blocks or jack stands beneath it to
Motor on page 7-28.
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the NOTE: It is not necessary to separate the brake
jack or jack stand alone to support the assembly from the traction motor if the
lift truck. See Jacking on page 2-9. drive unit is the only item requiring
service.
2. Place a magnetic base dial indicator on the
deck plate and position the indicator point
on top of the drive unit top cover.
3. Adjust the dial indicator to zero, then
lower the lift truck to the floor.
4. Note the new indicator reading. If the
reading is 0.089 in. (2.26 mm) or less, the
radial rings do not have to be replaced. If
the reading exceeds 0.089 in. (2.26 mm),
the rings must be replaced. If the reading
is between 0.055 and 0.089 in. (1.4 and
2.26 mm), the bearing rings must be
checked during future scheduled
maintenance visits.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Pivot Ring Disassembly

14. Visually inspect the outside of the housing

for damage, wear, or cracks. Pay particular
attention to the area where hub wear may
Use extreme care when the lift truck is be evident.
jacked up. Never block the lift truck
between the telescopic and the floor. Pivot Ring Disassembly
Attach an appropriately rated rigging
device to the top of the mast, and an 1. Remove the bearing filler plug screws
overhead hoist to stabilize the mast if using a 1/2 in. socket. See Figure 7-27.
jacking higher than described in the
Jacking Safety section. Keep hands and
feet clear while jacking the lift truck.
After the lift truck is jacked, place solid
blocks or jack stands beneath it to
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the
jack or jack stand alone to support the
lift truck. See Jacking on page 2-9.

7. Jack and block the tractor so the drive tire

is off the floor.
8. Drain the oil from the drive unit. 71826_011.tif

9. Unbolt the lift/lower manifold from the Figure 7-27. Bearing Filler Plug Screws Removal
drive unit casting.
2. Remove the bearing filler plug with grease
10. Remove the steering motor/gear reducer
fitting.
assembly.
3. Remove the steel balls through the bearing
11. Remove the cap screws holding the drive
filler plug hole. To work the steel balls
unit assembly to the tractor frame.
forward, insert a putty knife between the
12. Lift the drive unit out of the tractor frame pivot ring and the housing. See
using a suitable lifting device. Figure 7-28. Use care to prevent damaging
13. Clean the outside of the drive unit the radial rings. Move the pivot ring
thoroughly and drain any remaining oil slightly from side to side while working the
from the drive unit by removing the drain putty knife toward the bearing filler plug
plug. hole.
NOTE: If the pivot ring will not spin or even
turn, it is an indication of damaged
radial rings and/or excessive wear to the
channel in the housing. If this is the
case, replace the entire drive unit. No
further disassembly is necessary.

71826_006.tif

Figure 7-26. Inspect Housing for Hub Wear

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Pivot Ring Disassembly

Due to normal or excessive wear, the

edges of the radial rings could be very
sharp.

6. Use a mallet and a punch to remove the

spherical bearing and brass bushing from
the pivot ring. See Figure 7-31.

1826_014.tif

Figure 7-28. Remove Steel Ball Bearings

4. After removing all the steel balls, remove

the pivot ring by lifting it off, toward the
drive end of the housing. See Figure 7-28.

71826_020.tif

Figure 7-31. Spherical Bearing and Brass Bushing

Removal

7. Remove the grease fittings using a punch

and a mallet. See Figure 7-32.

71826_015.tif

Figure 7-29. Pivot Ring Removal

5. Use a screwdriver to remove the radial

rings and thrust ring from the pivot ring.
See Figure 7-30.

71826_022.tif

Figure 7-32. Grease Fitting Removal

8. Use a punch and mallet to remove the two

roll pins that are used to hold the radial
rings in position. See Figure 7-33. Inspect
the roll pins. If they are worn, replace with
new roll pins when reassembling the pivot
ring.
71826_018.tif

Figure 7-30. Radial and Thrust Ring Removal

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Drive Unit Housing Disassembly

Due to normal or excessive wear, the

edges of the radial rings could be very
sharp.

2. Clean the grease from the radial ring

channel in the housing. Inspect the
channel for uneven wear. See Figure 7-35.
If there is excessive wear, no further
disassembly is necessary. The housing
must be replaced.
71826_024.tif

Figure 7-33. Roll Pin Removal

9. Clean the grease from the radial ring

channel in the pivot ring. Inspect the
channels for wear. If there is excessive
wear, replace the pivot ring.

Drive Unit Housing Disassembly

Excessive housing wear in the channel, pivot
ring, or hub areas are signs of a damaged
housing. If this occurs, replace the entire drive
71826_026.tif
unit. No further disassembly is necessary.
Figure 7-35. Inspect Housing Channel

Radial Ring Removal Axle Shaft and Bevel Gear Removal

1. Use a screwdriver to remove the radial 1. Loosen the set screw locking the clamp
rings from the housing. See Figure 7-34. nut using a 4 or 5 mm Allen socket and a
breaker bar. See Figure 7-36. You may
need to use an Allen wrench if access is
limited.

71826_025.tif

Figure 7-34. Radial Ring Removal from Housing

71826_027.tif

Figure 7-36. Loosen Clamp Nut Set Screw

2. Use a screwdriver in the clamp nut slot to

turn the clamp nut off. See Figure 7-37.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit Housing Disassembly

Spiral Gear and Helical Gear

Removal
1. Turn the drive unit housing over to remove
the clamp nut from the spiral gear. Loosen
the set screw locking the clamp nut using
a 4 or 5 mm Allen wrench. See
Figure 7-40.

71826_029.tif

Figure 7-37. Turn Clamp Nut Off

3. Remove the axle from the housing using a

large mallet. See Figure 7-38.

71826_041.tif

Figure 7-40. Remove Clamp Nut Set Screw

2. Use a screwdriver in the clamp nut slot to

turn the clamp nut off. Inspect the clamp
nut for damage. See Figure 7-41.

71826_030.tif

Figure 7-38. Remove Axle from Housing

4. The bevel gear can now be lifted from the

housing. In cases where severe chipping is
present, you may need a mallet to knock
the bevel gear loose. See Figure 7-39.

71826_042.tif

Figure 7-41. Remove Clamp Nut

3. Use a brass drift punch and mallet to drive

the spiral pinion gear shaft through the
housing. The brass drift punch will
prevent damage to the threads on the end
of the spiral shaft. See Figure 7-42.
NOTE: It may be necessary to remove the spiral
pinion gear with a press or pressing
71826_038.tif device equivalent.
Figure 7-39. Lift Out Bevel Gear

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Drive Unit Housing Disassembly

71826_043.tif 71826_047.tif

Figure 7-42. Remove Spiral Pinion Figure 7-44. Lift Bearing from Housing

4. Lift the helical gear and spacer from the Bearing Cup and Shim Removal
housing. See Figure 7-43.
NOTE: The bearing cups and cones are usually
damaged during removal. They must be
replaced as sets.
1. Use the mallet and a long punch to drive
the spiral gear bearing cup from the
housing. Take care not to damage the
shims. Save the shims for reference in
reassembly. See Figure 7-45.

71826_045.tif

Figure 7-43. Lift Helical Gear from Housing

5. Inspect the helical gear and the spiral gear

for damage or wear.
NOTE: The bevel gear and spiral gear are a
matched set. Their alignment is critical.
Do not replace them separately.
71826_053.tif
6. Lift the bearing the spiral shaft goes
Figure 7-45. Spiral Gear Bearing Cup Removal
through from the housing to remove it. See
Figure 7-44. 2. Use the mallet and a punch to drive the
helical gear bearing cup from the housing.
See Figure 7-46.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit Housing Disassembly

71826_059.tif
71826_055.tif

Figure 7-46. Helical Gear Bearing Cup Removal Figure 7-48. Spur Gear Removal

3. Remove the axle shaft bearing cup from Housing Cleaning and Inspection
the housing using the punch and mallet.
See Figure 7-47. Thoroughly degrease the housing. Visually
inspect the entire housing again for excessive
damage, cracks, or wear.
Bevel Gear
Bearing Cup Axle Shaft Disassembly

Always watch for pinch points when

using a press or pressing tools.
Axle Shaft
1. Place a bearing puller clamp between the
Bearing Cup
axle seal and beneath the axle bearing
cone.
71826_057.tif

Figure 7-47. Axle Shaft and Bevel Gear Bearing Cup 2. Press the bearing from the axle using a
Removal bearing press and a 6 in. tube. See
Figure 7-49.
4. Use the mallet and a punch to drive the
bevel gear bearing cup from the housing.
Take care not to damage the shims. Save
the shims for reference during reassembly.
5. Visually inspect the housing bores and
sealing surfaces for damage or wear.

Spur Gear Removal

Check the spur gear for damage or wear. If the

spur gear is damaged, use a drift punch and
mallet to remove it from the housing. See
Figure 7-48. 71826_032.tif

Figure 7-49. Bearing Removal

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Drive Unit Housing Disassembly

3. Lift the axle seal from the axle. See

Figure 7-50.

71826_039.tif

Figure 7-52. Puller Clamp on Bevel Gear

71826_034.tif
2. Press the bearing from the bevel gear
Figure 7-50. Lift Seal Removal
using a bearing press and an 8 in. tube.
4. Inspect the axle for damage or wear. See See Figure 7-53.
Figure 7-51.

71826_040.tif

Figure 7-53. Press Bearing from Bevel Gear

71826_035.tif

Figure 7-51. Axle Inspection

Spiral Gear Disassembly
Bevel Gear Disassembly 1. Place a bearing puller clamp beneath the
bearing cone on the spiral gear. See
Figure 7-54.

Always watch for pinch points when

using a press or pressing tools.

1. Place the bearing puller clamp on the bevel

gear beneath the bearing. See Figure 7-52.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit Housing Disassembly

71826_051.tif

Figure 7-54. Puller Clamp on Spiral Gear

2. Press the bearing from the spiral gear

using a bearing press. See Figure 7-55.

71826_052.tif

Figure 7-55. Pressing Bearing from Spiral Gear

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Assembly Procedures

Assembly Procedures

Bearing Cone

Safety glasses are required.

Prepare the housing for assembly by running a

Spiral Gear
tap through all bolt and screw holes. Cleaning
the threads makes sure that there is no
damage. It also enables you to determine the
correct tooling to use in the assembly process.

Record the bearing seat data stamped on the 71018_015.tif

housing before beginning assembly of the drive Figure 7-57. Press Bearing onto Spiral Gear
unit. Record the setting distance information
stamped on the bevel and spiral gears. This
data is used in the formula to determine shim
thickness later on.
Always watch for pinch points when
using a press or pressing tools.
Gear Set Assembly
1. Press the bearing cone on the bevel gear 3. Use a bearing zero offset tool and the
until it is seated. Place the matching formulas below to determine the shim
bearing cup on the bearing cone for thickness that is required to assemble the
measuring purposes. See Figure 7-56. gear set in the housing.

Calculate Shim Formulas

Spiral Pinion Gear Shim Calculation:

• A = Dimension A (See Figure 7-58.)
stamped on housing (4.438)
• B = Number (See Figure 7-59.) etched on
gear (S/D 2.378)
• C = Zero Offset (See Figure 7-60.)
Use a dial indicator to determine the zero
offset. Turn the spiral gear as if seating the
bearings. Record the data from the dial
71826_064.tif
indicator to use in the formula.
Figure 7-56. Press Bearing on Bevel Gear
• D = Plug Height (2.025)
2. Press the bearing cone on the spiral gear • E=B+C+D
until it is seated. Place the matching
• F=A-E
bearing cup on the bearing cone for
measuring purposes. See Figure 7-57. F = Shim thickness required

This calculation is used to determine the shim

amount behind the bearing cup in the main
housing. The shim(s) positions the spiral gear
for correct backlash.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Assembly Procedures

Bevel Gear Shim Calculation:

• G = Dimension B (see Figure 7-61)
stamped on housing (2.506)
• H = Number (see Figure 7-62) etched on
gear (S/D 0.541)
• J = Zero Offset (see Figure 7-63)
Use a dial indicator to determine the zero
offset. Turn the bevel gear as if seating the
bearings. Record the data from the dial
indicator to use in the formula.
• K = Plug height (1.875)
71826_060.tif
• L=H+J+K
Figure 7-58. Record Bearing Seat Data from Housing
• M=G-L
M = Shim thickness required

This calculation is used to determine the shim

amount behind the bearing cup in the main
housing. The shim(s) positions the bevel gear
for correct backlash.

71826_071.tif

Figure 7-59. Record Bearing Seat Data from Spiral Gear

Dial
Indicator
71826_061.tif

Figure 7-61. Record Bearing Seat Data from Housing

Pinion
Gear

Gear
Checking
Fixture

7pingear.tif

Figure 7-60. Check Zero Offset of Spiral Gear

71826_072.tif

Figure 7-62. Record Bearing Seat Data from Bevel Gear

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Assembly Procedures

Spiral Gear
Bearing Cup

Dial
Indicator

71018_014.tif

Crown Figure 7-65. Drive In Bearing Cup

Gear
3. Place the bevel gear shim in the housing,
7crngear.tif
followed by the bearing cup. Use a press or
Figure 7-63. Check Zero Offset of Bevel Gear mallet to press the bearing cup into the
housing bore. See Figure 7-66.
Housing Bearing Cup and Shim NOTE: Make sure to wipe away any chips or
Assembly excess metal pieces resulting from
driving the race to seat it.
1. Place the spiral gear shims in the housing,
then place the bearing cup in the housing.
See Figure 7-64.

71826_080.tif

Figure 7-66. Bevel Gear Bearing Cup Installation

71826_076.tif
4. Place the drive axle bearing cup in the
Figure 7-64. Spiral Gear Bearing Cup Installation
housing. Use a mallet or press to seat the
axle bearing cup in the housing. See
2. Install the bearing cup into the housing
Figure 7-67.
bore. See Figure 7-65.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Assembly Procedures

71826_084.tif 71826_087.tif

Figure 7-67. Axle Bearing Cup Installation Figure 7-69. Preheat Bearing Cone

5. Turn the drive unit housing over. Install NOTE: Steps 2 through 5 need to be completed
the helical bearing cup in the housing. Use before the bearing cools to provide a
a press or mallet to seat the bearing cup in correct installation.
the housing. See Figure 7-68.
2. Install the heated bearing cone in the
bearing cup in the housing.
3. Place the spacer over the bearing cone,
then place the helical gear into the
housing.

71826_085.tif

Figure 7-68. Helical Bearing Cup Installation

Helical Gear/Spiral Pinion Gear

Assembly
71826_089.tif

NOTE: The pinion shaft and bevel gear are a Figure 7-70. Install Helical Gear
matched set. Their alignment is critical.
Do not replace them separately. 4. Install the spiral pinion gear shaft up
through the helical gear. Push up until the
spiral gear bearing is seated against its
race. See Figure 7-71.

The bearing can become extremely hot.

Use gloves to protect your hands from
burns.

1. Preheat the bearing cone with a bearing

heater. See Figure 7-69.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Assembly Procedures

71826_091.tif 71018_028.tif

Figure 7-71. Spiral Pinion Gear Installation Figure 7-73. Removing End Play

5. Apply three vertical lines of thread-locking 7. Tighten the clamp nut the distance of a
compound (P/N 990-669) to the pinion spanner nut space to preload the gears.
shaft. Place the clamp nut on the end of 8. Back the nut off, then hand tighten it.
the spiral pinion gear shaft and hand
tighten until the bearing cools. See 9. Apply thread-locking compound
Figure 7-72. (P/N 1013829) to the bolt in the clamp
nut. Torque the clamp bolt to 128 in. lbs.
(14.5 Nm). Make sure the open ends of the
clamp nut do not touch. See Figure 7-74.

71018_027.tif

Figure 7-72. Install Clamp Nut

6. When the bearing has cooled, spin the 71826_094.tif

helical gear to check for end play. Remove Figure 7-74. Applying Locking Compound to Screw
any end play in the bearings between the
helical gear and the spiral gear using a nut 10. Spin the helical gear to make sure there is
driver tool (P/N 761-870/T04) and a no end play or that the bearings are not
wedge. Slowly tighten the clamp nut on too tight.
the end of the spiral gear until there is no
end play between the gears. Use a spin Axle Assembly
and tighten method to tighten clamp nut
1. Lubricate the oil seal. Place the seal over
as the bearings are seating in the races.
the axle shaft with the spring side toward
See Figure 7-73.
the oil.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Assembly Procedures

71826_096.tif 71826_100.tif

Figure 7-75. Axle Seal Installation Figure 7-77. Apply Gasket Compound to Sealing Surface

2. Place the axle bearing cone over the axle 4. Place the bevel gear into the housing. See
shaft. Press the bearing cone on the axle Figure 7-78.
shaft until it is seated. See Figure 7-76.

Always watch for pinch points when

using a press or pressing tools.

71826_101.tif

Figure 7-78. Bevel Gear Installation

5. Place a seal pressing ring

(P/N 828-004-901) beneath the axle seal.
Install the axle shaft through the bevel
gear. See Figure 7-79.
71826_097.tif

Figure 7-76. Axle Bearing Cone Installation

3. Apply a thin layer of gasket compound to

the housing to seal the axle seal. See Seal Pressing Ring
Figure 7-77.

71826_102.tif

Figure 7-79. Axle Seal Pressing Ring

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Assembly Procedures

6. Press the axle into the housing until the 12. Loosen the clamp nut, then retighten it to
seal is fully installed. See Figure 7-80. 5 ft. lbs. (7 Nm) using the rotate tightening
process until the clamp nut does not turn
any further.
13. Apply thread-locking compound
(P/N 1013829) to the bolt in the clamp nut.
See Figure 7-82. Torque the bolt to 128 in.
lbs. (14.5 Nm). Make sure the open end of
the clamp nut does not touch.

71826_103.tif

Figure 7-80. Press Axle into Housing

Always watch for pinch points when

using a press or pressing tools.
71826_107.tif

7. Remove the seal pressing ring. Figure 7-82. Applying Locking Compound to Clamp
Screw
8. Apply three vertical lines of thread-locking
compound (P/N 990-669) to the threads of
the axle.
Measuring Backlash
9. Install the clamp nut shoulder side down. NOTE: Backlash tolerance is critical to the
Hold the axle to keep it from turning as performance of the drive unit.
the clamp nut is tightened. Incorrectly adjusted units will
experience premature failure.
10. Use clamp nut tool (P/N 761-870/T07)
and torque the clamp nut to 18 ft. lbs. 1. Place a gear-locking tool on the helical
(24 Nm). See Figure 7-81. gear and secure. See Figure 7-83.

Crown
Gear Gear
Fixture

71826_106.tif

Figure 7-81. Tighten Clamp Nut to Seat Bearings

7gearfixt.tif

11. Rotate the axle and tighten the clamp nut. Figure 7-83. Gear Locking Tool
Repeat this step six times to make sure the
bearing cones are seated into the cups.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Assembly Procedures

2. Position the probe of the dial indicator at 5. Repeat steps 1 through 3 of this procedure
the heel of the bevel gear tooth. Position until the backlash is between 0.004 and
the dial indicator probe perpendicular to 0.006 in.
the gear tooth surface. 6. Install the pivot ring when backlash is
within the acceptable range.

Crown Pivot Ring Assembly

Gear
1. Place a light coating of thread-locking
compound (P/N 990-544) in the hole on
the pivot ring assembly.
2. Line up the grease fitting hole with the
Dial grease fitting port. See Figure 7-86.
Indicator

7dial.tif

Figure 7-84. Dial Indicator Position

3. Zero the indicator. Clasp the bottom of the

gear and rotate it. Read the backlash
measurement on the dial indicator. Total
backlash tolerance is between 0.004
and 0.006 in.
71826_111.tif

Gear Figure 7-86. Spherical Bearing Alignment

Locking
Fixture 3. Install the spherical bearing using a mallet
or press. See Figure 7-87.
Crown
Gear

Dial Transmission
Indicator Housing
7backlsh.tif

Figure 7-85. Measure Backlash

71826_112.tif
4. If the tolerance is not within the
Figure 7-87. Install Spherical Bearing
acceptable limits, calculate any necessary
adjustments to the shims. Remove the 4. Install the grease fitting in the pivot ring
clamp nut, axle assembly, and bevel gear. assembly using a grease fitting driver and a
Install the correct amount of shims, and mallet or press. See Figure 7-88.
repeat steps 3 and 4 of “Housing Bearing
Cup and Shim Assembly” procedure on
page 7-40.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Assembly Procedures

Radial Rings

71826_113.tif 71018_036.tif

Figure 7-88. Grease Fitting Installation Figure 7-90. Radial Ring Installation

5. On the inside of the pivot ring, make sure 8. Install the brass bushing using a mallet or
the roll pins are installed and in good press. See Figure 7-91.
condition on either side of the bearing filler
plug hole. If they are missing or damaged,
install new roll pins. See Figure 7-89.

Pivot Ring

Roll Pin

71826_125.tif

Figure 7-91. Brass Bushing Installation

71018_035.tif

Figure 7-89. Roll Pin Installation

6. Clean the surface of the radial ring grove.

7. Install the radial rings so that the gap
aligns with the bearing hole. Install the flat
radial ring on the inside flat surface of the
pivot ring. Then install the chamfered radial
rings to the radial ring. The chamfered
edges will face the steel balls. The ends of
the radial ring are against the roll pins. See
Figure 7-90.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit Assembly

Drive Unit Assembly

\

1. Install the radial rings on the housing.

Stagger the ends of the rings around the
housing so the gaps are off-set at 3, 6, and
9 o’clock. The beveled edges will face the
steel balls. See Figure 7-92.

71018_038.tif

Figure 7-94. Ball Bearing Installation

4. Place the bearing filler plug in the filler

hole. The grease fitting should face the
spur gear.

71826_116.tif

Figure 7-92. Radial Ring Installation on Housing

2. Install the pivot ring assembly to the

housing. The spherical bearing should face
the spur gear. See Figure 7-93.

71826_119.tif

Figure 7-95. Bearing Filler Plug Installation

5. Install the filler plug bolts and flat washers

on each side of the grease fitting. Tighten
to 17 ft. lbs. (23 Nm). See Figure 7-96.

71826_117.tif

Figure 7-93. Pivot Ring Installation

3. Place one steel ball at a time into the pivot

ring filler hole. Use a screwdriver to direct
the steel balls first to one side then the
other. See Figure 7-94.
NOTE: Count the steel balls as they are
inserted in the pivot ring assembly for
correct pivot ring operation. The 71826_121.tif

standard drive unit requires 67 balls. Figure 7-96. Filler Plug Bolt Installation
Too many balls will cause binding and
too few balls will cause excessive 6. Grease and then test the pivot ring. Check
motion. to see that it spins freely.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Drive Unit Assembly

Housing Cover Installation

1. Clean old sealant from the gear housing
and cover plate. Remove any paint from
the sealing surface of the inside face of the
plate.
2. Clean the sealing surfaces of the gear
housing and cover plate with an alcohol
based cleaner.
3. Apply liberal amounts of silicone sealing
compound (P/N 990-659) in a continuous
bead around the perimeter on the surface
71826_124.tif
of the gear housing. Go completely around
Figure 7-98. Tighten Cover Bolts
the bolt holes. Start the bead on a flat
surface between holes. Make sure there is 6. Apply thread-locking compound
a 0.5 in. overlap when completing the (P/N 990-626) to the drain plug.
bead. The bead width should be 0.12 in.
minimum and 0.25 in. maximum. 7. Install the drain plug in the cover plate and
See Figure 7-97. tighten.
4. Install the cover plate with the unpainted 8. Fill the gear housing with oil.
surface contacting the RTV.

71826_123.tif

Figure 7-97. Apply Gasket Compound

5. Install six screws, torque in a star pattern,

and then torque in a star pattern again.
Refer to Component Specific
Service/Torque Chart on page A-4. See
Figure 7-98.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Unit - Heavy Duty

Drive Unit - Heavy Duty Drive Unit Removal

1. Turn the key switch OFF and disconnect
the battery connector.
Pivot Ring Inspection
2. Remove the bumper gate. See Figure 7-99.
The fit of pivot ring bearings in the drive unit is
such that some play is expected, however, as
the radial rings wear, the play may increase. If
the play is permitted to become extreme, it will
become quite noticeable in the drive unit.
If worn rings are suspected as the cause of
excessive play in the drive unit, inspect the
drive housing to determine if the bearing radial
rings must be replaced:
1. Jack the tractor of the lift truck up just
enough to permit the drive tire to clear the
floor.
Bumper Gate

7
Figure 7-99. Removing Drive Unit
Use extreme care when the lift truck is
3. If the lift truck is wire guided, remove the
jacked up. Never block the lift truck
sensor mounted on the back side of the
between the telescopic and the floor.
bumper gate.
Attach an appropriately rated rigging
device to the top of the mast, and an 4. If the drive tire is to be removed, loosen the
overhead hoist to stabilize the mast if lug nuts.
jacking higher than described in the 5. Remove the proximity sensor and
Jacking Safety section. Keep hands and associated hardware on the drive unit
feet clear while jacking the lift truck. casting.
After the lift truck is jacked, place solid
6. Remove the traction motor. See Traction
blocks or jack stands beneath it to
Motor on page 7-28.
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the NOTE: If the drive unit is the only item
jack or jack stand alone to support the requiring service, separating the brake
lift truck. See Jacking on page 2-9. assembly from the traction motor is not
necessary.
2. Place a magnetic base dial indicator on the
deck plate and position the indicator point
on top of the drive unit top cover.
3. Adjust the dial indicator to zero then lower
the lift truck to the floor.
4. Note the new indicator reading. If the
reading is 0.089 in. (2.26 mm) or less, the
radial rings do not have to be replaced. If
the reading exceeds 0.089 in. (2.26 mm),
the rings must be replaced. If the reading
is between 0.055 and 0.089 in. (1.4 and
2.26 mm), the bearing rings must be
checked during future scheduled
maintenance visits.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Pivot Ring Disassembly

Bearing Filler
Plug
Use extreme care when the lift truck is
jacked up. Never block the lift truck
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an
overhead hoist to stabilize the mast if
jacking higher than described in the
Jacking Safety section. Keep hands and
feet clear while jacking the lift truck. Pivot Ring
After the lift truck is jacked, place solid 71018_003.tif

blocks or jack stands beneath it to Figure 7-100. Grease Fitting and Filler Plug Removal
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the 2. Turn the pivot ring to remove the steel balls
jack or jack stand alone to support the through the bearing filler plug hole. See
lift truck. See Jacking on page 2-9. Figure 7-101.

7. Jack and block the tractor so the drive tire NOTE: If the pivot ring will not spin or even
is off the floor. turn, it is an indication of damaged
radial rings and/or excessive wear to the
8. Drain the oil from the drive unit. channel in housing. If this is the case,
9. Unbolt the lift/lower manifold from the replace the entire drive unit. No further
drive unit casting. disassembly is necessary.
10. Remove the steering motor/gear reducer
assembly.
11. Remove the cap screws holding the drive
unit assembly to the tractor frame.
12. Lift the drive unit out of the tractor frame
using a suitable lifting device.
13. Clean the outside of the drive unit
thoroughly and drain any remaining oil
from the drive unit by removing the drain
plug.
14. Visually inspect the outside of the housing
for damage, wear, or cracks. 71018_002.tif

Figure 7-101. Remove Steel Ball Bearings

Pivot Ring Disassembly
3. After removing all the steel balls, remove
1. On the pivot ring, remove the grease fitting the pivot ring by working it off toward drive
and the bearing filler plug. Inspect the end of the housing. See Figure 7-102.
bearing filler plug hole for uneven wear.
See Figure 7-100.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Main Cover and Output Shaft Disassembly

Main Cover and Output Shaft

Disassembly
1. Visually inspect the housing around the
main cover for wear outside the cover
bolts.
NOTE: Excessive housing wear outside the
cover bolts can make them difficult to
remove. If this occurs, replace the entire
drive unit. No further disassembly is
necessary.

71018_004.tif
2. Remove the main cover bolts.
Figure 7-102. Pivot Ring Removal 3. Using a mallet, knock the flanged output
shaft to break the seal on the main cover.
4. Remove the radial rings from the channel in 4. Remove the main cover and output shaft
the housing and inside the pivot ring. See assembly. See Figure 7-104.
Figure 7-103.

Radial Rings

Main Cover

71018_005.tif

71018_001.tif
Figure 7-104. Cover and Output Shaft Removal
Figure 7-103. Radial Ring Removal
NOTE: A press and 8 x 6 in. tube are required
5. Remove the roll pins and grease fittings
to remove the bearing cup on the end of
from the pivot ring to enable thorough
the output shaft.
cleaning.

Always watch for pinch points when

Due to normal or excessive wear, the
using a press or pressing tools.
edges of the radial rings could be very
sharp.
Safety glasses are required after this
point in disassembly.
6. Clean the grease from the radial ring
channel in the housing. Inspect the
5. Place the main cover assembly, gear side
channel for uneven wear. Clean and
down, on the tube under press.
inspect the inside of the pivot ring.
6. Press the output shaft down slightly to
create a space between the bevel gear and
the output bearing spacer. See
Figure 7-105 on page 7-52.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Main Cover and Output Shaft Disassembly

8. Place the main cover assembly, gear side

up, on a 12 x 6 in. tube so the bearing
puller clamp is resting on the tube.
Output Shaft 9. Press out the flanged output shaft and the
output bearing spacer.
10. Remove the exterior retaining ring.
11. To remove the bevel gear, support the
main cover assembly on an 8 x 6 in. tube
under press.
Bevel Gear 12. Press the output shaft down through the
bevel gear. The bearing cone is removed at
71018_010.tif the same time. See Figure 7-107.
Figure 7-105. Press Down Output Shaft

7. Tighten a bearing puller clamp under the

lip of the output bearing spacer, being
careful not to catch the exterior retaining
ring. See Figure 7-106.
Output Shaft

71018_012.tif

Figure 7-107. Bevel Gear Removal

13. Remove the bearing cup from the main

cover with a race driver and pry bars.
14. Remove the lip seal from the main cover.
71018_010.tif
See Figure 7-108.
Figure 7-106. Bearing Puller Clamp Installation

Lip Seal

71018_003.tif

Figure 7-108. Bearing Cup and Lip Seal Removal

15. Remove the output shaft bearing cone in

the base of the housing using two pry
bars.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Spiral Pinion Disassembly

16. Insert the pry bars under the bottom edge 2. Using a brass punch and hammer, drive
of the cone on opposite sides. Apply even the spiral pinion gear shaft out of the
pressure on both tools to lift the cone out. housing. See Figure 7-111.
See Figure 7-109.
NOTE: You may need to remove the spiral
pinion with a press or pressing device
equivalent.

Output Bearing
Cone

71018_009.tif

Figure 7-109. Output Shaft Bearing Cone Removal

17. Remove the shims from the housing bore. 71018_007.tif

Save shims for reference only, as they are Figure 7-111. Spiral Pinion Removal
usually damaged when removing the
bearing cone. 3. Remove the helical gear and the bearing
cone from the housing.
18. Remove the cover shims. Save the shims
for reference only. 4. Drive out the bearing cup. Inspect the
bearing cup and housing bores for wear.
See Figure 7-112.
Spiral Pinion Disassembly
NOTE: The bearing cups and cones are usually
NOTE: The spiral pinion and bevel gear are a damaged during removal. They must be
matched set. Their alignment is critical. replaced as sets.
Do not replace them separately.
1. Loosen the set screw on the clamp nut on
the spiral pinion gear shaft. Using Tool
761-870/T03, remove the clamp nut. See
Figure 7-110.
Bearing Cup

Clamp Nut

71018_008.tif

Figure 7-112. Bearing Cup Removal

5. Thoroughly wash the housing and visually

inspect the entire housing again for
excessive damage, wear, or cracks.
71018_006.tif

Figure 7-110. Clamp Nut Removal

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Assembly Procedures

Assembly Procedures

Safety glasses are required. Bearing Cone

Prepare the housing for assembly by running a

tap through all bolt and screw holes. Cleaning
the threads also makes sure that there is no
damage. Spiral Pinion

Spiral Pinion Assembly

71018_015.tif

1. Using a press or mallet, install the bearing Figure 7-114. Pressing Bearing onto Spiral Pinion
cup into the housing bore. See
Figure 7-113. Main Cover and Output Shaft
Assembly
1. Before installing the output shaft lip seal,
apply a thin layer of sealing adhesive
around the seal surface of the main
housing. Install the lip seal, spring side
down, in the housing. See Figure 7-115.

Bearing Cup

71018_014.tif
Lip Seal
Figure 7-113. Bearing Cup Installation

2. Install the second bearing cup into the

housing bore on the opposite side.

71018_016.tif
Always watch for pinch points when
Figure 7-115. Press Lip Seal
using a press or pressing tools.
2. Press the lip seal into the housing until it
3. Press the bearing cone onto the spiral is just below flush with the housing
pinion gear shaft until it is seated. See surface.
Figure 7-114.
3. Press the output bearing cup into the
main cover until it is seated. Place the
bearing cone into the bearing cup. See
Figure 7-116.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Assembly Procedures

cone down over the output shaft. See

Figure 7-118.

Bearing Cone
Output Bearing Cup

71018_017.tif

Figure 7-116. Pressing Output Bearing Cup Output Shaft

71018_021.tif
4. Push down on the bearing and turn to seat
Figure 7-118. Install Main Cover and Bearing Cone
the bearing into the cup.
5. Using dial indicators, measure dimension 10. Press the bearing cone onto the output
D from the edge of the bearing cone to the shaft. See Figure 7-119.
main cover flange surface. See
Figure 7-117.

71018_020.tif

Figure 7-119. Pressing Bearing Cone

71826_127.tif

Figure 7-117. Bearing Cone to Flange Measurement 11. Place the bevel gear down over the output
shaft, teeth side up. Press the bevel gear
6. The reading on the two dial indicators down, seating the bearing cone into the
should be the same. If they are different, bearing cup. See Figure 7-120.
repeat steps 4 and 5 until the readings are
identical. Record the final reading as
dimension D on the flange surface. This is
required during final assembly.
7. Remove the bearing cone in preparation
for installing the flanged output bearing
shaft.
8. Use a light oil on the surface of the lip seal
and inside the bearing cup.
9. Place the main cover down over the output
shaft, flange side up. Place the bearing

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Helical Gear Assembly

Bevel Gear

Bearing Cone

71018_022.tif 71018_024.tif

Figure 7-120. Pressing On Bevel Gear Figure 7-122. Eliminate Backlash

12. Install the external retaining ring on the 16. Place a bearing cup onto the bearing and
output shaft. Pull up on the bevel gear to rotate the cup while applying downward
make sure the external retaining ring is pressure to seat the bearing. See
installed securely. Figure 7-122.
13. Place the output bearing spacer, with the 17. Using dial indicator(s), check that the
recessed area down, over the output shaft. bearing is correctly seated. The readings
Place the bearing cone on top of the output on the two dial indicators should be the
shaft. See Figure 7-121. same. If they are different, repeat steps 15
and 16 until the readings are identical.
See Figure 7-123.

Output Bearing Spacer

71018_023.tif

Figure 7-121. Pressing Down Bearing Cone

71826_130.tif

14. Press the bearing cone down until it is Figure 7-123. Bearing Cup to Flange Measurement
fully seated against the spacer and snap
ring. 18. Record the final readings as Dimension E.
15. Press the bearing cone into place. At the This is required during final assembly.
same time, pull the gear sideways to
eliminate any backlash in the spline area. Helical Gear Assembly
See Figure 7-122.
NOTE: The pinion shaft and bevel gear are a
matched set. Their alignment is critical.
Do not replace them separately.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Helical Gear Assembly

• E = Distance from bearing cup to flange

surface (see Figure 7-126)

The bearing can become extremely hot.

Use gloves to protect your hands from
burns.

1. Preheat the bearing cone with a bearing

heater. Install the heated bearing cone in
the bearing cup in the housing.
NOTE: Steps 2 through 4 need to be completed
before the bearing cools.
2. Place the helical gear into the housing.
3. Install the spiral pinion gear shaft up 71826_127.tif

through the helical gear. Figure 7-125. Bearing Cone to Flange Measurement
4. Apply three vertical lines of thread-locking
compound (P/N 990-669) to the pinion
shaft. Put the clamp nut on the end of the
spiral pinion gear shaft and hand tighten
until the bearing cools. See Figure 7-124.

Clamp Nut

71826_130.tif

Figure 7-126. Bearing Cup to Flange Measurement

Helical Gear S1 = (B - A - E + D + C)

71018_027.tif
S1 = Shim amount behind bearing cup in main
Figure 7-124. Helical Gear and Pinion Installation housing to position gear for correct backlash
(S1).
5. While the bearing cone is cooling,
calculate the formula for determining the
S2 = E + S1 - B - 0.006 preload
required shim thickness.
S2 = Shim amount between cover plate face to
Calculate Shim Formulas set preload of bearings for output shaft (S2).
• A = Dimension A stamped on housing
(2.102/2.108) Installing and Testing Shims
• B = Dimension B stamped on housing 1. Remove any end play in the bearings
(3.409/3.412) between the helical gear and the spiral
• C = Number etched on back of gear gear using lock nut wrench
(nominal 1.812) (P/N 761-870/T03). Wedge the helical gear
and tighten the clamp nut until there is no
• D = Distance from bearing to flange
surface (see Figure 7-125)

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Helical Gear Assembly

end play between the gears. See 6. Place the predetermined shims into the
Figure 7-127. housing bore for the bearing cup. Install
the bearing cup into the housing bore over
the shims. See Figure 7-129.
7. Install the cover shims. See Figure 7-129.

Bearing Cup Shims

71018_028.tif

Figure 7-127. Removing End Play

Cover Shims
2. Preload the helical gear for 0.000 to
71018_030.tif
0.002 in.
Figure 7-129. Cover Shims Installation
3. Remove any oil from the clamp nut. Apply
thread-locking compound (P/N 1013829) 8. Place the main cover assembly over the
to the bolt in the clamp nut. Tighten the shims, making sure to line up the marked
bolt to 128 in. lbs. (14.5 Nm). Make sure teeth on both the spiral and bevel gears.
the open ends of the clamp nut do not See Figure 7-130.
touch.
4. Spin the helical gear to make sure that the
Spiral and
bearings are not too tight.
Bevel Gears
5. One tooth on the spiral gear is etched or
marked with an X. With a marker, mark
that tooth surface for the purpose of lining
up the spiral and bevel gears to check
backlash. One tooth on the matching bevel
gear is also marked. Mark that tooth
surface also. See Figure 7-128.

Spiral Gear 71018_031.tif

Figure 7-130. Lining Up Spiral and Bevel Gears

9. Install four housing cover bolts, evenly

spaced, and torque to 40 ft. lbs. (54 Nm).

71018_029.tif

Figure 7-128. Marking Spiral and Bevel Gears

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Helical Gear Assembly

Measuring Backlash

Safety glasses are required.

Backlash tolerance is critical to the

performance of the drive unit.
Pivot Ring Assembly
Incorrectly adjusted units will 1. On the inside of the pivot ring, make sure
experience premature failure. the roll pins are installed and in good
condition on either side of the bearing filler
1. Wedge the helical gear, then slightly turn plug hole. If they are missing or damaged,
the output shaft to determine backlash. install new roll pins. See Figure 7-132.
Backlash reading on the dial indicator
must be between 0.004 and 0.006 in. See
Figure 7-131.
Pivot Ring

Roll Pin

71018_035.tif

Figure 7-132. Roll Pin Installation

71826_131.tif 2. Install the grease fitting on the outside of

Figure 7-131. Measuring Backlash the pivot ring.
3. Screw in the grease fitting in the bearing
2. Calculate any necessary adjustments to
filler plug.
the shims. Remove the main cover
assembly and the bearing cup, and adjust 4. Using radial rings, install the flat radial
the shims. ring on the inside flat surface of the pivot
ring. Place the ends of the chamfered
Repeat steps 6 through 9 in “Installing and
radial rings against the roll pins to install
Testing Shims” until backlash is between
them in the pivot ring. See Figure 7-133.
0.004 and 0.006 in.
3. When backlash is within acceptable range,
remove the main cover assembly and the
cover shims.

Main Cover Installation

1. Clean the cover mating surface on the
housing, then apply thread-locking
compound (P/N 990-411) sparingly.
2. Install the cover shims and the main cover Radial Rings
assembly. Install the main cover bolts and
torque to 40 ft. lbs. (54 Nm).
71018_036.tif

Figure 7-133. Radial Ring Installation

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Helical Gear Assembly

5. On the housing, install the radial rings. See 9. Fit the bearing filler plug with the grease
Figure 7-134. fitting pointing toward the steering ring
gear. See Figure 7-136.

Radial Rings

71018_037.tif
71018_040.tif

Figure 7-134. Outer Radial Ring Installation Figure 7-136. Bearing Filler Plug Installation

6. Lift the drive end of the housing and slide 10. Install the bolts and washers on either side
the pivot ring over the housing, being of the bearing filler plug and tighten to
careful not to jar the radial rings out of 17 ft. lbs. (23 Nm).
place. Slide the pivot ring into place just
behind the steering ring gear. 11. Grease and then test the pivot ring,
checking to see that it spins freely.
7. Make sure that the pivot ring bearing filler
plug hole is on top, in preparation for
installing the steel balls.
8. Put one ball at a time into the pivot ring
filler hole. Use a screwdriver to direct the
steel balls first to one side then the other.
Continue until all 70 balls are installed.
See Figure 7-135.
\

71018_038.tif

Figure 7-135. Install Ball Bearings

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Brake

Brake the armature disk. Brake wear is indicated

if the total gap is greater than 0.015 in.
(0.38 mm).
The brake assembly is mounted on top of the
traction motor. The brake is spring applied and NOTE: Different thickness shims and spacers
electrically released. The brake can be manually are available to maintain correct brake
released by installing the brake release bolts. gap.
See Figure 7-137. 4. Add/remove shims as necessary to achieve
the correct gap.

When brake release bolts are used,

make sure they are removed before the
lift truck is returned to service. If the
bolts are not removed, the brake will
not work correctly.

Brake Adjustment
Perform the brake gap inspections on a regular
schedule.

Use extreme care when the lift truck is

jacked up. Never block the lift truck
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an
overhead hoist to stabilize the mast if
jacking higher than described in the
Jacking Safety section. Keep hands and
feet clear while jacking the lift truck.
After the lift truck is jacked, place solid
blocks or jack stands beneath it to
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the
jack or jack stand alone to support the
lift truck. See Jacking on page 2-9.

1. Jack and block the tractor so the drive tire

is off the floor.
2. With the brake de-energized (fully applied),
use a feeler gauge to measure the total
gap. See Figure 7-137.
3. Take measurements at three
equally-spaced locations around the
armature disk. The total gap must be
0.010 to 0.015 in. (0.25 to 0.38 mm). The
gap must be uniform all the way around

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Brake Rotor Replacement

Assy
Compression Spring (Qty. 8) Brake Release Bolt
Screw (Qty. 3) (Qty. 2)
normally stowed on frame
Shims (can be
located above or
below the spacer)
Brake Coil Assy
Armature Total Gap
Disk

Spacer
(Qty. 3)

Brake Rotor Mounting Brake Assy Mtg

(wearable mat’l) Plate Bolt (Qty. 3)
7
Figure 7-137. Brake Assembly Components

Brake Rotor Replacement Assembly/Installation

1. Slide the new rotor into the assembly. The
Replace the rotor if worn to a thickness of rotor is positioned between the armature
0.236 in. (6 mm) or less. disk and the brake mounting plate. See
Figures 7-138 and 7-139.
Removal/Disassembly
2. Install the one assembly screw removed to
1. Turn the key switch OFF and disconnect replace the rotor. Make sure to install any
the battery connector. spacers removed. Torque the three M6
2. Remove the covers from the tractor. screws that secure the coil to the assembly
to 9 ft. lb. (12 Nm) with the threads
3. Disconnect the electrical cable to the
lubricated.
brake assembly.
3. Carefully center the rotor within the
4. Remove the three screws that secure the assembly and remove the brake release
brake to the drive unit. bolts.
5. Remove the cable support. 4. Measure the total gap as shown below. The
6. Lift the brake unit up and off the drive total gap must be between 0.010 in.
unit. Take the assembly to a workbench. (0.25 mm) and 0.015 in. (0.38 mm). If the
You will need the brake release screws gap is not within tolerance, add or remove
located on the tractor. shims and/or spacers as necessary.
7. Insert the brake release screws into the Different thickness shims and spacers are
brake assembly. Tighten the two brake available.
release screws to release the brake
completely.
8. Remove one of the three screws that hold
the brake assembly together. Use care not
to lose any shims that may be used.
9. Slide the rotor out of the assembly.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Brake Rotor Replacement

If the total gap exceeds 0.015 in.

(0.38 mm), brake release problems will
result particularly when the brake is hot
and/or the battery is low.

Shims (can be located above Brake Release Bolt (Qty. 2)

or below the spacer) normally stowed on tractor frame

Total Gap

Spacers Armature Disk Mounting Plate Brake Rotor

7
Figure 7-138. Installing Brake Rotor

Brake Coil Assy Rotor Hub Nut

(Normal coil resistance at room torque to 75 ft. lb. (105 Nm)

temp is approx 13.5 ohms)

Rotor Hub
(part of brake assy)
Assy Screw
torque to 9 ft. lb. (12.6 Nm) Brake Release Screws
(normally stowed on tractor frame)

Mounting Screw
torque to 12 ft. lb.
(16.8 Nm)

Traction Motor

7
Figure 7-139. Brake Assembly - Section View

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Brake Rotor Replacement

5. After the correct gap is achieved, torque

the assembly screws as specified in step 2.
6. Inspect the splines on the rotor hub (on
the traction motor). If the splines on the If the brake does not work while
rotor hub have excessive wear, replace the performing the next step, the lift truck
hub before proceeding. Using a rotor hub will not stop but will coast for
with worn splines may cause rotor damage approximately 30 ft. (9 m).
when the lift truck is driven.
13. Test the brake. In an open area allowing
7. Carefully install the brake assembly on the
for travel over a long distance, perform the
traction motor. It is critical that the splines
following:
on the rotor are not damaged during
assembly. a. Drive the lift truck approximately 2 to 3
mph (3.2 to 4.8 km/h).
b. Push the EPO switch. The lift truck
should stop within approximately 2 to 4
Damaging the splines on the brake rotor
ft. (0.6 to 1.2 m).
may cause brake failure.

8. Install the cable clamp that holds the

power cables on the traction motor.
9. Secure the brake assembly to the traction Stepping off the deadman pedal does
motor. Apply thread-locking compound not test the brake.
(P/N 990-462). Torque the three mounting
screws to 12 ft. lb. (16.8 Nm). NOTE: During acceleration, a slight rattle from
the brake rotor is considered normal
10. Connect the brake to the lift truck and does not affect brake durability or
electrical circuit. function.
11. If the rotor hub nut was removed, apply
14. Install covers.
thread-locking compound (P/N 990-462)
to the threads on the rotor hub nut. Install
the rotor hub nut on the rotor hub. Torque
to 25 ft. lb. (35 Nm).

Make sure the brake release bolts are

removed before placing the lift truck
back into service. If the brake release
bolts are not removed, the brake will
not work correctly.

12. Reconnect the battery connector and turn

the key switch ON.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Drive Wheel

Drive Wheel Drive Tire Replacement

Removal
Any misalignment of the tire and hub
1. Turn the steering wheel all the way to the while the tire is being pressed onto the
right so you can access the drive wheel hub can damage the hub. For this
mounting bolts. reason, chamfers are provided on the
2. Turn the key switch OFF and disconnect outside edge of the hub and on the end
the battery connector. of the inside diameter of the tire’s metal
insert. The chamfers help to center the
hub and tire during the pressing
operations and reduce the possibility of
misalignment. To prevent damage, the
Use extreme care when the lift truck is
hub must be installed on the circular
jacked up. Never block the lift truck
ram with its chamfered side up.
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an
overhead hoist to stabilize the mast if Outside of Hub
jacking higher than described in the and Tire Assembly
Jacking Safety section. Keep hands and
feet clear while jacking the lift truck.
After the lift truck is jacked, place solid New Tire
blocks or jack stands beneath it to
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the
jack or jack stand alone to support the Worn Tire
lift truck. See Jacking on page 2-9.

3. Jack and block lift truck under the tractor

frame. Circular Ram
4. Remove the bumper plate.
5. Remove the drive wheel mounting bolts. Press Table
7
6. Remove the drive wheel.
Figure 7-140. Drive Tire Installation

Installation 1. Check the inside surface of the metal

insert on the new tire. Use sandpaper to
1. Install the drive wheel on the drive wheel remove any scaling or rust. Clean the
shaft. inside of the metal insert and lubricate it
2. Install the drive wheel mounting bolts. with a soap solution.
Torque to 170 ft. lbs. (230 Nm). 2. Place a circular ram on the press table.
3. Install the bumper plate. See Figure 7-140. The length of the ram
4. Remove the block and lower the tractor must be longer than the width of the old
with a jack. tire to allow complete removal of the old
tire. The outside diameter of the ram must
5. Reconnect the battery connector and turn be small enough to fit loosely in the insert
the key switch ON. Test the lift truck of tire but must be large enough to rest
operation before returning to service. squarely on the flat surface on the outer
edge of the hub.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Drive Wheel

3. If the outside edge of the hub is not flush

with the edge of the metal insert in the old
tire, measure how far the hub is recessed
inside the tire. The new tire must be
placed in the same position the old tire
was installed on the hub. You can use a
spacer (slightly smaller in diameter than
the inside diameter of the tire insert and
the same thickness as the depth of the
recess) to obtain the correct amount of
recession.
4. Position the hub assembly with the old tire
on top of the circular ram so the outside of
the wheel is positioned upward. The
outside edge of the hub has a chamfer to
help guide the new tire onto the wheel. The
chamfered edge must always be the
leading edge when a tire is pressed onto
the hub.
5. Center the hub assembly on top of the ram
and make sure that they mate squarely.
6. Position the new tire with its chamfered
insert facing the hub. Align the new tire
and hub so that they are concentric.
7. Begin pressing the new tire onto the hub
and the old tire off the wheel. Run the
press slowly for the first few inches of
travel, because this is the critical stage of
the operation. If the tire begins to cock to
one side, stop the press and realign the
tire. A sharp jar with soft-headed mallet
usually realigns the tire on the hub.
NOTE: If the new tire does not press on with a
minimum of 5 tons (68,947 kPa) of
pressure, replace the hub.
8. Release the press. Remove the wheel, tire
assembly, and old tire from the press
table. Inspect the wheel and tire assembly.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Electrical Components

Electrical Components
Section 7. Component Procedures

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Battery Procedures Electrical Components

Battery Procedures touching and causing a short circuit.

Do not allow the metal cable end to
touch the battery. Use insulated tools
and avoid contact with the battery case
or cable ends.
Before working on the battery, review
1. To remove a cable from the connector,
“Battery Safety”, beginning on
push the retainer down while pulling the
Page 2-5. Batteries for this lift truck
battery cable towards the rear and out of
weigh between 1980 and 3250 lb. (898
the connector. See Figure 7-141 and
to 1475 kg). Use extreme care during
Figure 7-142.
replacement. Use a suitable battery
moving device or hoist for lifting.
Do not extend a battery more than 1/3
of its length outside the battery
compartment without being attached to
a battery-moving device.

Battery Connector/Cables
Inspection
1. Turn the key switch OFF and disconnect
the battery connector.
2. Check the battery connector for damaged
cables.
3. Check to see if the battery cables are
pulling out of the connector.
Figure 7-141. Battery Cable and Connector
4. Check the cables at the battery terminals.
Connections should be tight, with no
corrosion.
5. Look inside the connector. Check all
internal contacts for damage, dirt, or
corrosion. Do not use a metal object to
clean the connector.
NOTE: Some degreasers and parts cleaners
cause the connector shell to
disintegrate. Avoid contacting battery
connectors with solvents.

Removal, Replacement, and

Installation

The cables to either half of the connector have a

lip on their forward end. This lip snaps over a
spring-loaded retainer that is part of the Figure 7-142. Battery Cable Removal from Connector
connector.
NOTE: When replacing battery cable ends, 2. Do not attempt to repair battery cables by
remove only one end at a time from the crimping new terminals. Replace the
connector, to avoid the cable ends cable.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Electrical Components Battery Connector/Cables

Battery Exterior Cleaning 6. Wash dirty batteries (or any that have had
electrolyte spilled on them) with a solution
1. Read, understand, and follow procedures, of 1 lb. (0.45 kg) of baking soda added to
recommendations, and specifications in 0.5 gal. (1.9 liters) of hot water.
the battery and battery charger
manufacturer’s manuals. 7. Use a brush with flexible bristles to clean
the entire top of the battery with the soda
solution. Wait until all foaming stops,
indicating that the battery exterior is
neutralized.
8. Rinse the battery with clean water.
9. Dry the battery completely before
reinstalling it.
10. Reinstall the battery in the lift truck, using
a suitable battery moving device.
2. Wear personal protective equipment. See Reconnect the battery connector.
“Battery Safety” on page 2-5.
3. Turn the key switch OFF and disconnect Testing, Charging, and Maintenance
the battery connector. Remove the battery
from the lift truck. For information on testing, charging, and
maintaining your lift truck battery, consult the
4. Inspect the battery cables to make sure battery manufacturer’s specifications and
they are not frayed or loose. Inspect the instruction manual.
battery connector to make sure there is no
foreign material inside the connector. NOTE: Never plug the battery charger into the
Make sure the filler plugs are tight and the lift truck. This severely damages the lift
vent holes in the filler plugs are open. truck’s electrical system. Plug the
charger only into the connector from the
battery.
Battery Cable

Filler Plug
Vent Hole
Battery State-of-Charge
Figure 7-143. Battery Cable and Filler Plug
Battery State-of-Charge (BSOC) is a feature that
5. Keep the top of the battery clean and dry. monitors and remembers the charge level of the
Corrosion, dust, and moisture provide a battery connected to the lift truck and prevents
conducting path to short-circuit cells or excessive discharging of that battery. Operating
create shorts to ground. a lift truck using a discharged battery can
NOTE: Do not clean the top of the battery with damage both the battery and the electrical
the soda solution while it is installed in components of the lift truck. See page 5-5 for a
the lift truck. Water can seep into the detailed description of how BSOC works.
electrical components and cause serious
damage.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Power Cables Electrical Components

Power Cables Table 7-4. Cable Jacket Strip Length - Short Barrels
AWG Lug P/N Strip Length
Check power cables for: 1/0 1002215/001-004 11/16 in. (17 mm)
• evidence of overheating 2/0 1002215/005-008 13/16 in. (21 mm)
• burned spots in the cable
3/0 1002215/009-012 1 in. (25 mm)
• nicks in the insulation
4/0 1002215/013-015 1-1/16 in. (27 mm)
• damaged or overheated terminal lugs
• damaged mounting hardware or brackets Table 7-5. Cable Jacket Strip Length - Long Barrels

Replace damaged cables or mounting hardware AWG Lug P/N Strip Length
as necessary. 1/0 1002217/001-003

Power cables are marked on the terminal lug 2/0 1002217/004-006 1-9/16 in. (40 mm)
with the location where they belong. If the
3/0 1002217/007-009
marking is missing or is not readable, remark
the cable with the correct information. 4/0 1002217/010-011 1-11/16 in. (43 mm)
NOTE: Terminal lugs may be replaced in the
field using the appropriate crimping 5. Insert the cable into the terminal.
tools. Crimping tool, lugs, and 6. Place the cable and terminal into the tool
heat-shrink are available through the die and crimp. Refer to Figure 7-144 and
Parts Distribution Center. Failure to use Figure 7-145 on page 7-71.
correct cables, terminal hardware, and
torque values can result in overheating
and damage to components.

Power Cable Repair

Traditional lug crimping techniques for power
cables on DC motors may not meet the higher
current requirements of AC motors. Use the
Manual Crimp Tool (P/N 1069861) when
crimping power cables for all AC motors. This
tool may also be used to repair power cables for
DC motors.
1. Remove the bad cable(s).
2. Using the removed cable(s) for reference,
cut an appropriate amount of replacement
cable of the same gauge.
Figure 7-144. Short Barrel Terminal
3. Set the adjustment screw on the manual
crimp tool head to match the cable gauge.
4. Strip the cable jacket to fit the terminal to
be crimped. Refer to Table 7-4 and
Table 7-5.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Electrical Components Power Cable Repair

Figure 7-145. 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 5300/5500/5600 Maintenance Manual

Motors Electrical Components

Motors DC Motor Service

Motor Brushes
General
Inspection
Power Cable Terminals
Table 7-6. 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. Figure 7-146. Motor Brush Location

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 5-11.
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 5-15. whether a brush must be changed or if it
can wait until the next inspection. Refer to
Table 7-7, “Minimum Brush Length and
Spring Tension,” on page 7-74 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 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Electrical Components DC Motor Service

2. Check brush spring tension. Refer to 4. Remove the sandpaper.

“Motor Brush Spring Tension”. 5. Blow any dust out of the motor with clean,
3. Clean brushes and holders. Wipe the compressed air at a maximum of 30 psi
commutator with a dry, lint-free cloth. Do (207 kPa).
not use lubricants of any kind on or
around the commutator. Motor Brush Spring Tension
4. Check brush holders for a solid connection
to the mounting support. Tighten the Inspection
mounting screws as necessary. 1. Turn the key switch OFF and disconnect
5. Check the cap screws that hold the brush the battery connector.
cross-connectors to the brush holder 2. Remove the tractor covers.
body.
3. Slide the brush up slightly in its holder.
6. Make sure the motor terminals are
secured tightly to the motor frame. Use 4. Insert a paper strip between the brush
care not to strip the threads or crush the face and the commutator. See
insulating parts. See “Power Cable Figure 7-147.
Terminals” on page 7-72.
7. Check all the cap screws around the frame Spring Scale
for tightness.
8. Keep the outside frame of the motor clean
and free from dirt. Maintain a free air
passage around the motor to permit heat
radiation.

Replacement
NOTE: If one brush needs replacement, always
replace the entire set of brushes. Leather
Loop
Use only genuine Raymond brushes. Using
another type of brush could cause damage to
the commutator or cause excessive brush wear
and voids your warranty.
Paper
If the end of the brush is not already contoured
to fit the commutator, seat the brush to the
commutator:
NOTE: If the motor commutator is not
accessible, form the brush contour
Rotation
using a brush seating stone.
Pull paper in direction of rotation
1. Move the motor brush springs out of your
way. Figure 7-147. Motor Brush Spring Tension Inspection
2. Wrap a piece of 00 sandpaper around the
commutator. Do not use emery cloth to 5. Place a small leather loop around the coil
seat brushes. spring for the brush. If the brush spring
has a loop at the brush, hook the spring
3. Move the brushes back down into their scale directly to the spring.
holders. Rotate the armature until the face
of the brushes are contoured to match the 6. Attach a 5 lb. (2.27 kilogram) spring scale
curve of the commutator. to the leather loop.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Polishing the Commutator Electrical Components

7. While gently pulling the scale outward, 4. Using minimal pressure, run the stone
slowly pull the paper strip in the direction back and forth across the commutator
that the commutator normally rotates. until it is polished. Do not pass the stone
8. When the paper strip begins to move over the ends of the commutator
freely, the spring scale will read the brush segments.
spring tension. 5. Thoroughly blow out the motor with
9. Refer to Table 7-7 for correct spring compressed air.
tension. 6. Inspect the commutator. Reinstall the
10. Repeat steps 3 through 9 for the armature or brush and any removed
remaining brushes. covers.
Table 7-7. Minimum Brush Length and Spring Tension 7. Check operation.

Min. Brush Brush Spring

Motor
Length Tension

0.62 in. 40 to 65 oz.

Lift (15.7 mm) (1134 to 1842
grams)

0.50 in.
Steer N/A
(13 mm)

Polishing the Commutator

NOTE: Wrap the stone with narrow (1/2 to 3/4
inch wide) masking tape in a spiral
configuration. Leave only enough stone
exposed to make contact with the
commutator. As the length of the stone
becomes shorter with use, peel back and
remove portions of the tape.

Make sure loose clothing and hair are

tied back. Do not wear jewelry. Wear
insulated gloves to protect your hands
during this procedure.

1. If the motor has four or more brushes,

remove an accessible brush from the
motor with the motor still installed in the
truck. If the motor only has two brushes or
the commutator is not accessible with the
stone, the armature must be installed in a
lathe or replaced. If so, go to step 4.
2. Activate the motor.
3. With the motor turning, carefully insert
the commutator stone into the brush box
area.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Electrical Components AC Motor Service

AC Motor Service 8. Install the top end bell in the position that
was previously marked. Verify correct
stator installation and install the snap ring
AC Motor Temperature Sensor using snap ring pliers.
9. Secure the top end bell to the bottom end
Temperature sensors in the AC traction and lift bell using the four bolts previously
motors are integral to the motor. When a motor removed.
temperature sensor fails, it can be replaced 10. Install the brake mounting motor flange
using the procedures below. with new mounting bolts.
11. Re-install the brake assembly including
Traction Motor Replacement: the rotor hub mount and rotor hub.
1. Turn the key switch OFF and disconnect 12. Check the brake adjustment. See “Brake
the battery connector. Adjustment” on page 7-61.
2. Remove the brake assembly including the 13. Install the terminal board, reconnect
rotor hub nut and rotor hub. Note the JPTA3, and power cables. Torque the
number of spacers used. motor cable securing nuts to 18 ft. lb. (24
• Disconnect the temperature sensor Nm).
connector JPTA3. 14. Reconnect the battery connector and turn
• Disconnect the power cables making the key switch ON.
sure that you note locations for
reassembly later. Lift Motor Replacement:
• Remove the terminal board. 1. Turn the key switch OFF and disconnect
the battery connector.

Use correct electrostatic discharge

precautions. See “Static Precautions” on Use correct electrostatic discharge
page 2-8. precautions. See “Static Precautions” on
page 2-8.
3. Mark the position of the top end bell and
bottom end bell relative to the stator, then 2. Disconnect the temperature sensor
remove the snap ring using snap ring connector JPLA3.
pliers.
3. Disconnect the cables and motor harness
4. Remove the brake mounting motor flange. connections, making sure that you note
NOTE: Use new flange mounting bolts when locations for reassembly later.
reassembling. 4. Separate the pump assembly from the lift
5. Remove the four bolts that secure the top pump motor and remove the lift pump
end bell to the bottom end bell. motor. See “Lift Pump and Motor” on
page 7-96.
6. Remove the top end bell using a puller.
Use care that the encoder bearing remains 5. Remove the four bolts that secure the top
in the bottom end bell to reduce the end bell to the bottom end bell.
chance of damaging the bearing. 6. Remove the top end bell. Use care that the
7. Install a new temperature sensor using bearing remains in the bottom end bell to
high temperature silicone (neutral curing). reduce the chance of damaging the
Mount the sensor close to the location of bearing.
the original. Secure the cable with a cable
tie to one of the power leads for stress
relief.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

AC Motor Service Electrical Components

7. Install a new temperature sensor using the 5. Remove the nut that secures the pinion
high temperature silicone (neutral curing) gear. Remove the gear and key using a
supplied with the temperature sensor. suitable puller.
Mount the sensor close to the location of 6. Mark the position of the top end bell and
the original. Secure the cable to one of the bottom end bell relative to the stator, then
power leads with a cable tie. remove the snap ring using snap ring
8. Carefully press the top end bell to the pliers.
stator. Do not pinch the cables or allow 7. Remove the brake mounting motor flange.
contact with the rotor. Verify correct stator
installation. NOTE: Use new flange mounting bolts when
reassembling.
9. Secure the top end bell to the bottom end
bell using the four bolts previously 8. Remove the four bolts that secure the top
removed. end bell to the bottom end bell.
10. Reinstall the lift motor to the lift pump 9. Remove the top end bell and bottom end
assembly. bell using a puller.
11. Reconnect JPLA3, and power cables. 10. Remove the clamps that secure the
12. Reconnect the battery connector and turn encoder bearing cable.
the key switch ON. 11. Remove the encoder bearing from the rotor
using a suitable puller, pulling on the
outer race only.
AC Motor Bearing Encoder
12. Remove the oil seal to allow pressing of the
bottom end bell to the stator for later
Traction Motor Replacement:
reassembly.
1. Turn the key switch OFF and disconnect 13. Make sure that the O-ring and wave
the battery connector. washer are correctly positioned in the
2. Remove the brake assembly including the bottom bell bearing pocket.
rotor hub nut and rotor hub. Note the 14. Position the new encoder bearing in the
number of spacers used. bottom end bell with the cable oriented in
• Disconnect the temperature sensor the middle of the notch in the side of the
connector JPTA3. bearing pocket.
• Disconnect the bearing encoder 15. Use an assembly bushing on the outer
connector JPTA2. race and press the bearing into place. Do
not press on the encoder part of the
• Disconnect the power cables making
bearing.
sure that you note locations for
reassembly later. 16. Re-install the encoder bearing cable
• Remove the terminal board. clamps.
17. Install the top end bell in the position that
was previously marked. Verify correct
stator installation and install the snap ring
Use correct electrostatic discharge using snap ring pliers.
precautions. See “Static Precautions” on
18. Carefully press the bottom end bell to the
page 2-8.
stator.
3. Remove the steering position reference 19. Secure the top end bell to the bottom end
bracket. bell using the four bolts previously
removed. Re-install the oil seal.
4. Remove the traction motor. See “Traction
Motor” on page 7-28. 20. Install the key, pinion gear, and nut to the
bottom of the traction motor. Re-install the

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Electrical Components AC Motor Service

traction motor. See “Traction Motor” on 9. Carefully press the top end bell to the
page 7-28. stator. Do not pinch the cables or allow
21. Install the brake mounting motor flange contact with the rotor. Verify correct stator
with new mounting bolts. installation.

22. Re-install the brake assembly including 10. Secure the top end bell to the bottom end
the rotor hub mount and rotor hub. bell using the four bolts previously
removed.
23. Check the brake adjustment. See “Brake
Adjustment” on page 7-61. 11. Install the lift motor and reconnect the lift
pump assembly. See “Lift Pump and
24. Install the terminal board, reconnect Motor” on page 7-96.
JPTA2, JPTA3, and power cables. Torque
the motor cable securing nuts to 18 ft. lb. 12. Reconnect JPLA2, JPLA3, and the power
(24 Nm). cables.

25. Re-install the steering position reference 13. Reconnect the battery connector and turn
bracket and filler tube if previously the key switch ON.
removed.
26. Reconnect the battery connector and turn
the key switch ON.

Lift Motor Replacement:

1. Turn the key switch OFF and disconnect
the battery connector.

Use correct electrostatic discharge

precautions. See “Static Precautions” on
page 2-8.

2. Disconnect the bearing encoder sensor

connector JPLA2.
3. Disconnect connectors JPLA2, JPLA3,
cables, and motor harness connections,
making sure that you note locations for
reassembly later.
4. Separate the pump assembly from the lift
pump motor and remove the lift pump
motor. See “Lift Pump and Motor” on
page 7-96.
5. Remove the four bolts that secure the top
end bell to the bottom end bell.
6. Remove the top end bell using a suitable
puller.
7. Remove the encoder bearing from the
rotor, pulling on the outer race only.
8. Install the new encoder bearing by
applying steady pressure to the inner ring.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Power Amplifiers Electrical Components

Power Amplifiers 2. Position the power amplifier and install the

four mounting screws.
NOTE: If the power amplifier being removed is 3. Tighten the mounting screws to 7.4 ft. lb.
to be returned to stock, a power (10 Nm).
amplifier reset must be performed. See
page 3-24.
Do not attempt to repair power cable
Removal terminal lugs without approved tools. If
a power cable has worn or damaged
lugs, either replace the cable or replace
the lugs. Refer to “Power Cable Repair”
on page 7-70. Failure to use correct
Before removing a power amplifier, cables, flanged nuts, and torque values
discharge the amplifier’s internal can result in overheating and damage to
capacitor by jumpering the + and – components.
terminals with a 100 ohm 25W resistor.
4. Reconnect the power cables to the correct
1. Turn the key switch OFF and disconnect terminals. Torque to 85 to 94 in. lb. (9.6 to
the battery connector. 10.6 Nm).
2. Disconnect JT1 from the power amplifier.
NOTE: When correctly torqued, the cable and
3. Disconnect the power cables from the terminal can rotate up to 5° in either
power amplifier. direction.
4. Remove the four mounting screws. 5. Reconnect JT1.
5. Lift the power amplifier off the mounting 6. Reconnect the battery connector and turn
plate. the key switch ON.

75077_037.TIF

Figure 7-148. Traction Power Amplifier

Installation
1. Install new thermal conductive material
(provided with new power amplifier)
between the base of the power amplifier
and the heatsink.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Electrical Components Horn

Horn
NOTE: For replacement parts information refer
to the Parts Manual.

Horn Removal
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the tractor cover.
3. Disconnect the wires from the horn.
4. Remove the horn mounting bolt.

Horn Installation
1. Attach the horn to the floor of the tractor
frame and tighten the mounting bolt. See
“Horn” on page 7-6 for location. Make sure
the horn bracket is isolated from the lift
truck frame.
2. When replacing an old style three prong
horn with a new style two prong horn,
install 0.5 in. (12.7 mm) heat shrink
tubing over the unused spade connector.
3. Connect the Horn (+) and Horn (-) wires to
the new horn.
4. Fasten the unused wire back to the
harness using a cable tie or equivalent.
5. Reconnect the battery connector and turn
the key switch ON.
6. Test the horn operation.
7. Install the tractor cover before returning
the lift truck to service.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Carriage Control Card Replacement Electrical Components

Carriage Control Card 3. Reset all of the information in the

Configure Menu to the customer’s
Replacement specifications.
4. Run the complete Learn process.

Observe proper ESD precautions. See

Static Precautions on page 2-8.

The CCC stores specific lift truck information.

See Figure 7-149. This information includes
Model Number, Serial Number (S/N), Date of
Manufacture, Hour Meters, and a list of enabled
Options. A backup copy of this information is
also stored in the VM.

7vvv

Figure 7-149. Carriage Control Card

If a blank CCC is installed, the information

from the VM is uploaded to the CCC. A
Pre-programmed CCC must be ordered and
installed any time the Error Code corrective
actions tells you to or if the CCC and VM are
being replaced at the same time.
1. On lift trucks without the 60 in. limit
switch option, a jumper/resistor assembly
must be installed at JPC3. Remove the
assembly from the original CCC and
install it on the new one.
2. Enter Configure Mode and verify the lift
truck S/N stored in the CCC matches the
S/N on the lift truck Specification Tag. If
not, a new pre-programmed CCC must be
obtained and installed prior to operating
the lift truck.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Electrical Components Wiring and Harness Repair

Wiring and Harness When replacing wires, follow these guidelines:

• Use the appropriate tools to remove and
Repair insert terminations at each connector.
• Remove damaged terminations and
discard. Never reuse a termination from a
General Connector Repair wire.
Procedures
• Do not cut away a terminal lug and reuse
the wire strands that were crimped into
Inspection the original lug.

Whenever working on the lift truck, use care • When stripping wire, use new wire strands
around wiring harnesses. for new terminations. Make sure to use a
new wire with extra length to allow for
• Carefully connect and disconnect all cutting and stripping of the ends to install
connections. new terminations.
• Do not pry connectors apart with • Use a new wire that is the same gauge
unspecified tools. (typically gauge 18 AWG), size, type, and
color as the wire it is replacing.
There should be a wire marker at each
termination. If the marker is missing or • Use a hand stripper capable of stripping
unreadable, remark the wire to allow easier by wire gauge number. Use care not to
identification. nick or cut any of the wire strands.
Discard and replace a wire with damaged
NOTE: It is normal to find unused connectors strands. Insert the wire strands the
for uninstalled options that have had correct length into termination before
heat shrink applied over them and have crimping.
been strapped to the harness.
Soldering Procedures
Repair
To prevent damage from excessive heat when
soldering small components in assemblies,
follow these guidelines:
Use correct electrostatic discharge
• Make sure the soldering tip is clean. A
precautions. See “Static Precautions” on
dirty tip does not transfer heat well and
page 2-8.
encourages long dwell time and greater
pressure. Apply light pressure on the
When pulling a wire out through a bundle, cut
terminal.
off the pin or socket so it does not snag. When
replacing wires, in some cases you can tape or • Flux: rosin base
solder one end of a new wire to one end of the • Solder: 60/40 rosin core or equivalent
failed wire. Then you can pull the old wire out of
• Solder Iron: 15-25 watt “pencil-type”
the bundle and pull the new wire into the
maximum
bundle, all at the same time. Make sure to
disconnect the old wire from the new wire. • Tip Size: 3 mm (0.118 in.) diameter x
30 mm (1.182 in.) long screwdriver tip.
In other cases, it is easier to secure a new wire Make sure the tip is clean.
to the outside of the existing wire bundle with • After soldering, clean the terminals with a
cable ties of an appropriate size. The failed wire brush dampened with an alcohol based
can be left in the bundle, or can be pulled by cleaner. Do not allow any cleaner to seep
one end to remove it from the bundle. into the switches or potentiometers, or
contact contamination may occur.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Molex Connectors Electrical Components

Molex Connectors Pin Extraction

Molex connectors have pins with locking ears To remove a pin from a Molex connector, use
that engage ridges in the plastic connector the pin extraction tool (P/N 950-026). See
body. See Figure 7-150. Figure 7-151.
1. Insert the extraction tool over the pin and
Pin
push all the way into the connector. This
releases the locking ears on the pin.
2. Pull the wire and pin from the connector.
Socket
Pin Insertion
1. To insert a pin into a Molex connector,
insert the pin into the back side of the
connector and push the wire all the way in
until it clicks.
Locking Ears
2. The locking ears have now engaged the
Figure 7-150. Molex Connectors - End View connector.

To remove a pin from a Molex connector, these

locking ears must be pressed far enough to
clear the ridge in the connector.

Tool Inserted Over Pin

Top View

Locking Ears

Extraction Tool

Side View

Figure 7-151. Pin Extraction Tool

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Electrical Components AMP Water-Resistant Connectors

AMP Water-Resistant
Connectors
AMP connectors provide water-resistant
connection by the use of seals between wires
and connectors and between the mating
connector halves. See Figure 7-152.

Wire Seal

Interface
Seal
Contact
Cavity

Wire Seal Jack

Housing

Pin Contact

Pin Housing

Sealing Plug

Figure 7-152. AMP Water-Resistant Connector

Extraction Tool
To maintain the integrity of water-resistant
seals, use the following procedures when
working with AMP connectors.

Pin Extraction

To aid in separating AMP connectors, use an

unlatching tool (P/N 950-042). To remove a pin
from an AMP connector, use a pin extraction
tool (P/N 950-009).
1. While holding the wire seal, push the Locking
selected wire forward, then insert the Lance
extraction tool into the contact socket. See
Figure 7-153. Figure 7-153. AMP Pin Extraction

2. Pull the wire gently until you feel the

contact locking lances disengage.
3. Holding the wire seal and connector
housing together, rotate the wire while
pulling it through the wire seal. This
prevents damage to the seal. See
Figure 7-154.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

AMP Water-Resistant Connectors Electrical Components

Rotate and Pull

Pin Contact
Figure 7-154. Removing Wire

Figure 7-156. Wire Insertion

Pin Insertion
1. Make sure the connector has a wire seal Seals
attached to the connector back. See
Figure 7-155. 1. Use a wire seal at the back (wire end) of
each connector half. See Figure 7-155.
2. Plug unused pin positions with sealing
Wire Seal
plugs. See Figure 7-157.
3. Align the split tapered end of the sealing
plug with the unused opening in the wire
seal. Push the plug through the wire seal
into the connector until it snaps into
position.
4. Remove sealing plugs by pulling with
Pin Housing
needle-nose pliers while grasping the wire
seal and connector.
Figure 7-155. Wire Seal
Sealing Plug
2. If re-inserting a wire previously removed,
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 7-156.

Figure 7-157. Sealing Plug

5. Use an interface seal between pin and jack

halves of the connector. To prevent
damage to the seal, use the matching
connector cap to slide the interface seal

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Electrical Components AMP Water-Resistant Connectors

over the contact silos on the pin housing.

See Figure 7-158.

Interface Seal

Pin Housing

Figure 7-158. Interface Sea

6. When mating connectors, make sure

polarized silos are correctly oriented. Push
pin and jack halves of the connector
together until locking latches engage. See
Figure 7-159.

Locking
Latches

Figure 7-159. Latching AMP Connector

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

AMP Harness/Traction Power Amplifier Connector Electrical Components

AMP Harness/Traction Power

Amplifier Connector
Connector Components
Plug and Header Assembly
Colors are Mechanically Keyed to Header Assembly
Mate Only with Identical Colors

Mating Seal

Plug Assembly

Retention Leg

Wedge Lock

Housing
Figure 7-160. Power Amp Connector Components Contact Insertion

The axial concentricity of the crimped contact

Disassembly (Contact Removal) must fall into an area defined by a 2 mm
diameter cylinder whose center is the centerline
1. Insert a 4.8 mm screwdriver blade between of the contact front end. See Figure 7-162.
the mating seal and one of the red wedge
lock tabs. See Figure 7-160.
Assembly
2. Pry the wedge lock to the open position.
3. While rotating the wire back and forth over Make sure the wedge lock is open.
a half turn (1/4 turn in each direction), 1. To insert a contact, push it straight into
gently pull the wire until the contact is the appropriate circuit cavity as far as it
removed. See Figure 7-161. goes. See Figure 7-162. (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 7-162. (c).

Wedge
Lock
Tab

Figure 7-161. AMP JPT1 Connector

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Electrical Components AMP Harness/Traction Power Amplifier Connector

Contact Wire Seal Retention

(Partially Fingers
Inserted)
Centerline
of Circle
and
Contact

2 mm Diameter

Diaphragm Wedge Lock

Mating Seal
(Shown in Open
Position)

(a)

(b)

(c)
Pull Back
on Wire
Retention Fingers
Holding Contact

Figure 7-162. Contact Insertion

3. After all contacts are inserted, close the

wedge lock to its locked position. Release Be very careful when putting the wedge
the locking latches by squeezing them lock in the locked position. Forcing the
inward. See Figure 7-163. wedge lock can cause damage to the
connector. Make sure the wedge lock is
aligned correctly. If resistance is felt,
slightly adjust the wedge lock until it
slides in freely.

4. Slide the wedge lock into the housing until

it is flush with the housing. See
Figure 7-164.
Squeeze Locking
Latches to Seat
Wedge Lock
(Both Sides)
Figure 7-163. Wedge Lock Latches

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

AMP Harness/Traction Power Amplifier Connector Electrical Components

Wedge Lock
Flush with
Housing

Figure 7-164. Wedge Lock Flush With Housing

Testing

Do not pierce wire insulation with a sharp point

while troubleshooting.

The wedge lock has slotted openings in the

forward (mating) end. These slots accommodate
circuit test tabs that are approximately 3.3 by
0.6 mm and prevent damage to the receptacle.
For circuit testing in the field, use a flat probe
such as a pocket knife blade. Do not use a
probe with a sharp point.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Hydraulic Components

Hydraulic Components
Section 7. Component Procedures

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Flow Sensor Service Notes Hydraulic Components

Flow Sensor Service to make sure the pickup functions

correctly.
Notes 7

Servicing of the hydraulic flow sensor is limited J22 not visible in photo
to checking the turbine assembly inside the
hydraulic flow sensor for cleanliness and Flow Sensor
freedom of movement.
NOTE: The flow sensor is electrically isolated
from the lift truck chassis with
insulating material and orange
non-conductive hydraulic hose. Be
careful that the connector plugs do not
cause shorts between the body of the
flow sensor and the lift truck chassis.

J21

The flow sensor must be electrically

isolated. When servicing the flow
sensor, make sure there is at least 2
megohm resistance between the body of
the flow sensor and the lift truck chassis
with JPY6 and JPY7 disconnected from
the flow sensor pickups.

Make sure the connectors are reconnected to

the correct pickup. Identify connector
placement for correct reassembly. See
Figure 7-165. Figure 7-165. Flow Sensor

O-Ring Replacement
1. To make sure of correct alignment during
reassembly, use a pencil to mark the block
and pickup on the small black nut, the
large gold nut and the main block in a
straight line.
2. Remove the assembly by unscrewing the
large gold nut closest to the main block.
Make sure the small black nut does not
turn in relation to the large gold nut or the
calibration of the pickup is altered.
3. Remove the bad O-ring and install a new
one.
4. Install the pickup back into the main
block and tighten the large gold nut. Make
sure the marks made in step 1 are aligned.
5. Run Test I26 - Flow Sensor Count
(Without Full Height Sensing) (Page 6-86)

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Hydraulic Components Disassembly

Disassembly
Flow
Disassemble the flow sensor in a clean area to Snap Turbine Sensor
Ring
prevent contamination from entering the
turbine section of the flow sensor.
1. Remove the snap ring from the inlet port
using snap ring pliers. See Figure 7-166.

Figure 7-168. Turbine Assembly Removed

3. With the turbine assembly removed,

inspect the turbine blades for damage
and/or for debris that may have become
entangled around the turbine. If the
turbine is damaged, the entire assembly
must be replaced.
4. Wash the turbine assembly in clean
mineral spirits (or equivalent) and shake
dry.
7

Figure 7-166. Snap Ring Removal

2. Use a soft object (like the eraser end of a Do not use compressed air to dry the
pencil) to carefully push the turbine turbine. Compressed air may
assembly out of the sensor body from the over-speed the turbine, damaging the
outlet end. See Figures 7-167 and 7-168. bearing surfaces.

5. With the longer section of the turbine

assembly pointed up, compress the
turbine shaft and spin the turbine using
your fingers. The turbine should spin
freely for several seconds without
chattering. If the turbine does not spin
freely, the entire flow sensor assembly
must be replaced.

Figure 7-167. Removing Turbine Assembly

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Assembly Hydraulic Components

Assembly
1. Reinstall the turbine assembly in the body
of the sensor so that one of the vanes of
the straightening section is between two
stake marks located in the turbine bore.
See Figure 7-169.

Stake Marks

Vane Positioned
Between Stake
Flow Sensor
Marks as Shown

Figure 7-169. Reinstalling Turbine Assembly in Flow Sensor

2. Use a soft object (like a pencil eraser) to

press the turbine assembly into the flow
sensor body. Reinstall the inlet snap ring
using snap ring pliers.
3. Reinstall the flow sensor in the lift truck.
4. Bleed the hydraulic system and refill the
reservoir. Check for leaks.
5. Run Learn. See Learn Hgt/Wgt on
page 3-19.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Hydraulic Components High Pressure Relief Valve Adjustment

High Pressure Relief

Valve Adjustment
1. Install a calibrated pressure gauge
(3000 psi/20,682 kPa) in the test port. See
Figure 7-170.
2. Back-out the high pressure relief.
3. Make sure that the Emergency Lower
Valve is closed.
4. Place a rated load plus 200 lb. (90.7 kg) on
the forks.
5. Start the lift system and turn the pressure
relief screw clockwise until the platform
starts to lift. Note the pressure required
when the platform starts to elevate.
Continue lifting until the third stage of the
mast starts lifting. Record the pressure
reading.
6. Lower the platform and remove the weight.
7. Chain the mast sections together and lift
or lift against the stops.
8. Adjust the pressure relief valve to a
pressure 100 to 300 psi (689.4 to
2068 kPa) greater than the values
recorded in step 5.
9. Tighten the relief valve lock nut after the
adjustment is complete.
10. Check the lift system for correct operation.

Emergency
High Pressure Lower Valve
Relief Valve

Test Port

Figure 7-170. High Pressure Relief Valve Adjustment

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Lift/Lower and Load Holding Valves Hydraulic Components

Lift/Lower and Load 4. Inspect the sealing surface for

contaminants. Clean the surface as
Holding Valves necessary.
5. Lubricate O-rings with clean hydraulic
Use this procedure when it is necessary to fluid.
remove and install a lift/lower or load holding 6. Install the valve. See Figure 7-171.
valve.

When servicing hydraulic components,

keep the work area clean.
Contaminants can cause damage to the
hydraulic system.

1. Make sure the operator platform is

completely lowered.
2. Turn the key switch OFF and disconnect
the battery connector.
3. Remove the valve.

Tighten the valve cartridge 1/2 turn,

then loosen 1/4 turn. Continue this
sequence until a torque value of 120
to 150 in. lb. (13.6 to 17.0 Nm) is
achieved. (Tightening the valve in this
manner reduces the chance of
damaging the seal.)

20° to 30°

30 to 35 in. lb.
(3.38 to 3.95 Nm)
(4 places)

Tighten nut holding coil to 4 to 5 ft. lb. (5.6 to 7 Nm)

7
Figure 7-171. Lift/Lower and Load Holding Valves Installation

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Hydraulic Components Bleeding Lift Cylinders

Bleeding Lift Cylinders

Bleed the lift cylinders after maintenance or The bleed screw should only be
when operation indicates that air has entered loosened enough to allow the air to
the system (such as a bouncing operator escape.
platform).
3. When only oil flows from the cylinder,
tighten the bleed screw. Repeat the
Main Lift Cylinders process on the other cylinder.
NOTE: For lift trucks with an OACH of less than
107 in. (272 cm), see Figure 7-172. Free Lift Cylinder
To bleed the free lift cylinder:
1. Elevate the operator platform enough to
extend the free lift cylinder approx 3 in.
(7.6 cm).
2. Carefully loosen (do not remove) the bleed
screw located on the left side of the free lift
cylinder.

Figure 7-172. Main Cylinder Bleed Screw - Lift Trucks with

OACH of Less Than 107 in. (272 cm)

1. For lift trucks with an OACH above 107 in.

(272 cm), elevate the operator platform Figure 7-173. Free Lift Cylinder Bleed Screw
approx 3 in. (7.6 cm).
3. When only oil flows from the cylinder,
2. Carefully loosen (do not remove) the bleed tighten the bleed screw.
screw near the top of the main cylinder
just enough to bleed the air from the
cylinder.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Lift Pump and Motor Hydraulic Components

Lift Pump and Motor 10. Check the lift pump for leaks.

For 36V lift trucks, refer to “AC Motor Service”

Suction Hose
on page 7-75 for motor temperature sensor and
encoder bearing replacement procedures.

Removal
1. Turn the key switch OFF and disconnect
the battery connector. Motor

2. Clamp the suction hose closed. See

Figure 7-174.
3. Remove the two mounting bolts securing
the lift pump to the lift motor.
4. Carefully separate the pump from the
motor, taking care not to damage the
toothed spline. Pump
5. Remove the hydraulic fittings from the lift
pump.

Installation
1. Attach the hydraulic fittings to the pump.
2. Apply molybdenum anti-seize compound
(P/N 990-638) to the mating surfaces of
the lift motor spline and pump.
3. Apply thread-locking compound
(P/N 1013829) to the lift pump mounting
bolts.
4. Carefully mate the lift pump spline to the 7

lift motor and attach the lift pump to the Figure 7-174. Lift Pump and Motor
lift motor with the two mounting bolts.
Torque lift pump mounting bolts to 43 ft.
lb. (58 Nm) AC motors; 15 ft. lb. (20 Nm)
DC motors.
5. Unclamp the suction hose and add
hydraulic fluid to the reservoir if
necessary.
6. Reconnect the battery connector and turn
the key switch ON.
7. Adjust the high pressure relief valve. See
page 7-93.
8. Bleed the hydraulic system.
9. Test the lift function for smooth and
correct operation.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Hydraulic Components Main Lift Cylinder

Main Lift Cylinder 7. Remove the snap ring from the bottom of
the cylinder using snap ring pliers. See
Figure 7-176.
NOTE: A mirror enables you to see the snap
ring at the bottom of each cylinder
housing in the main lift cylinder
procedures.

Washer
Remove
1. Elevate the carriage just enough to access
the tubing connected to the bottom of the
main lift cylinder but not far enough to
extend the main cylinder. Block the Snap Ring
carriage.
2. Remove the tubing from the bottom block
on the cylinder that is to be removed. Cap
both the tubing and the fitting to the main 7

lift cylinder. Figure 7-176. Bottom View of Housing (Using Mirror)

8. Remove the bolt that attaches the cylinder

housing to the main frame of the lift truck.
Main Lift Cylinder
See Figure 7-177.

Hydraulic Tubing
Connector

Cylinder
7
Retaining
Figure 7-175. Hydraulic Connection, Main Cylinder, Bolt
Bottom

3. Unblock and lower the carriage to the

floor.
4. Remove the bolt in the top of the main lift 7

cylinder that connects it to the bracket on Figure 7-177. Main Cylinder

the mast.
5. Elevate the carriage until it clears the 9. Remove the main lift cylinder from the lift
cylinder assembly enough to allow cylinder truck.
removal.
6. Block the carriage. Installation
1. Install the cylinder in the lift truck.
2. Install the bolt that attaches the cylinder
housing to the main frame of the lift truck.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Cushion Service Hydraulic Components

3. Install the snap ring on the bottom of the 5. Pull the piston out of the housing. Place
cylinder housing using snap ring pliers. the piston on a cushioned stand. Do not
4. Unblock and lower the carriage enough to damage the piston surface.
collapse the other outer cylinder but still 6. Push the cushion into the piston at the
have access to the fitting at the bottom of base of the piston.
the cylinder.
5. Block the carriage. Connect the tubing to
the bottom of the cylinder.
6. Unblock and lower the carriage to the The cushion is under extreme pressure.
floor. Install the bolt in the top of the main Keep pressure on the cushion when
lift cylinder that connects it to the bracket removing the items in the next step.
on the mast. Failure to do so could cause injury from
projectile parts.
7. Bleed the hydraulic system. See Bleeding
Lift Cylinders on page 7-95.
7. Remove the snap ring using snap ring
8. Lift and lower the carriage completely to pliers, and retaining ring. See
check lift function. Figure 7-179.

Cushion Service Piston

Spring
1. Remove the cylinder from the lift truck.
See Main Lift Cylinder on page 7-97.
Seal Cushion
2. Remove the snap ring using snap ring
pliers, and wiper. See Figure 7-178.

Retaining
Adapter Ring
(Brass)

Snap Ring
Seal

Wiper Figure 7-179. Cushion, Removed

Retaining 8. Release the pressure on the cushion. Pull

Ring the cushion out of the piston. See
Figure 7-179.
Snap 9. Remove the spring.
Rings

Figure 7-178. Piston Removal

3. Remove the snap ring in the cylinder

housing using snap ring pliers.
4. Pull the piston until the piston stop
pushes the retaining ring, packing, and
adapter out of the cylinder.
See Figure 7-178.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Hydraulic Components Cleaning

10. Remove the seal from the cushion. 12. Install the spring. Make sure it is fully
seated in the cushion piston.
13. Install the cushion piston.
14. Install the retaining ring and snap ring
using snap ring pliers.
15. Install the cylinder in the lift truck. See
Main Lift Cylinder on page 7-97.
Cushion
1
2 Piston
3

Figure 7-180. Cushion Piston Seal Kit, Shown In Order of

Installation

Do not separate the piston from the

piston plug unless necessary. If 7

disassembly is required, use a strap Figure 7-182. Cushion Assembly

wrench only. Do not damage the piston
surface. Cleaning
NOTE: When repacking the cylinder, replace all 1. Flush the inside of the housing.
packings. See the Parts Catalog for 2. Wipe the piston with clean kerosene or a
packing kits. suitable industrial solvent.
11. Install the seal kit on the cushion piston. 3. Inspect all surfaces for galling or heavy
See Figure 7-180. scratches. Remove minor damage with a
fine emery cloth.
Tip: Twisting the fiber rings prior to installation
helps them retain their “memory.” See 4. Inspect all parts. Replace as necessary.
Figure 7-181.

Fiber
Ring

Figure 7-181. Twisting Fiber Rings

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Seal Repacking Hydraulic Components

Seal Repacking
1. Remove the cylinder. See Main Lift Ram
Cylinder on page 7-97. Housing

Adapter Service
(Brass) Service Driver
Guide

Seal

Wiper

Retaining
Ring 7

Figure 7-184. Using Cylinder Service Tools

Snap
Rings 5. Slide the brass adapter on the piston.
6. Install the piston assembly into the
7
housing.
Figure 7-183. Packing Components on Main Cylinder
7. Install the service guide. See Figure 7-184.
8. Dip the seal in oil and slide over the
piston, back first.
Do not damage the chrome plating on 9. Drive the seal into the assembly with a
the piston. service driver. See Figure 7-184.
10. Remove the service guide.
2. Remove the snap rings using snap ring
11. Install the packing backup ring.
pliers, seals, retaining ring, and brass
adapter. See Figure 7-183. 12. Install a snap ring using snap ring pliers.
3. Dip all packings in clean hydraulic fluid. 13. Install the wiper.
4. Lubricate the inside of the cylinder 14. Install a snap ring using snap ring pliers.
housing with hydraulic fluid. 15. Install the cylinder. See Main Lift Cylinder
NOTE: To prevent damage to packings at the on page 7-97.
top of the cylinder, use the following
tools:
• Service driver (P/N 401-000-050)
• Service guide (P/N 401-000-051)

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Hydraulic Components Free Lift Cylinder

Free Lift Cylinder Service of Cylinder with

Cushions
Removal Cushion Replacement
1. Remove the carriage. See Carriage on
Refer to Figure 7-187 on page 7-102 for the
page 7-106.
following steps.
2. Remove the snap ring, using snap ring
pliers. 1. Remove threaded end cap with Raymond
3. Remove the washer from the bottom of the tool (P/N 1090761/002). See
free lift cylinder. See Figure 7-185. Figure 7-186.
7

Snap
Ring

Washer

Figure 7-185. Free Lift Cylinder, Bottom View

Figure 7-186: Threaded End Cap, Side View
4. Remove and cap the hydraulic hoses.
2. Remove the top bearing.
5. Remove the U-shaped bracket.
NOTE: When the end cap is removed, a spring
6. Remove the free lift cylinder.
behind the top bearing may push the
bearing out of the housing.
Installation 3. Remove the spring and pressure ring.
1. Install the free lift cylinder. Make sure the 4. Remove the three staging screws located
bushing is on the mounting bolt. about 6 in. from the top of the housing.
2. Install the washer. 5. Remove the piston from the cylinder
3. Install the snap ring to the bolt under the housing.
free lift cylinder using snap ring pliers. See 6. Remove the cushion assembly.
Figure 7-185.
7. Coat the threads of the new cushion
4. Install the U-shaped bracket. assembly with thread-locking compound
5. Install the carriage. See Carriage on primer (P/N 990-666). Allow the primer to
page 7-106. cure a minimum of 1 minute.
6. Install the end cap and hydraulic hoses on 8. Apply thread-locking compound
the free lift cylinder. (P/N 990-575) on the internal threads of
the piston rod.
7. Reconnect the battery connector and turn
the key switch ON. 9. Start threading the cushion assembly into
the piston.
8. Bleed the hydraulic system. See Bleeding
Lift Cylinders on page 7-95. 10. Apply thread-locking compound
(P/N 990-575) on the external threads of
9. Test the lift function for smooth and
the cushion assembly.
correct operation.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Free Lift Cylinder Hydraulic Components

11. Continue installing the assembly into the 15. Lightly oil a new seal. Install the seal in
piston. the pressure ring. Check to make sure the
small orifice in the pressure ring is not
NOTE: Assemble components within 30
obstructed.
seconds of application as the
thread-locking compound begins to cure 16. Install the spring.
immediately. 17. Remove the bad parts from the top
12. Allow the assembly to cure a minimum of bearing.
10 minutes. 18. Lightly oil a new seal, O-ring, backup ring
13. Re-install the piston assembly in the and wiper. Install them into the top
cylinder housing. bearing.

14. Re-install the three staging screws. Refer 19. Install the top bearing.
to Component Specific Service/Torque 20. Install the threaded end-cap. Refer to
Chart (Page A-4). Component Specific Service/Torque Chart
(Page A-4).

Seal Wiper
End Cap

Cushion Assembly Spring

Top End

See View B See View A

Piston

Staging Screw
Backup Ring Top Bearing
Seal Wiper
Pressure Ring
O-Ring
Seal
Bleed Screw
Snap Ring

View B
View A
7

Figure 7-187. Center Lift Cylinder, Three-Stage with Cushions

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Hydraulic Components Seal Replacement

Seal Replacement
Refer to Figure 7-187 for the following steps.

1. Remove the threaded end-cap and the top

bearing.
NOTE: When the snap ring or end-cap is
removed, a spring behind the top
bearing may push the bearing out of the
housing.
2. Remove the spring and pressure ring.
3. Check to make sure the small orifice in the
pressure ring is not obstructed.
4. Lightly oil a new seal and install in the
pressure ring.
5. Remove the bad parts from the top
bearing.
6. Lightly oil a new seal, O-ring, backup ring,
and wiper. Install them into the top
bearing.
7. Install the top bearing.
8. Install the threaded end-cap. Refer to
Component Specific Service/Torque Chart
(Page A-4).

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Seal Replacement Hydraulic Components

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Mast Section

Mast Section
Section 7. Component Procedures

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Carriage Mast Section

Carriage Snap Ring Chain

Rocker
Assembly
Removal
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the operator console cover. Free Lift
Cylinder
3. Remove the mast guard.
4. Remove the electrical over-the-mast cable
from the bottom pulley on the carriage.
See Figure 7-188.
5. Disconnect the cable tension spring from
7
the carriage. See Figure 7-188.
Figure 7-189. Free Lift Cylinder, Top View

Cable 9. Attach a suitable hoist to the carriage and

Tension lift approximately 1 ft. (30.5 cm).
Spring 10. Remove the rocker assembly, its
associated hardware, and chain from the
free lift cylinder. Place the chain on the
Cable operator platform.
11. Remove the end cap from the free lift
cylinder.
Pulley
12. Remove the two carriage stops from the
inner telescopic.
13. Remove the 5 flat head and 12 hex head
mounting bolts from the inside of the
7

Figure 7-188. Electrical Over-the-Mast Cable battery compartment.

14. Pound in the locator pins until the
6. Disconnect JPC8 and JPC9 from the carriage can clear the telescopic. See
Carriage Manager. Cut the cable tie from Figure 7-190 and Figure 7-191.
the tractor side.
Locator
Pin
Do not place hands between the masts
before blocking the carriage.

7. Feed the cable through the carriage to the

tractor.
8. Use 90° snap ring pliers to remove the
snap ring holding the chain rocker
assembly to the free lift cylinder. See
Figure 7-189. Carriage
Stop
7

Figure 7-190. Inner Telescopic, Top Corner

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Mast Section Carriage

4. Position the operator platform 3 ft. (1 m)

from the floor.
5. Install the rocker assembly using snap
ring pliers.
Locator
6. Install the chain on the free lift cylinder.
Pin
See Figure 7-189 on page 7-106.
7. Install the end cap pulley on the free lift
cylinder.
8. Feed the chains for the free lift cylinder
and over-the-mast cable.
9. Feed the over-the-mast cable through the
back of the carriage to the Carriage
Manager. Connect to JPC8 and JPC9.
7

Figure 7-191. Inner Telescopic, Top Corner, Stops Removed 10. Use cable ties to secure the electric cables
to the operator platform.
15. Remove the operator platform. 11. Install the carriage stops at the top of the
inner telescopic. See Figure 7-190 on
Installation page 7-106.
12. Lower the carriage. Install the cable on the
1. With a suitable hoist, lower the bottom
bottom pulley of the carriage. Install the
bearings on the carriage into the channel
cable retainer spring. See Figure 7-188 on
on the inner telescopic.
page 7-106.
2. Make sure there are sufficient shims to
prevent side play. See Upper Mast Bearing NOTE: There is 5 1/2 in. (140 mm) from the top
Replacement on page 7-111. of the spring on the carriage to the
center of the bolt in the cable clamp.
3. Make sure the two switches (S36 and S37)
at the bottom of the carriage are riding on 13. Mate the tractor to the mast, engaging the
their switch rail correctly. See locating pins in the tractor with the holes
Figure 7-192. in the mast frame.
14. From the battery compartment, thread 12
Switches hex head bolts and five socket flat head
bolts through the tractor frame in the
center, left side, and right side into the
mast. See Figure 7-193 on page 7-108.

Switch
Rail

Figure 7-192. Underside of Carriage

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Carriage Mast Section

Flat Head
Mounting Bolts
Qty. 5

Hex Head
Mounting Bolts
Qty. 12

Figure 7-193. View of Battery Compartment

15. Torque the hex head bolts. Refer to

“Component Specific Service/Torque
Chart” on page A-4.
16. Install the console cover.
17. Install the mast guard.
18. Reconnect the battery connector and turn
the key switch ON.
19. Lift and lower the platform fully. Check the
functions of the lift system. Look for:
• Hydraulic fluid leaks
• Cables on pulleys
• Switch actuation
• Unusual bearing noise

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Mast Section Mast Shimming

Mast Shimming Compare the wear pattern on the rail (where the
roller rides) to the examples shown in
Figure 7-194.
Shimming a mast makes a smooth running unit
• If the wear pattern is optimal, shimming is
that is not too tight or too loose. If you find any
adequate.
marks within the telescopics or main frame
where the rollers have been running, remove • If the wear pattern is excessive, shimming
them using a sanding disc and 80 grit paper. Do is too tight.
not attempt to remove all marks, only the • If the wear pattern varies between optimal
ridges. Shim the bearings to the tightest spot on and excessive, the telescopic weldment is
the assembly (as the rollers run up and down suspect.
the rail). Buff small areas that are slightly
higher than the rest of the web to avoid NOTE: Uneven wear can also indicate if a
shimming the major portion of the rail too loose. bearing set is too tight.
The shims used under each roller bearing come
in the following sizes: thin, medium, and thick.
Although you can use different combinations of Approx. 1 in. (25.4 mm)
wide wear pattern
shims to obtain the correct adjustment, you
should try to maintain equal shim thickness on
each side of the mast.
OPTIMAL
Mast and Bearing Inspection WEAR
PATTERN
Observe mast operation in free and main lift
Shimming is
with no load.
adequate
• When stopping a lift or lower, there should
be a slight bounce.
• If the bounce dampens out quickly, the
mast may be shimmed too tight.
Side of rail bearing rides on
Observe the mast operation at full elevated
height, just short of hitting the hard stops, with
no load.
• The telescopics should all act as one.
EXCESSIVE
• The interface between the telescopics WEAR
should be snug with no excessive relative PATTERN
motion between the telescopics when the
Shimming is
lift truck is moved back and forth slightly.
too tight
If motion is excessive, the mast may be
shimmed too loose. Example of good
• If a 0.010 in. feeler gauge can be inserted wear pattern on a
between the roller and beam web at the mast with several
tightest spot, they are shimmed too loose. hundred hours
Wear pattern greater than
Some telescopics can be narrower at the 1 in. (25.4 mm) wide
top or bottom, therefore shimming
clearance should be measured at the
tightest location.
Figure 7-194. Mast Bearing Wear Patterns

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Shimming Procedure Mast Section

Shimming Procedure prevent the bearing from walking on the

stud shaft.
1. Elevate the mast to gain access to the
bearings.
2. Place a block between the outer telescopic
crosstie and the main frame.
3. Fully lower the carriage.
4. Turn the key switch OFF and disconnect
the battery connector.
NOTE: When removing the upper bearings, use
caution not to let the bearing fall down
into the mast assembly. If the bearings
are worn or damaged, replace them.
5. Remove the bolt and roller stud sleeve
securing the roller bearing to the
respective mast or telescopic. Figure 7-195. Inner Race
6. Remove the bearing.
14. Install the bearing assembly into its
NOTE: It may be necessary to drive a wedge respective mast or telescopic. Make sure
between the respective telescopics to that the flat spot of the bearing stud aligns
provide clearance for removal and with the welded stop on the mast or
installation. telescopic.
7. Remove the socket head cap screw and 15. Install the roller stud sleeve.
washer retaining the bearing on the stud.
16. Apply thread-locking compound
NOTE: Shim the main frame top bearing and (P/N 1013829) to the threads of the
the outer telescopic lower bearing set to mounting bolt and torque to 260 ft. lb.
a 0.000 ±0.010 in. overall interference. (352.5 Nm).
8. Shim the outer telescopic upper bearing 17. Reconnect the battery connector and turn
set to 0.000 ±0.010 in. overall the key switch ON.
interference with the inner telescopic after 18. Remove the block from between the outer
the top main frame bearings have been telescopic and the main frame.
correctly shimmed.
19. Test the operation of the elevating
9. Shim the inner telescopic lower bearing set assembly.
to 0.000 ±0.010 in. overall interference
with the outer telescopic after the outer
telescopic lower bearings have been set.
10. Install or remove the required amount of
shims.
11. Install the bearing on the shaft.
12. Apply thread-locking compound
(P/N 990-536) to the socket head cap
screw and fasten the screw and washer in
place.
13. If the inner race of the bearing does not
protrude past the end of the bearing stud
when the bearing is fully seated, bend the
flat washer to contact the bearing to

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Mast Section Upper Mast Bearing Replacement

Upper Mast Bearing roller bearing. Put a strap suitable to

handle the weight of the carriage around
Replacement the uppermost crosstie. Once the carriage
is raised in place, block it in position.
5. Turn the key switch OFF and disconnect
the battery connector.

Use extreme care when blocking the

mast for any reason. Never remove the
Do not damage the telescopic when
block when it is supporting the mast.
prying with the screwdriver.
1. Use the hydraulic system to slightly
NOTE: For the upper mast bearings, wedge a
elevate the carriage to gain access to the
screwdriver between the roller bearing
bearings or use an appropriately rated
and the mast to prevent the bearing
rigging device to pull the carriage upward
from falling.
to gain access to the roller bearing.
NOTE: When removing the roller bearing, use
NOTE: Refer to “Jacking” on page 2-9 for hoist
caution not to let the bearing fall down
requirements.
into the mast assembly.
2. Put a strap suitable to handle the weight
6. Remove the bolt securing the roller
of the carriage around the uppermost
bearing to the respective mast or
crosstie.
telescopic.
3. Block the carriage once it is raised in
place. NOTE: If the bearings are worn or damaged,
replace them.
4. Block the carriage with a suitable support 7. Install the same number of shims that
stand before you attempt to remove the were removed from under the bearing.
roller bearing. See Figure 7-196.
8. Make sure the roller bearing mounting
bolts are clean before you install them.
9. Apply thread-locking compound
(P/N 1013829) on the threads. Torque the
bolts per Table 7-8.
10. Reconnect the battery connector and turn
the key switch ON.
11. Lift the carriage and mast and unblock the
mast.
12. Test the operation of the telescopics.
13. Return the lift truck to service.

Table 7-8. Mast Bearing Stud Retaining Bolt Torque Values

Location *Torque

Main Frame 300 ft. lb. (406.7 Nm)

709G6S001.TIF Outer Tele Upper 250 ft. lb. (339 Nm)

Figure 7-196. Blocking Carriage
*After torquing, back bolt off 1/4 to 1/2 turn.
You may also use a lift hoist to pull the
carriage upward to gain access to the

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Mast Disassembly and Shimming Mast Section

Mast Disassembly and 13. Remove the upper roller bearing bosses
and roller bearings from the outer
Shimming telescopic.
This section describes procedures for: 14. Remove the telescopics and main frame
stops.
• Disassembling the three-stage mast
15. Slide the inner telescopic out of the top of
• Shimming main frame to outer telescopic
the outer telescopic. Attach the hoist to
• Shimming outer telescopic to inner the outer telescopic.
telescopic
16. Remove the upper roller bearing bosses
• Shimming inner telescopic to carriage and roller bearings from the main frame.
17. Slide the inner telescopic out of the top of
Mast Disassembly the main frame.
1. Remove the forks and mast guard.
2. Fully lower the carriage and make sure the
Shimming Main Frame to Outer
pressure is out of the cylinders. Telescopic
3. Turn the key switch OFF and disconnect 1. Install the mast roller bearings at the
the battery connector. Remove the battery. bottom of the outer telescopic.
4. Disconnect the over-the-mast cables and 2. Use a suitable lifting device and insert the
hoses inside the tractor compartment and outer telescopic into the main frame all the
plug the hoses. Disconnect the lift hose to way to the bottom.
the main cylinders inside the tractor 3. Using a pry bar, move the outer telescopic
compartment and plug. Disconnect all and roller bearing to one side.
other cables that run from the tractor to
the mast. 4. Use spare shim(s) as a gauge to determine
the amount required to move the roller
5. Secure the main carriage and telescopics bearings outward to make contact with the
so they cannot move. main frame.
6. Remove the tractor from the mast and 5. Remove the outer telescopic from the main
block each securely. frame.
7. Disconnect and remove the lift chains 6. Remove the roller bearings from both roller
from the center lift cylinder. Remove the bearing bosses at the bottom of the outer
over-pulley-cables and hoses. Remove the telescopic.
free lift cylinder end cap assembly.
7. Install half of the total shim thickness
8. With a suitable hoist, carefully lay the required to each roller bearing boss at the
mast assembly down and block securely in bottom of the outer telescopic. (Applying
place. Remove the carriage stops from the one half of the total shim thickness to each
inner telescopic. side of the telescopic maintains the center
9. Remove the main carriage by sliding it out line of the mast assembly.)
the top of the inner telescopic. Set it aside 8. Reinstall the roller bearings. Torque the
for later reassembly. bolts per Table 7-8 on page 7-111.
10. Remove the lift chains, chain pulleys, hose 9. Use a suitable lifting device and reinstall
pulleys, and cable pulleys. the outer telescopic into the main frame.
11. Disconnect and remove the lift cylinders Check for tightness while moving the outer
from the telescopics. telescopic to the bottom of the main frame.
12. Attach the hoist to the inner telescopic. Add or remove shims as necessary to
maintain a snug, but free-running, fit.
NOTE: If the outer telescopic hangs up, a pry
bar may be used to move the telescopic.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Mast Section Mast Disassembly and Shimming

10. Assemble the two top main frame roller outward to make contact with the outer
bearings and bosses without shims. telescopic.
11. Install the roller bearing assemblies, 5. Remove the inner telescopic from the outer
attach with a retaining bolt, and snug up telescopic.
to the main frame. 6. Remove the bearings from both roller
NOTE: Failure to snug the assemblies to the bosses at the bottom of the inner
main frame will result in the wrong telescopic.
amount of shims, since the studs are 7. Install half the total shim thickness
canted. required to each roller boss at the bottom
12. With the outer telescopic fully nested, use of the inner telescopic.
a pry bar and carefully move the outer 8. Reinstall the roller bearings. Torque the
telescopic to the opposite side. Using spare bolts per Table 7-8 on page 7-111.
shims between the bearing and outer 9. Use a suitable lifting device and reinstall
telescopic, determine the amount of shims the inner telescopic into the outer
required to remove side play. telescopic. Check for tightness while
13. Remove the roller bearing assemblies. moving the inner telescopic to the bottom
14. Install half of the total shim thickness to of the outer telescopic.
each roller bearing assembly. NOTE: If the inner telescopic hangs up, a pry
15. Install the roller bearing assemblies and bar may be used to move the telescopic.
attach with the mounting bolts and Do not apply excessive pressure to the
tighten. bearings with the pry bar.
16. With the outer telescopic fully nested, use 10. With the inner telescopic fully nested, use
a pry bar to check for bearing tightness. If a pry bar to check for bearing tightness. If
more shims can be inserted between the a thin shim can be inserted between the
bearing and the outer telescopic, remove bearing and the outer telescopic, remove
the roller bearing assembly and install the the inner telescopic and install the shim
shim(s). Reinstall the bearing assembly. between the bearing and the roller boss.
17. Check for correct shimming by pulling the Torque the bearing stud retaining bolt per
outer telescopic out and then pushing it in Table 7-8 on page 7-111. Leave the lifting
all the way. The outer telescopic should device connected to the outer telescopic.
not hang up while moving it in and out. 11. Assemble the two roller bearings and
Torque the bearing stud retaining bolts bosses for the top inner telescopic without
per Table 7-8 on page 7-111. shims.
18. Install the stops in the main frame. 12. Insert the bearing/boss assemblies and
attach with the retaining bolts. Draw the
Shimming Outer Telescopic to Inner bearing bosses up snug to the outer
telescopic.
Telescopic
NOTE: Failure to snug the assemblies to the
1. Install the mast roller bearings at the
main frame will result in the wrong
bottom of the inner telescopic.
amount of shims, since the studs are
2. Use a suitable lifting device and insert the canted.
inner telescopic into the outer telescopic
all the way to the bottom. 13. Use a pry bar and carefully move the inner
telescopic to the other side. Using spare
3. Use a pry bar and carefully move the inner shims between the bearing and inner
telescopic and bearings to one side. telescopic, determine the number of shims
4. Use spare shim(s) as a gauge to determine required to remove side play.
the amount required to move the bearings 14. Remove the bearing/boss assemblies.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Mast Disassembly and Shimming Mast Section

15. Install half the total shim thickness to 9. Use a suitable lifting device and reinstall
each bearing/boss assembly. the carriage into the inner telescopic.
16. Install the bearing/boss assemblies into Check for tightness while moving the
the outer telescopic/inner telescopic. carriage to the bottom of the inner
Attach with a mounting bolt and tighten. telescopic.

17. With the inner telescopic fully nested, use 10. Use a pry bar to check for bearing
a pry bar to check for bearing tightness. If tightness. If a thin shim can be inserted
more shims can be inserted between the between the bearing and the inner
bearing and the inner telescopic, remove telescopic, remove the carriage and install
the bearing/boss assembly and install the the shim between the bearing and the
shim(s). Reinstall the bearing/boss roller boss.
assembly. Torque the bearing stud NOTE: Do not apply excessive pressure to the
retaining bolt per Table 7-8 on page 7-111. bearings with the pry bar.
18. Check for correct shimming by pulling the 11. Use a suitable lifting device and reinstall
inner telescopic out and then pushing it in the carriage, checking for tightness. Make
all the way. The inner telescopic should sure the carriage can be moved in and out
not hang up while moving it in and out. by hand.
19. Install the stops at the upper crosstie. 12. When the correct fit is obtained, measure
20. Install the outer lift cylinders. the gap between the top of the platform
21. Install the chain rollers and lift chains. and the inner telescopic on both sides. If
the gap between the platform and the
22. Install the center lift cylinders inner telescopic is not within 1/16 in.
(1.59 mm) of each other, remove the
Shimming Inner Telescopic to platform.
Carriage 13. Take shims from the top roller on the side
1. Install the mast roller bearings on the that is farthest away and install them on
carriage roller bosses. the opposite side. Repeat this procedure
until 1/16 in. (1.59 mm) is obtained. If all
2. Use a suitable lifting device and insert the shims are on one side of the top rollers,
carriage into the inner telescopic all the remove shims from the bottom roller on
way to the bottom. the side that is farthest away and install
NOTE: The carriage may have to be removed them on the opposite side.
several times to obtain the correct fit. 14. Repeat this procedure until the required
3. Using a pry bar, move the bottom carriage clearance at the top of the platform is
bearings to one side. obtained.

4. Use spare shim(s) as a gauge to determine 15. Install the carriage and the carriage stops.
the amount required to move the bearings 16. Install the pulleys for the over-mast-hoses
outward to make contact with the inner and cables.
telescopic. 17. Secure the main carriage and telescopics
5. Move the carriage to the top of the inner in place so that they do not move while
telescopic and repeat the process for the standing the assembly back up.
top set of bearings. 18. Install all the other items removed during
6. Remove the carriage from the inner the disassembly process after laying the
telescopic. assembly down.
7. Install half of the total shim thickness 19. Attach the hoist to the mast assembly and
required to each roller boss. stand the mast back up. Install all the
other items removed during the
8. Reinstall the roller bearings.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Mast Section Mast Disassembly and Shimming

disassembly process prior to laying the

assembly down.
20. Attach the tractor to the mast.
21. Install the remaining components.
22. Connect the hoses and cables inside the
tractor compartment.

Make sure all mast stops are installed

and securely tightened before operating
the lift truck.

23. Reinstall the battery.

24. Reconnect the battery connector and turn
the key switch ON.
25. Adjust the main lift chain so the top of the
inner telescopic is even with the outer
telescopic +/- 0.125 in. (3.2 mm) and both
chains have equal tension.
26. Adjust the free lift chains so the top of the
fork just in front of the platform is at a
minimum of 2.75 in. (70 mm) from the
floor and the tips are at a maximum of 3.5
in. (89 mm) from the floor.
27. Install the forks and mast guard.
28. Check for correct operation.
29. Grease the channels.
30. Bleed the lift cylinders. See Bleeding Lift
Cylinders on page 7-95.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Lift Chains, Three-Stage Mast Section

Lift Chains, Three-Stage

Main Chain
Cylinder Anchor

Use extreme care when the lift truck is Anchor

jacked up. Never block the lift truck Block
between the telescopic and the floor.
Attach an appropriately rated rigging
device to the top of the mast, and an
overhead hoist to stabilize the mast if
jacking higher than described in the
Jacking Safety section. Keep hands and
7
feet clear while jacking the lift truck. Figure 7-197. Lower Anchor Block
After the lift truck is jacked, place solid
blocks or jack stands beneath it to
support it. Lower the lift truck onto the Main Cylinder Chains
blocks or jack stands. Do not rely on the
jack or jack stand alone to support the Replace
lift truck. See Jacking on page 2-9.
1. Inspect the lift chain for wear or broken
links. See Chain Maintenance on
Free Lift Cylinder Chain page 4-11.
2. Lift the carriage enough to block between
Replace the carriage and inner telescopic.
1. Turn the key switch OFF and disconnect 3. Place blocking between the carriage and
the battery connector. the inner telescopic.
2. Inspect the lift chain for wear or broken 4. Turn the key switch OFF and disconnect
links. See Chain Maintenance on the battery connector.
page 4-11. 5. Disconnect the chain from chain anchors.
3. Attach a suitable hoist. Lift the carriage Feed the chain off the pulley. See
approximately 3 ft. (0.9 m) and block. Figure 7-197 and Figure 7-198 on
4. Disconnect the chain from the chain page 7-117.
anchor and feed out of the lift truck. 6. Replace the chain as necessary. See
5. Replace the chain as necessary. Figure 7-199 on page 7-117.

6. Feed the chain over the pulley. Connect 7. Refer to “Lift Chain” on page 7-122 for lift
the chain to the chain anchor. chain adjustment.

7. Remove the block and hoist.

8. Reconnect the battery connector and turn
the key switch ON.
9. Test the lift function for smooth and
correct operation before returning the lift
truck to service.
10. Refer to “Lift Chain” on page 7-122 for lift
chain adjustment.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Mast Section Main Cylinder Chains

8. Feed the chain over the pulley. Connect

the chain to the anchors. See Figure 7-197
and Figure 7-198.

Chain
Pulley

Chain
Anchor
7

Figure 7-200. Inside Chain Anchor, View from Operator

Platform

7
9. Remove the block and hoist.
Figure 7-198. Upper Chain Anchor and Pulley 10. Reconnect the battery connector and turn
the key switch ON.
11. Test the lift function for smooth and
correct operation before returning the lift
truck to service.

Figure 7-199. Master Link of Lift Chain

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Free Lift Cylinder Ride Spring Chain Anchors Mast Section

Free Lift Cylinder Ride

Spring Chain Anchors
Inspect the chain anchors and rocker any time
that the chains are lubricated and adjusted.

Inspection
1. Remove the operator compartment console
cover and tractor cover.
2. Lift the operator platform just high enough
to have the chain anchor and rocker Chain Anchor
visible through the opening under the
operator control panel.
3. Place blocking under the operator
platform. Lower the platform onto the
support.
4. Turn the key switch OFF and disconnect
the battery connector. Open the
emergency lower valve.
7
The free lift cylinder moves down and the Figure 7-201: Chain Anchors
chains go slack. If the free lift cylinder
does not go down far enough to slacken 5. Inspect the chain anchor and rocker for
the chains, push down on the top of the wear and replace if necessary.
cylinder. This allows the chain anchor to 6. Close the emergency lower valve.
be visible for inspection. See Figure 7-201. Reconnect the battery connector and turn
the key switch ON.
7. Lift the platform slowly to take slack out of
the chains and to clear the support from
beneath it.
8. Remove the support and lower the
platform.
9. Reinstall all covers.

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Mast Section Forks

Forks 6. Drive out the pin. The fork, washers, or

shim will drop.
7. Replace the damaged fork.
Removal
1. Raise operator platform high enough to Installation
reach the bottom of the forks.
1. Hold the new fork in place under the
2. Block the operator platform. operator platform.
3. Secure the fork to a hoist using a suitable 2. Install the pivot pin through the fork.
strap or chain. See Figure 7-202.
NOTE: Always use new snap rings when
4. Remove the cap screw from underneath assembling components.
the fork at the tractor end of the fork.
3. Install a new snap ring on the pivot pin
using snap ring pliers.
Socket Head Fork 4. Install the correct amount of washers or
Cap Screw shims at the tractor end of the fork to
maintain a level fork. See Figure 7-204.

Shims

Figure 7-202. Fork Removal

5. Remove the snap ring from the pivot pin in

the fork mounting block using snap ring
pliers. See Figure 7-203. 7

Figure 7-204. Installing Forks and Shims

5. Install the socket head cap screw through

the fork and shims at the tractor end of
the fork.
6. Remove the blocking from the operator
platform.
Snap 7. Lower the operator platform to the floor
Ring and make sure forks are level. The top
surface of the forks should be within 0.25
in. (6.3 mm) of each other (31 in. and
7
longer) or 0.125 in. (3.2 mm) of each other
Figure 7-203. Snap Ring, Pin, and Mounting Block (under 31 in.) at the tips. If the forks are
not level, add more shims to the fork.
8. Check the fork up tilt. It must be between
level and 0.5 in. (12.7 mm) maximum.

The fork will drop in step 6. It weighs

approx 150 lb. (68 kg).

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Pallet Clamp Mast Section

Pallet Clamp between the pallet clamp and the left-hand

pallet support. Torque the remaining hex
nut to 21 ft. lbs. (29 Nm).

Tension Spring
Pallet Clamp

Pedal Weld

Bracket

Figure 7-205. Pallet Clamp Assembly, Underside

Installation
1. Install the pallet clamp assembly on the
platform front plate. Secure it with four (4)
M10 x 20 screws. Torque to 30 ft. lbs.
(41 Nm).
2. Install the pedal assembly to the platform
main support plate. Secure it with two (2)
M8 x 20 screws. Torque to 15 ft. lbs.
(20 Nm).
3. Hook the tension spring into the 1/4-inch
holes in the bracket and pedal weld in the
pedal assembly. See Figure 7-205.
4. To extend the spring so you can connect
the cable assembly, slide a two inch-wide
block between the left-hand pallet support
and the pallet clamp on the pallet clamp
assembly.
5. Install the cable bracket on the pedal
assembly. Secure it with the M8 x 10
shoulder bolt and M8 hex nut. Torque to
15 ft. lbs. (20 Nm).
6. Place the cable assembly in the cable
bracket and secure with the M6 hex nuts.
Finger-tighten the hex nut closest to the
pedal mounting and leave the other nut
loose.
7. Remove the two inch block you used in
step 4.
8. Adjust the hex nut closest to the pedal
mounting until there is a 90-degree angle

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Models 5300/5500/5600 Maintenance Manual Section 7. Component Procedures

Mast Section Load Wheels

Load Wheels 6. Remove the snap ring from the axle using
snap ring pliers. See Figure 7-206.
7. Drive the axle out of the wheel and
baseleg.
8. Remove the load wheel from the baseleg.
Use extreme care when the lift truck is 9. If the lift truck is equipped with dual load
jacked up. Never block the lift truck wheels, lift the second load wheel out the
between the telescopic and the floor. top of the baseleg. See Figure 7-206.
Attach an appropriately rated rigging
10. Replace the load wheel assembly.
device to the top of the mast, and an
overhead hoist to stabilize the mast if 11. Drive the axle in through the wheel and
jacking higher than described in the baseleg.
Jacking Safety section. Keep hands and 12. Install the snap ring using snap ring
feet clear while jacking the lift truck. pliers.
After the lift truck is jacked, place solid
13. Remove the block from under the baseleg
blocks or jack stands beneath it to
and lower the truck to the floor.
support it. Lower the lift truck onto the
blocks or jack stands. Do not rely on the 14. Connect the battery connector and turn
jack or jack stand alone to support the the key switch ON.
lift truck. See Jacking on page 2-9. 15. Raise the operator platform and remove
the block between the platform and the
Installation baseleg.

Snap Ring

Axle

Figure 7-206. Load Wheel

1. Raise the operator platform approximately

1 ft. (0.3 m) from the floor and place a 4 x
4 in. (100 x 100 mm) block across the top
of baselegs underneath the platform.
2. Lower the platform onto the block.
3. Turn the key switch OFF and disconnect
the battery connector.
4. Jack up and block the baseleg high
enough to remove the load wheel axle.
5. Lower the baseleg onto the block.

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Section 7. Component Procedures Models 5300/5500/5600 Maintenance Manual

Lift Chain Mast Section

Lift Chain 5. Tighten the adjusting nut until the chain

is free of any twist and the tension is
correct.
Lift chains are important components of the lift
6. Re-tighten the locking nut on the chain
truck. The chain system on the mast is
anchor.
designed for efficient, reliable transmission of
lifting force from the hydraulic cylinder to the
forks. Safe, uninterrupted use of the lift truck Lift Chain Maintenance
depends on correct care and maintenance of the
lift chain. Unsatisfactory chain performance is traced
directly to inadequate maintenance. Highly
stressed precision chains require periodic
Lift Chain Adjustment maintenance to deliver maximum service life.
1. Adjust the center lift chains so the top of Refer to “Lift Chains” on page 4-7.
the fork in front of the platform is at a
minimum of 2.75 in. (70 mm) from the
floor and the tips are at a maximum of 3.5
in. (89 mm) from the floor.
2. Adjust the main lift chain so the top of the
inner telescopic is even with the outer
telescopic +/- 0.125 in. (3.2 mm) and both
chains have equal tension.
3. Check that the lift chain tension is correct
by forcing the chain sideways
approximately 1/2 to 1 inch (13 to 25.4
mm) before the lift frame raises slightly.
4. If any of the chains need to be adjusted,
loosen the locking nut on the chain
anchor. See Figure 7-207.

Locking Nut

Figure 7-207. Lift Chain Locking Nut

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

Section 8. Theory of Operation

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Section 8. Theory of Operation Models 5300/5500/5600 Maintenance Manual

System Architecture

System Architecture
Section 8. Theory of Operation

The following table identifies the various

electronic components found on this lift truck
and their function.

Ident Component Function

Controlling manager for the lift truck. See Vehicle Manager on

VM Vehicle Manager
page 8-3.

Powers the traction motor. See Traction Power Amplifier on

TPA Traction Power Amplifier
page 8-4.

Powers the lift motor on AC lift systems. See Lift Power

LPA Lift Power Amplifier
Amplifier on page 8-4.

Distributes B+/– throughout the lift truck. Houses the B+/–

FRC Fuse/Relay Card
control fuses. See Fuse/Relay Card on page 8-4.

Interfaces with the operator and various components on the

CCC Carriage Control Card
carriage. See Carriage Control Card on page 8-3.

Interfaces with the guidance coils and VM. See Guidance

GM Guidance Manager
Manager on page 8-4.

Receives and conditions the output from the guide wire. See
Antenna Cards
Antenna Cards on page 8-4.

Contactor/Fuse Panel Contactors and power fuses are located on this panel.

Processes inputs used for height calculation. See intellispeed

intellispeed Module and Sensor
Module and Sensor on page 8-5.

Displays information and fault codes to the operator. Also

Operator Interface Card contains the push button entry keys. See Operator Interface
Card on page 8-4.

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

Systems Overview

Systems Overview Manual modes of operation, but does not

current limit the steering motor. The VM
The orderpicker control system uses five calculates and maintains the platform height
“intelligent” devices working together to control count based on direct inputs from the
the lift truck and respond to operator intellispeed Flow Module. The VM reduces the
commands. These devices pass information to travel speed of the lift truck as necessary, based
each other via the communications (CAN) Bus. on the platform height and load weight as well
The devices are: as traction motor temperature. When in the
guided mode, the VM receives information
• Vehicle Manager
regarding the lift truck’s position relative to the
• Carriage Control Card wire from the Guidance Manager (GM). During
• Traction Power Amplifier guided operation, the VM receives steering
correction requests from the GM. It is the VM
• Lift Power Amplifier (AC Lift only)
that slows or stops the lift truck as Heading
• Guidance Manager (Wire Guidance Option Angle (HA) and Distance From Wire (DFW)
only) limits are reached or exceeded. The VM
contains a power supply that provides a
The system utilizes up to five other regulated +12V and +5V. It provides +12V to the
“non-intelligent” devices, depending on options. CCC. The VM calculates the Battery
The following devices may also be installed on State-of-Charge (BSOC) from the voltage
the lift truck: measured at Battery Sense In.
• Antenna Cards (Wire Guidance Option
only) Carriage Control Card
• Operator Interface Card
Although the Carriage Control Card (CCC)
• Fuse/Relay Card contains a microprocessor, a communications
• Steering Amplifier chip, and a firmware chip, it has very limited
decision making ability and communicates only
• intellispeed Module
with the VM. The CCC and the VM share
control of the brake release circuitry. The CCC
Intelligent Devices functions primarily as an Input/Output (I/O)
board for the devices connected to it, such as:
Vehicle Manager
• deadman switches, sidegate switches, and
lower limit switches
The Vehicle Manager (VM) controls the
orderpicker control system. It communicates • steering tiller encoder
with all other devices that are on the • travel and lift potentiometers
communications Bus. It receives, via the CAN
Bus, all requests for travel and lift. The VM also The CCC converts the voltages it reads from
receives information on the status of all these inputs into a message that it sends to the
carriage switches such as the deadman, VM that takes any action required. The CCC
sidegate, and height switches. It also receives also drives the display and is the only manager
traction motor speed, direction, and that can put codes on the display. The only
temperature information from the Traction code that the CCC can actually precipitate is
Power Amplifier (TPA) and lift motor speed and Code 50 (no VM communications received by
temperature information from the Lift Power the CCC). The VM commands all other codes,
Amplifier (LPA). The VM determines allowable but must go to the CCC that causes the codes
vehicle operation based on those inputs and to be placed on the display. The CCC receives
operator requests. The VM and CCC share +12V from the VM. The CCC then regulates that
control of the brake release circuitry. The VM voltage to +5.3V for the various devices that it
directly monitors and controls the steering powers.
system of the lift truck in both Auto and

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Section 8. Theory of Operation Models 5300/5500/5600 Maintenance Manual

Systems Overview

Traction Power Amplifier Guidance Manager

The Traction Power Amplifier (TPA) The Guidance Manager (GM) communicates
communicates only with the VM, from where it with the VM only. The learned values for wire
receives all commands regarding travel guidance are stored in the GM. It determines
direction and speed. The TPA monitors both the the position of the lift truck relative to the wire
traction motor encoder and temperature sensor. when in the guided mode. The GM uses inputs
It determines, based on the encoder feedback from the Antenna Cards to calculate the
and the travel request, if the lift truck should be position of the lift truck relative to the wire. It
in travel, plugging, or regenerative braking, and then reports the lift truck position along with a
determines if the performance has achieved the command for steering direction to the VM over
travel command from the VM. If it has not, the the CAN Bus.
TPA adjusts the motor control voltage or sends
a fault code to the VM, as appropriate. The TPA Non-intelligent Devices
is solely responsible for controlling traction
motor current. The TPA sends the traction Antenna Cards
motor temperature to the VM. The VM then
alters the travel request if necessary depending The two Antenna Cards are located along the
on the traction motor temperature. The TPA center line of the lift truck. The Tractor Antenna
monitors its internal temperature and limits Card is attached behind the center bumper
current or travel speed as required by its plate in front of the drive tire. The Load End
internal programming. The TPA also checks the Antenna Card is located under the operator
operation of the TPC, the charging of the platform between the baselegs. The Antenna
amplifiers, and various internal operating Cards contain circuitry that receives the signal
parameters. It also sends fault codes to the VM from the floor wire and passes it to the GM.
if anything is operating incorrectly.
Operator Interface Card
Lift Power Amplifier
The Operator Interface Card is mounted on the
The Lift Power Amplifier (LPA) is used on AC lift carriage and connected to the CCC. It contains
models only. The LPA only communicates with the data entry push buttons and the character
the VM, from where it receives all commands display that messages and codes are displayed
regarding lift speed. The LPA monitors both the on. It is driven by the CCC from where it
lift motor encoder and temperature sensor. It receives all its inputs.
determines from the encoder feedback if the
motor has achieved the commanded speed Fuse/Relay Card
request. The LPA is solely responsible for
controlling lift motor current. It sends the lift The Fuse/Relay Card is a control power
motor temperature to the VM. The VM then distribution board. It contains the B+ and B–
determines if the motor must be shut down due control fuses and the K1 through K4 relays. It
to motor temperature. The LPA monitors its provides B+ and B– to the VM, TPC, LPC, and
internal temperature and limits current or lift CCC.
speed as required by its internal programming.
The LPA also checks the operation of the LPC, Steer Amplifier
the charging of the amplifiers, and various
internal operating parameters. It also sends The Steer Amplifier is an amplifier only. It takes
fault codes to the VM if anything is operating a low level steering input from the VM and
incorrectly. amplifies it to drive the steering motor. Steer
motor current is limited by the Steer Amplifier.
The Steer Amplifier also provides a steer motor
current feedback voltage and a voltage called

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

sPort

neutral pulse, which confirms amplifier

operation, back to the VM.

intellispeed Module and Sensor

The intellispeed module amplifies the inputs

from the flow sensor and passes them on to the
VM.

Stored Value Locations

Value Location

Primary Memory The Primary Memory in this lift

truck is stored in the CCC.
There is a backup copy in the
VM. If the CCC is blank or has
garbled memory, the VM will
send a copy up if the cards can
communicate. If both cards are
valid, but different, then the
CCC will overwrite the VM.

Configure Mode Configure Mode settings are

Settings stored in both the CCC and the
VM.

Learn Mode Learn Mode values are stored

Values in the VM.

Date and Time Date and time are calculated

and stored in the VM. There is
no clock chip on the CCC.

Hour Meters The hour meters (Hours

Deadman, Hours Lifting, Key
Hours, and Traction Miles) are
stored in the CCC.

sPort
The sPort enables the to truck communicate
with the Simulation PC in the Raymond Virtual
Reality Simulator. While in Simulator Mode, all
truck operation is disabled but any control
inputs an operator makes are displayed as part
of a computer-generated simulation.

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Section 8. Theory of Operation Models 5300/5500/5600 Maintenance Manual

Traction System

Traction System Travel

When the deadman is pressed, the brake is
Deadman Pedal Pressed released. During Learn Mode, the VM learns the
neutral position for the travel (VR1) and lift
When the deadman pedal is pressed, switches (VR2) potentiometers and stores those values in
S2 (Brake Deadman) and S23 (Carriage memory. During normal use, the VM learns the
Deadman) are closed. These switches are extreme values for full forward/reverse and full
connected to the Carriage Control Card. The lift/lower. These values are also stored in
output of S2 is hard wired through the CCC memory in the VM. Refer to page 3-9 for a
and over the mast at JPC11-5 to JPT22-8 as an complete description of Learn Mode. The CCC is
input to the VM processor. The Carriage in constant communication with the VM
Deadman voltage is not used by the CCC. It is through messages that report the status of the
only used by the VM. When S2 closes, it control potentiometers and carriage switches to
switches Carriage Deadman voltage from a high the VM. When the VM receives the message, it
state (>4.5VDC) to a low state (<0.7VDC). When compares the pot position information to the
the VM processor detects a low state at S2, it values that it stored when it learned the pots.
also needs to receive information that S23 is
closed. When the control handle is moved from neutral,
the CCC detects a different voltage at JPC9-9
When S23 closes, it activates a circuit on the from VR1. The CCC updates the VR1 position
CCC that provides a high input (>4.5VDC) value in the next message sent to the VM. When
through the connect detect jumper (steering the VM receives the new position value, it
request encoder connector JPC1-8 and 9) to the compares that position value to the learned
processor on the CCC. The purpose of this value for VR1 to determine the direction and
connect detect jumper is to make sure that the magnitude of the travel request. The VM then
steering card is connected before the brake is looks at all speed limiting inputs such as motor
released. When the processor receives that temperature, height, weight, steering angle, and
voltage, it performs two operations fault codes to determine if the requested speed
simultaneously. It sends a message over the is allowable. The VM then initiates a command
communications bus telling the VM that the for the appropriate direction and speed to the
Brake Deadman is pressed. When the VM TPA over the communications Bus. The CCC is
receives that message, it acknowledges to the constantly monitoring the travel request at VR1
CCC that the message was received. The CCC and updating the VR1 position value to the VM.
also activates a circuit on the CCC that The VM therefore, constantly updates the travel
switches the output Brake Deadman (JPC11-4) command to the TPA.
from a high state (>4.5VDC) to a low state
(<0.7VDC). The output Brake Deadman is hard When the TPA receives a travel command from
wired from the CCC at JPC11-4 to the VM at the VM, it produces a control output to the
JPT22-7 through the over-the-mast cable. traction motor. All operational parameters that
affect travel motor torque and speed are
To release the brake, the VM must know that all controlled exclusively by the TPA. It monitors
deadman switches are operational and that the motor current, voltage, and RPM, and from
steering encoder is connected. When the VM them, can determine motor performance. The
receives the communication message that S23 TPA will alter its control output to the traction
is closed, and detects low inputs at both motor to match the motor performance to the
JPT22-7 (Brake Deadman) and JPT22-8 travel command from the VM. As the travel
(Carriage Deadman), it knows that all the request from the CCC to the VM changes, so
required conditions are met. The VM then does the travel command from the VM to the
provides B– to JPT20-14 (Brake) that energizes TPA that in turn, alters motor operation to track
the brake coil and releases the brake. the travel request from the operator. The TPA
also monitors drive motor temperature and the

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

Tractor-First/Forks-First (TF/FF)

internal temperature of the amplifier and can

alter travel based on the TPA temperature. The
TPA sends motor temperature to the VM, and
the VM alters the travel command based on
traction motor temperature.

When the lift truck is moving and the travel

control handle is moved to request the opposite
direction, the same sequence of events takes
place. The VM does not request plugging or
regeneration: it just requests travel in the
opposite direction at whatever speed the CCC
communicated. The TPA, that calculates both
direction and speed, determines whether the
travel command from the VM must be met with
a travel, a plug, or a regeneration control
output to the traction motor.

Tractor-First/Forks-First (TF/FF)
Tractor-First and Forks-First travel settings
allow independent configurations for the
maximum speed that the truck can travel while
moving in the tractor-first direction and the
forks-first direction.

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Section 8. Theory of Operation Models 5300/5500/5600 Maintenance Manual

Steering System

Steering System the steering motor to obtain the movement that

was requested from the tiller.

This section contains a description of the Both steering encoders in the dual encoder
steering system. For wire guided steering must be operational for full travel speed. If only
information, refer to page 8-13. one steering encoder is operational, travel speed
is limited to 2.5 mph (4.0 km/h).
System Components
The VM monitors steer current (JPT6-3), the
• Steering Request Encoder – a dual Steer Motor Encoder, and Neutral Pulse to
encoder located behind the steer wheel on determine that the steering system is operating
the carriage converts the operator request correctly. The VM supplies +12VDC to the Steer
into electronic pulses Amplifier at JPT6-6 to power the circuits inside
• Carriage Control Card - converts the the Steer Amplifier. When the deadman pedal is
inputs from the steering request encoder pressed, the VM energizes the TPC contactor,
into a message sent to the Vehicle providing B+ to TP2 on the Steer Amplifier to
Manager power the steer motor.
• Vehicle Manager - the controlling
manager of the steering system. Generates Functional Description
commands to the steer amplifier based on
the message from the Carriage Control The dual steering encoder is connected to the
Card CCC at JPC1 (encoder 1) and JPC21
(encoder 2). Each encoder has a +5.3V supply,
• Steer Amplifier - amplifies the steering
a DGND, two quadrature phased channels
commands from the Vehicle Manager and
(CHA and CHB), and a jumper that is used as a
drives the steer motor
connect detect to make sure that the steering
• Electric Steer Motor/Gear Reducer - encoder is connected to the CCC before normal
positions the drive unit operation of the lift truck is allowed by the VM.
• Steer Motor Encoder - located inside the
steer motor and used to determine if the When the tiller is moved, each encoder
motor is responding to the commands of produces an output pair (CHA and CHB from
the VM encoder 1 and CHA-E2 and CHB-E2 from
encoder 2). If the tiller is turned faster, the
• Home Sensor Prox - used by the steering
frequency of the output from the encoder
system to position the drive unit straight
increases. Each pair is converted into a positive
ahead during Auto Steer Center
or negative steering count that contains
information on the direction and speed of the
System Overview steering request from the tiller. This is sent over
the communications bus to the VM. If either of
The Steering Request Encoder is attached to the the steering counts are missing, the VM will
steer tiller on the carriage. The Steering Request cause a steering code to be displayed;
Encoder is a dual encoder. It contains two
• Code G0 if CHA/CHB is missing
encoders in a single package.
• Code G7 if CHA-E2/CHB-E2 is missing
Each encoder produces two channels that are
quadrature phased and are used by the CCC to When the VM receives the steering count from
produce a steering request (steering count) that the CCC, it produces the appropriate steering
is sent to the VM over the communications bus. command for the Steer Amplifier. This steering
The VM, in turn, sends steering commands for command is sent to the Steer Amplifier at
either clockwise or counterclockwise rotation to JPT6-5 (CCW-PWM for CCW rotation) or JPT6-2
the Steer Amplifier. The Steer Amplifier drives (CW-PWM for CW rotation). Although these
commands are a PWM voltage, either can be

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

Functional Description

measured as a DC voltage with a Digital Multi that the encoder is not connected and the VM
Meter. The voltage will vary from approx. causes a Code G7. If the jumper is intact and
11VDC when the steering tiller is stationary, encoder 2 fails, the CCC will send a count for
and decreases as the steer tiller is moved faster. encoder 1 and not encoder 2, to the VM, and
A slow request is represented by a voltage of the VM will still cause a Code G7. Either failure
about 9VDC and a fast request is represented will cause the same code.
by a voltage of approx. 5VDC measured with
respect to (wrt) B–. Because the VM is
monitoring both the steer motor current and
the output from the Steer Motor Encoder, it
knows that the steer motor moves when
requested.

When the steer motor is not moving, there is no

input to the VM from either the steer motor
current or the steer motor encoder. This
situation can occur when driving in a straight
line. The VM needs a way to make sure the
steer system is operational. This is
accomplished through the Neutral Pulse. When
the Steer Amplifier has an input at the
CW-PWM line, it drives the Neutral Pulse
output low (<0.5VDC). When the Steer Amplifier
has an input on the CCW-PWM, it drives the
Neutral Pulse high (>4VDC). When the
deadman pedal is pressed and there is no input
on either the CW-PWM or the CCW-PWM lines,
the VM dithers the CW-PWM and CCW-PWM
control lines, causing the Neutral Pulse line to
toggle between high and low states. The VM
detects the Neutral Pulse is toggling as the
CW-PWM and CCW-PWM lines vary, thereby
informing the VM that the steering system is
operational.

The connect detect jumper for encoder 1 is

JPC1-8 and 9 and is called BRKDMAN/
DEADMAN. If that jumper is open or JPC1 is
disconnected, the hard wired voltage, BRAKE
DEADMAN, from the CCC to the VM is
interrupted and the VM will cause a Code 8C. If
the jumper is intact and the encoder fails, the
VM will lose steering encoder one and the VM
will cause a Code G0.

The connect detect jumper for encoder 2 is

JPC21-5 and 6 and is called CD SUPPLY/CD.
This jumper connects a 5VDC supply to an
input on the CCC processor. When the voltage
is present, the CCC sends a message to the VM
that the steering encoder is connected. If the
voltage is not present, the message to the VM is

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Section 8. Theory of Operation Models 5300/5500/5600 Maintenance Manual

Lift/Lower System

Lift/Lower System enough to start elevating the main cylinders. Oil

flow spins the turbine in the flow sensor. As the
turbine spins, the vanes pass by the magnetic
Emergency Lower pickups screwed into the flow sensor housing.
This creates a series of high and low pulses (or
Provisions are made to lower the carriage from counts) that go into the flow sensor module. The
the ground. When the Emergency Lower Valve pickups are 90° out of phase. This allows the
is opened, hydraulic fluid is allowed to pass system to determine if the carriage is elevating
through the emergency lower valve at a or lowering, based on the direction the vanes
constant rate. are spinning. The flow sensor module passes
these counts to the VM. The VM determines the
direction of travel and the number of counts.
Variable Speed DC Lift with The VM uses this information to calculate fork
intellispeed height, which it uses to determine speed
reductions at elevated height.
NOTE: For lift trucks without intellispeed, all
functions are the same excluding When the VM first commands the activation of
references to the flow sensor, the lift system, it is looking for the feedback
intellispeed Manager, and height counts. from the flow sensor. If the lift is commanded to
activate and no counts from the flow sensor are
The CCC is constantly monitoring the output present, the VM will flag an error condition and
voltage of VR2 and sending it to the VM over the assume it is at maximum elevated height for
BUS. The VM compares this voltage to the speed limiting. Travel speed is reduced linearly
voltages stored during the Learn process. The by about 0.5 mph (0.8 km/h) for every
VM checks the battery voltage (for lift cutout), 18 in. (45.7 cm) from full speed down to 1 mph
all enabled options and switches that could (1.6 km/h), between the lower reference switch
prevent the activation of the lift system. When and 240 inches (610 cm). A low volume of fluid
satisfied that no criteria are present to prevent flow will not cause the turbine to spin. Because
lift, it then determines the requested percentage of this, if the lift system is feathered often, an
of full speed lift. It then activates the lift/lower error is registered. If the intellispeed option is
proportional valve fully open and closes the lift not on the lift truck, the travel is reduced each
pump contactor by taking the coils to B–. time a mast limit switch is opened while
elevating.
Opening the lift/lower valve fully prevents
sudden movement of the platform when the lift The VM monitors the P Sense line to determine
pump is first activated by allowing the fluid to the condition of the LPC contactor and verify
return to the tank. As soon as the command to the lift motor is spinning. When a lift request
close the P contactor is activated, the VM looks has finished (VR2 has either returned to neutral
at the P Sense input, verifying the contactor or through neutral to a lower request), the VM
closed as commanded. It then slowly reduces monitors the LPC for back ElectroMotive Force
the PWM output to the coil for the lift/lower (EMF) from the motor to determine that the lift
proportional valve to match the percentage of motor has stopped spinning. As long as the VM
full speed lift requested. As the lift/lower senses voltage on the LPC, it will provide voltage
proportional valve closes, hydraulic fluid passes to the lift/lower proportional coil, keeping the
through the 5 psi (34 kPa) check valve, the valve open to allow the fluid from the pump to
normally closed check valve in the load holding return to tank. This makes sure that the
valve, through the flow sensor to the flow cylinders do not continue lifting after the
controls at the bottom of the lift cylinders. The request has ended. Once the lift motor has
flow control in the free lift cylinder allows completely stopped spinning, the VM removes
unrestricted fluid flow to the center lift ram. The voltage to the lift/lower coil, closing the
center ram elevates first because less pressure lift/lower proportional valve.
is required. Once the platform hits the stops on
the inner telescopic, the pressure increases

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

Variable Speed AC Lift with intellispeed

Variable Speed AC Lift with sensor module. The pickups are 90° out of
phase. This allows the system to determine if
intellispeed the carriage is elevating or lowering, based on
NOTE: For lift trucks without intellispeed, all the direction the vanes are spinning. The flow
functions are the same excluding sensor module passes these counts to the VM.
references to the flow sensor, The VM determines the direction of travel and
intellispeed Manager, and height counts. the number of counts. The VM uses this
information to calculate the fork height that it
The CCC is constantly monitoring the output uses to determine speed reductions at elevated
voltage of VR2 and sending it to the VM over the height. When the VM first commands the
BUS. The VM compares this voltage to the activation of the lift system, it is looking for the
voltages stored during the Learn process. The feedback from the flow sensor. If the lift is
VM checks the battery voltage (for lift cutout), commanded to activate and no counts from the
all enabled options, and all switches that could flow sensor are present, the VM flags an error
prevent the activation of the lift system. condition and assumes it is at maximum
elevated height for speed limiting. Travel speed
When satisfied that no criteria are present to is reduced linearly, about 0.5 mph (0.8 km/h)
prevent lift, the VM then determines the every 18 in. (45.7 cm), from full speed down to
requested percentage of full speed lift. It then 1 mph (1.6 km/h), between 60 (152 cm) and
sends an RPM command over the BUS to the 240 inches (610 cm). A low volume of fluid flow
Lift Power Amplifier. The LPA activates the LPC will not cause the turbine to spin. Because of
contactor by taking the coil to B– internally in this, if the lift system is feathered often, an
the LPA. As soon as the command to close the error is registered. If the intellispeed option is
LPC contactor is activated, the LPA looks at the not on the lift truck, the travel is reduced each
(+) input from the LPC verifying the contactor time a mast limit switch is opened.
closed as commanded. It then slowly increases
the voltage output to the lift motor to match the
RPM requested. As the voltage is increased to
the lift motor, the motor and pump spin faster,
increasing the output of oil to the lift system.

The LPA monitors the input from the bearing

encoder in the lift motor and determines the
RPM of the motor. It adjusts the output to the
motor to maintain the requested RPM. The
hydraulic fluid passes through the 5 psi
(34 kPa) check valve, the normally closed check
valve in the load holding valve, through the flow
sensor to the flow controls at the bottom of the
lift cylinders. The flow control in the free lift
cylinder allows unrestricted oil flow to the
center lift ram. The center ram elevates first
because less pressure is required. Once the
platform hits the stops on the inner telescopic,
the pressure increases enough to start elevating
the main cylinders. As the lift cylinders start to
elevate, the fluid flow starts to spin the turbine
in the flow sensor once the volume is large
enough. As the turbine spins, the vanes pass by
the magnetic pickups screwed into the flow
sensor housing. This creates a series of high
and low pulses (or counts) that go into the flow

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Section 8. Theory of Operation Models 5300/5500/5600 Maintenance Manual

Variable Speed Lower Activation

Variable Speed Lower 180 psi (1241 kPa) check valve in series with
the side lift cylinders and a 100 psi (689 kPa)
Activation check valve in the manifold for the free lift
cylinder. If the pressure on these valves is
The following is based on a lower request from a
reduced below their rated pressure, the check
full-speed lift situation.
valve closes, stopping the lower function. This
keeps fluid from draining out of the cylinders
VR2 passes through neutral to a full speed
and keeps the over the pulley hoses, cables,
lower request. The CCC sends the voltage to the
and lift chains from falling off the pulleys.
VM over the BUS. The VM recognizes the
change and realizes full speed lower is required.
All enabled options and switches that can
prohibit lower are checked.

Once the VM is satisfied that lower can be

allowed, it monitors the back EMF of the lift
motor through the LPC. The VM monitors the P
Sense line to determine the condition of the P
contactor and verifies the lift motor is spinning.
When a lift request has finished (VR2 has either
returned to neutral or through neutral to a
lower request), the VM monitors the P Sense
line for back EMF from the motor to determine
that the lift motor has stopped spinning. As
long as the VM senses voltage on the P Sense
line, it provides voltage to the lift/lower
proportional coil, keeping the valve open to
allow the fluid from the pump to return to tank.
This makes sure that the cylinders do not
continue lifting after the request has ended.

Once the lift motor has completely stopped

spinning, the VM removes voltage to the
lift/lower coil, closing the lift/lower
proportional valve. The Load Holding solenoid is
activated by the VM, opening the valve. The VM
then gradually opens the lift/lower solenoid to
the percentage of requested lower. This allows
the oil to flow from the side lift cylinders
through the flow controls at the bottom of the
cylinders, the 180 psi (1241 kPa) telescopic
hang up valve, the flow sensor, the load holding
valve, the lift/lower prop valve, the 100 psi
(689 kPa) platform hang up valve, the filter, and
back to the reservoir. The telescopics lower first
due to the greater amount of pressure on the
hydraulic fluid in the main cylinders. Once the
telescopics fully lower, the free lift cylinder
begins to lower. Lowering causes the turbine in
the flow sensor to spin in the opposite direction
of lift and reverses the counts to the VM. The
VM counts down, lowering the height count. If
the forks get hung up while lowering, there is a

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

Wire Guidance System

Wire Guidance System steering corrections to keep the lift

truck over the wire, guidance system
error codes, distance from wire, and
This section contains a description of the wire heading angle information.
guidance system. For manual steering
• Antenna Cards - there are two of these
information, refer to page 8-8.
antenna assemblies. The Tractor Sensor is
located behind the center bumper plate in
System Components front of the Drive Unit. The Load Sensor is
located on a bracket between the baselegs
• Auto/Manual Switch (S4) – located on the
beneath the operator platform. Each
dashboard near the speed control handle.
sensor card has 4 coils mounted on it. The
This switch is used by the operator to
center pair are the Nearwire Coils and the
select manual steering or wire guided
outer coils are the Guidance Coils. These
operation.
sensor coils have an AC voltage induced
• Carriage Control Card - located behind into them by the magnetic field being
the console cover and below the steer tiller radiated from the guide wire. These AC
assembly. It monitors the state of the voltages are then amplified and sent to the
Auto/Manual switch and advises the VM if GM.
it is open (Auto) or closed (Manual). Also
• Steer Motor Encoder - when the steer
operates the wire guidance icon LEDs on
motor armature is rotating, the steer
the Carriage Light Display card.
motor encoder produces a pair of
• Vehicle Manager - located in the tractor quadrature phased square waves that are
compartment. It is the controlling manager used by the VM to determine steer motor
for the steering and travel systems. When speed and direction of rotation. The VM
it is advised that the Auto/Manual switch then checks this information against the
is in the Auto position, it uses the lift truck steering commands from the GM to verify
position information supplied by the correct operation.
Guidance Manager to provide steering
• Home Reference Prox Sensor - used by
control for the lift truck. The VM also
the VM to determine “Home” or straight
provides direction and speed information
ahead position of the drive unit.
to the Guidance Manager that enables it to
provide correctly oriented steering • Guide Wire - a wire that is buried in the
commands for either forward or reverse facility floor that radiates a magnetic field
directions of travel. when an AC current flows through it.
• Steer Amplifier - located at the rear wall
on the top deck of the tractor
compartment. It amplifies the steering
commands from the VM and provides the
high power drive necessary to control the
steer motor.
• Guidance Manager (GM) - located on the
right side of the drive tire wheel well
housing in the tractor compartment. This
assembly is comprised of one physically
and electrically connected printed circuit
card:
Guidance Card - calculates the
position of the lift truck relative to the
guide wire using the voltages received
from the Antenna Cards. The GM
informs the VM of the necessary

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Section 8. Theory of Operation Models 5300/5500/5600 Maintenance Manual

System Overview

System Overview The GM then tells the VM to put the lift truck
into Seeking Mode and try to acquire the wire.
When the lift truck is in the wire guided mode, Travel speed is limited to 1 mph (1.6 km/h) in
the lift truck steering functions the same way as the forks-first direction and limited to the
when in the manual steering mode with one Acquire speed that is set in Configure Mode for
exception. Steering requests do not come from tractor-first travel. If the Wire Sense Creep
the CCC when in wire guided mode as they do (WrSnCrp) option is enabled in Configure Mode,
in manual steering. In the wire guided mode, lift truck speed is limited to 1 mph (1.6 km/h)
steering requests originate in the GM. To switch whenever S4 is detected closed (Manual
from manual steering to the wire guided mode, position) and the GM reports that a guide wire
several events need to occur. is detected. During Seeking Mode, an audible
tone is generated and the green LED triangles of
First, the CCC needs to detect that the the wire guidance icon (on the Carriage Light
Auto/Manual switch (S4) is open (Auto Display card) will blink. Steering at this time
position). Next, the CCC needs to advise the VM will still be in manual control because the lift
that S4 is open. When the VM is advised that truck has not acquired the wire. The operator
S4 is in the Auto position, it transfers steering must be steering the lift truck toward the guide
control from the Steering Encoder to the GM. wire location to help the lift truck acquire the
The GM calculates the position of the lift truck wire.
relative to the wire and advises the VM what
direction and how far to steer the drive unit. As either the tractor end or the load end center
During wire guided operation, the GM is pair of sensor coils (Nearwire coils) approach
constantly updating the VM with corrections the guide wire, they begin to detect the
since the lift truck’s position relative to the magnetic field around the guide wire. If the
guide wire is constantly changing. If the lift Nearwire coils do not detect this magnetic field
truck exceeds the deviation values for Distance for any reason, the lift truck will not acquire the
from Wire (DFW) or Heading Angle (HA) that are wire, even if the outer coils (guidance coils)
set in Configure, the GM informs the VM to detect the magnetic field. The magnetic field
either slow or stop the lift truck depending on around the guide wire causes an AC voltage to
the magnitude of the deviation. be induced into the sensor coils that is sent to
the GM for conditioning. The GM removes any
noise that was picked up by the antenna coils
Functional Description and also converts this AC voltage into a DC
voltage to be used by the Guidance Card. As
During normal manual steering operation, the
either the tractor end or the load end Nearwire
CCC is in constant communication with the
coils get closer to the wire, the value of the DC
VM, updating the VM with the status of the
voltage to the Guidance Card increases. When
components connected to it such as switches,
the Nearwire coils get close enough (to the wire),
the control handle, and the Steering Encoder.
and the voltage is high enough, the GM tells the
Likewise, the GM is constantly attempting to
VM to release full control of issuing the steering
calculate the position of the lift truck relative to
commands to the Guidance Card.
the guide wire. The VM is constantly being
updated as to the position of the drive unit
When the GM takes over issuing steer
relative to home position as well as travel speed
commands, the lift truck is in an Aligning Mode.
and direction that it in turn communicates to
While in Aligning Mode, the VM ignores the
the GM. When the CCC detects that S4 is
steering request from the CCC and all the wire
opened (Auto position), it advises the VM that
guidance icon LEDs on the Carriage Light
S4 is open. The VM determines that the lift
Display Card will blink. The lift truck is now
truck is ready for wire guided operation and
auto steering and no longer responds to
transfers the steering control from the Steering
operator steer tiller inputs. The Antenna Card
Encoder to the GM.
also monitors the DC voltages representing the
AC voltages being picked up by the outer coils

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

System Overview

(Guidance Coils) on both the tractor end and steering more than 10 degrees. This allows the
the load end sensors as the lift truck begins to lift truck to be powered down inside the aisle
align over the wire. When the voltages that the and remember that it is in an In-Aisle-State
lift truck detects from the load end and tractor when powered back up. System operation is not
end guidance coils begin to balance out and changed upon aisle entry
match the Learned Offset values for those coils,
the Guidance Card will switch from Aligning When the lift truck is exiting an aisle and each
Mode to Locked on Wire or Guided Mode. At sensor is activated by magnets within 10 in.
that time, all of the wire guidance icon LEDs on (254 mm) of each other, the lift truck will plug
the Carriage Light Display Card will illuminate to reduce speed until the speed is reached that
solid and full travel speed is allowed in either is stored in the Configuration Menu. Once this
direction. speed is reached, travel speed is limited by the
VM to the speed programmed in the
The Guidance Card constantly monitors the Configuration Menu until the control handle is
voltages from each of the four guidance coils via returned to neutral and travel is requested
the Antenna Cards. It compares the voltage again. During the plugging sequence, the
from each coil to the value for each coil that was operator can override the plugging strength
obtained through the Learn procedure. By with a request for a more aggressive plug from
comparing the actual values for all four the control handle. When the sensors are
guidance coils with the learned values stored in activated by magnets that are more than 11 in.
the memory, the Guidance Card can issue the (279 mm) but less than 30 in. (762 mm) apart,
appropriate steering commands to the VM to the VM plugs the lift truck to a complete stop.
keep the lift truck centered over the guide wire. The operator must then return the control
Also, using these values, the Guidance Card handle to neutral and request travel again.
calculates the Heading Angle (HA - angle of the
lift truck to the wire) and the Distance From End-of-Aisle Configurations
Wire (DFW - how far the lift truck is from the
wire) and issues the appropriate Slow or Stop Figure 8-1 shows the various EOA
commands to the VM when DFW or HA values configurations possible within a system.
set in Configure Mode are exceeded. See
Table 3-2, “Configure Mode Menu,” on
page 3-14. End-of-Aisle Magnet Installation
Information
End-of-Aisle Control
If there are consistent, repetitive problems with
end-of-aisle operation, and the lift truck
The End-of-Aisle system consists of lift truck
appears to be OK, the magnets may have been
mounted components and magnets embedded
installed out of tolerance. Figure 8-2 and
in the floor inside of the aisle. The lift truck
Figure 8-3 depict the correct location of the
mounted hardware consists of four magnet
magnets.
sensors mounted between the baselegs under
the operator's platform. They are connected
directly to the VM. When the system is
activated, the VM monitors the inputs from the
sensors. When entering the aisle and both
sensors cross a magnet in less than 24 in. (610
mm), the VM recognizes this as In-Aisle-State.
This information is stored in Non Volatile
Memory (NVM). NVM cannot be changed by a
loss of power to the system. The only way to
change it is by another input. This input can
only be initiated by crossing another set of
magnets or by traveling and turning the

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System Overview

Vehicle will slow to configured end-of-aisle

speed when parallel magnets are crossed.

Magnets Parallel

Vehicle will plug to a stop when

staggered magnets are crossed
(or just one magnet is sensed).
Magnets Staggered

Vehicle will slow to configured end-of-aisle speed when

parallel magnets are crossed.

Vehicle will plug to a stop when staggered magnets are

crossed (or just one magnet is sensed). Magnets parallel at one end
and staggered at the other.

Magnets parallel in one aisle and staggered in the next.

Vehicle will slow to configured speed in aisle that has parallel magnets and plug to a stop
in aisle that has staggered magnets.

8
Figure 8-1. End-of-Aisle Configurations

20 ft. ±3 in. (6.1 m ±7.6 cm) 4.5 in. ±1/2 in.

Both Ends (114 mm ±13 mm)
Both Ends
Guide Wire*

4.5 in. ±1/2 in.

(114 mm ±13 mm)
Magnet
Both Ends
Magnet Position for Deceleration

* In rail guided applications, use the center of the aisle as the reference point for the dimensions.

8
Figure 8-2. End-of-Aisle Magnet Position (Deceleration)

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

System Overview

20 ft. ±3 in. (6.1 m ±7.6 cm)

Both Ends
4.5 in. ±1/2 in.
(114 mm ±13 mm)
Both Ends
Guide Wire*

4.5 in. ±1/2 in.

(114 mm ±13 mm)
Magnet
Both Ends
24 in. ±1 in.
(610 mm ±26 mm) Both Ends

Magnet Position for Auto Stop

*In rail guided applications, use the center of the aisle as the reference point for the dimensions.
8
Figure 8-3. End-of-Aisle Magnet Position (Auto Stop)

20 ft. (6.1 m) 20 ft.

(6.1 m)

4.50 in.
4.50 in. (11.4 cm)
(11.4 cm)
Center of Aisle Magnet

8
Figure 8-4. End-of-Aisle Magnet Location

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Section 8. Theory of Operation Models 5300/5500/5600 Maintenance Manual

End-of-Aisle Slow Down

End-of-Aisle Slow Down

With Wire Guidance

When the lift truck is locked on the guide wire,

the VM will start looking for the input from the
magnet sensors. When a set of magnets is
crossed entering the aisle, the system functions
as described in End-of-Aisle Control. If the
magnets are crossed while exiting the aisle with
the Auto/Manual switch in the Auto position,
the lift truck will slow down or stop; whichever
the system is configured for. If the Auto/Manual
switch is moved to the Manual position prior to
crossing the magnets, the system will not look
for the magnets. Steering is reverted to the
operator and normal operation is resumed.
Once out of the aisle and the steering is turned
more than 10 degrees while traveling, the aisle
state is reset to out-of-aisle.

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

End-of-Aisle Slow Down

With auto steer center in a rail

guided system WITH a rail switch
installed on one guide roller
assembly.

When the lift truck enters the rails, the switch

mounted on the guide roller assembly is closed.
When the switch is activated, a tone will sound
until the Auto/Manual switch is placed in the
Auto position. When the switch is placed in the
Auto position, the drive unit auto steer centers
and steering control is taken away from the
operator. The speed restriction is removed and
full speed travel is allowed. The VM then starts
looking for floor magnet inputs. When exiting
the aisle, if the magnets are crossed with the
Auto/Manual switch in the Auto position, the
lift truck will slow down or stop, depending on
system configuration. If the Auto/Manual
switch is moved to the Manual position prior to
crossing the magnets, the system will not look
for the magnets. Steering is reverted to the
operator and normal operation is resumed. An
audible tone sounds until either the
Auto/Manual switch is turned back to Auto or
the rail switch on the guide roller opens. Once
out of the aisle and the steering is turned more
than 10 degrees while traveling, the aisle state
is reset to out-of-aisle.

With auto steer center in a rail

guided system WITHOUT a rail switch
installed on the guide roller
assembly.

When the lift truck is in the aisle and the

Auto/Manual switch is in Auto, the VM will
start looking for the input from the magnet
sensors. When a set of magnets is crossed
entering the aisle, the system functions as
described in “End-of-Aisle Control” on
page 8-15. When exiting the aisle, if the
magnets are crossed with the Auto/Manual
switch in either position, the lift truck will slow
down or stop, depending on how the system is
configured.

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End-of-Aisle Slow Down

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

Pin-Out Matrix

Pin-Out Matrix • Normal Level: the approximate voltage

Section 8. Theory of Operation

that must be seen on that wire for the

state indicated. Unless otherwise
The pin-out matrix chart lists functions and indicated, voltages are measured with
normal voltages of terminals and harness respect to (wrt) B– at TP4.
connector pins. The matrix columns have the • Signal Source: the device or connection
following meanings: that supplies the signal directly to the
• Item: sequential number to aid in wire.
reference. • Signal User: the device or connection
• Connection: the actual wire numbers or where the wire directly delivers the signal.
component abbreviations on the electrical
schematic.
• Function Description: brief definition of
the signal carried on the wire.
• Theory of Operation:
• A detailed description of the signal
carried on the wire. If the signal can be
variable, the state of a related
component that will cause the signal to
vary is indicated.
• Identifies possible causes for lack of
correct signal.

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

1 JPC1-1 +5.3V Supplies +5.3V to the Steering Request >5V CCC Steering
Encoder. It is dependent on the +12VP Request
from the VM and JPC11-1. Encoder

2 JPC1-2 DGND B– for the circuits of the Steering Request <0.3V wrt TP4 CCC Steering
Encoder. Request
Encoder

3 JPC1-3 CHA One part of the steering request from 0-5V nominal Steering CCC
the Steering Request Encoder when the w/tiller moving; Request
steering tiller is moved. It is a square >4.5V or <0.5V Encoder
wave signal (0V and 5V) identical to w/tiller
CHB but different phase. The CCC uses stationary
the phase relationship of CHA/CHB to
determine the direction and speed of the
steering request.

4 JPC1-4 CHB One part of the steering request from 0-5V nominal Steering CCC
the Steering Request Encoder when the w/tiller moving; Request
steering tiller is moved. It is a square >4.5V or <0.5V Encoder
wave signal (0V and 5V) identical to w/tiller
CHA but different phase. The CCC uses stationary
the phase relationship of CHA/CHB to
determine the direction and speed of the
steering request.

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Section 8. Theory of Operation Models 5300/5500/5600 Maintenance Manual

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

5 JPC1-8 BRAKE Output of the Brake Deadman switch >5V w/pedal CCC VM
DEADMAN (S2 at JPC7-1) that is looped back to the pressed; <0.5V
CCC at JPC1-9 and sent to the VM to w/pedal
inform the VM of the status of S2. If the released
Steering Request Encoder Cable
becomes unplugged, the VM will not
release the brake.

6 JPC1-9 BRAKE Receives output from JPC1-8 and sends >5V w/pedal CCC VM
DEADMAN the VM the status of S2. If the Steering pressed; <0.5V
Request Encoder Cable becomes w/pedal
unplugged, the VM will not release the released
brake.

7 JPC2-1 DGND B– for the Operator Interface Card. <0.3V wrt TP4 Fuse/Relay Operator
Card Interface

8 JPC2-2 UP ARROW The CCC monitors this input to >5V w/switch Operator CCC
determine when the up arrow on the open; Interface
Operator Interface is pressed. <0.5V w/switch
closed

9 JPC2-3 DN ARROW The CCC monitors this input to >5V w/switch Operator CCC
determine when the down arrow on the open; Interface
Operator Interface is pressed. <0.5V w/switch
closed

10 JPC2-4 ETR/SHFT The CCC monitors this input to >5V w/switch Operator CCC
determine when the Enter/Shift button open; Interface
on the Operator Interface is pressed. <0.5V w/switch
closed

11 JPC2-17 Not Used

12 JPC3-1 60” LIMIT The voltage on this line changes when <1V w/switch CCC CCC
the platform crosses S28 (60” Limit closed;
Non-intellispeed Switch). This change in voltage is used >9V w/switch
lift trucks by the CCC to limit travel speed. S28 open
opens when the platform is above the
60 in. switch and speed is limited to
1 mph (1.6 km/h) maximum. When the
platform is below 60 in. (1524 mm),
S28 is closed and the speed is
configurable from 0.5 to 2.5 mph (0.8
to 4.0 km/h).

intellispeed Lift There is a jumper on the CCC at JPC3.

Trucks Travel speed above S28 is determined
by height. The lift truck will have full
configured speed to 60 in.

13 JPC3-2 6-12VF 12V supply to S28 (60” Limit Switch). 6-8.8V VM S28
w/switch
connected;
>8.8V w/switch
disconnected

14 JPC3-3 PGND B– for S28 (60” Limit Switch). <0.3V wrt TP4 VM S28

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

15 JPC4-1 LOWER LIMIT Output from S25 used by the CCC to <1V w/platform S25 CCC
detect the location of the operator below switch;
platform. approx. 10V
with platform
above switch

16 JPC4-2 +12VF 12V supply to S25 (Lower Inhibit 10.8-13V VM S25

Switch). w/key switch
ON

17 JPC4-3 DGND B– for S25. <0.3V wrt TP4 VM S25

18 JPC5-1 B+KEY B+ that is switched by the key switch B+ w/key CCC Light and
and powers the optional light and fan. switch ON Fan
package

19 JPC5-2 B–F B– for the optional light and fan. <0.3V wrt TP4 CCC Light and
Fan
package

20 JPC5-3 B–F B– for the CCC power option (Control <0.3V wrt TP4 CCC Handle
Handle Heater). Heater

21 JPC5-4 B+KEY B+ that is switched by the key switch B+ w/key CCC Handle
and powers the CCC power option switch ON Heater
(Control Handle Heater).

22 JPC6-1 B+F B+F to S1 (Key Switch). If B+ is not B+ wrt TP4 Fuse/Relay S1

present, check for B+ at JPC16-3. w/battery Card
connected and
FU5 good

23 JPC6-2 B+KEY B+ switched by the key switch. If B+ is B+ w/key Fuse/Relay All

missing, check for B+ at JPC6-1. switch ON and Card
FU5 good

24 JPC6-2 B+KEY B+ for Security Start Switch Relay. B+ CCC K12

Relay for
Security
Start
Switch

25 JPC6-3 B+EPO B+ after going through S21 (EPO B+ when EPO CCC Fuse/
switch). If B+ is missing, the CCC will switch is up Relay
display EPO depressed. Check for B+ at (closed) Card
JPC6-4.

26 JPC6-4 B+KEY B+ Key from JPC6-2 to supply B+ EPO B+ from JPC6-1 S1 S21
when S21 is out (closed).

27 JPC6-5 DGND B– for S7. <0.3V wrt TP4 VM S7

28 JPC6-6 L/L INHIBIT Determines whether the CCC will allow >5V w/S7 CCC CCC
BYPASS lift or lower when either lift or lower limit closed (up);
is reached. When S7 is closed, <0.5V w/S7
lift/lower is prevented when the cutout open (down)
switch is activated. When S7 is open,
lift/lower is allowed.

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

29 JPC7-1 BRAKE The CCC monitors the voltage on this >4V up CCC VM and
DEADMAN line to determine the state of S2. This (released); CCC
signal is looped through the Steering <0.5V down
Request Encoder at JPC1-8 and 9 and (pressed)
sent to the VM at JPT22-7.

30 JPC7-2 +12VF 12V supply to S2 (Carriage Deadman 10.8-13V VM S2

Switch). w/key switch
ON

31 JPC7-3 DGND B– for S2. <0.3V wrt TP4 VM S2

32 JPC7-4 CARRIAGE The CCC monitors the state of S23 >10V w/S2 up; CCC VM and
DEADMAN (Brake Deadman) directly. The VM <0.5V w/S2 CCC
detects the state of S23 at JPT22-8. The down
CCC and the VM communicate S23
status and must agree that it is pressed
before the brake is released.

33 JPC7-5 +12VF 12V supply to S23 (Brake Deadman 10.8-13V VM S23

Switch). w/key switch
ON

34 JPC7-6 DGND B– for S23. <0.3V wrt TP4 VM S23

35 JPC8-1 24 IN. LIMIT The voltage on this line changes when <1V w/S11 CCC VM and
the platform crosses S11. The change in closed; CCC
voltage is used by the VM to reset the >9V w/S11
height counter and enable correct open
speed. S11 opens when the platform is
above 24 in. and speed is determined
by height. When the platform is below
24 in., S11 is closed and full speed is
allowed.

36 JPC8-2 6-12VF 12V supply to S11 (24 in. Limit Switch). 6-8.8V w/S11 VM S11
connected;
>9.0V w/S11
disconnected

37 JPC8-3 DGND B– for S11. <0.3V wrt TP4 VM S11

38 JPC9-1 AUTO/MANUAL The CCC monitors the state of the S4 <1V in manual; CCC VM
(Auto/Manual Switch) to determine if >5V on wire/in
the lift truck is in manual steering or rail
Wire Guidance/Rail Guidance mode.

39 JPC9-2 DGND B– for S4. <0.3V wrt TP4 VM S4

40 JPC9-3 HORN This input is monitored by the CCC. >5V Open; CCC VM and
When S3 (Horn Switch) is pressed, the <0.5V Closed CCC
CCC tells the VM to blow the horn.

41 JPC9-4 DGND B– for S3 and VR2 (Lift/Lower Pot). If <0.3V wrt TP4 VM S3
missing, Code 81 is displayed.

42 JPC9-5 +5.3V Supply voltage for VR2 (Lift/Lower Pot) >5V CCC VR2 and
and S3-3 S3 HORN. Horn S3

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

43 JPC9-6 L/L Variable voltage from VR2 wiper. The 1.3V Neutral; CCC VM
CCC monitors this voltage and sends it 0.4V Full Lift;
to the VM. Voltage must be between 0.4 2.1V Full Lower
and 4.6V. If not, Code 81 is displayed.

44 JPC9-7 DGND B– for VR1. <0.3V wrt TP4 VM VR1

45 JPC9-8 +5.3V Supply voltage for VR1 (Travel Pot). >5V CCC VR1

46 JPC9-9 TRAVEL Variable voltage from VR1 wiper. The 1.3V Neutral; CCC VM
CCC monitors this voltage and sends it 0.8V Full Fwd;
to the VM. Voltage must be between 0.4 2.6V Full Rev
and 4.6V. If not, Code 80 is displayed.

47 JPC9-10 Not Used

48 JPC11-1 +12VF Supplies working voltage to the CCC. 10.8-13V VM CCC

w/key switch
ON

49 JPC11-2 BUS– Carries the negative component of the 2.0V CCC LPA, TPA
digital communications between the and VM
CCC and the managers on the tractor
side of the communications bus.

50 JPC11-3 BUS+ Carries the positive component of the 3.0V CCC LPA, TPA
digital communications between the and VM
CCC and the managers on the tractor
side of the communications bus.

51 JPC11-4 BRAKE Sent by the CCC to the VM to energize >6V with CCC VM
DEADMAN the brake when all other conditions are deadman up
met. This output is sent when S2 is and brake
closed. applied;
<0.5V with
deadman down
and brake
released

52 JPC11-5 CARRIAGE Sent by the CCC to the VM to energize >6V with CCC VM
DEADMAN the brake when all other conditions are deadman up
met. This output is sent when S23 is and brake
closed. applied;
<0.5V with
deadman down
and brake
released

53 JPC11-6 DGND Reference and negative for the circuits <0.3V wrt TP4 VM CCC
on the CCC. Although it eventually
connects to B–, it is kept separate from
the other grounds to help reduce the
effects of noise on system operation.

54 JPC12-2 B–F SPARE B– for Security Start Switch Relay. B– CCC K2 Relay
for
Security
Start
Switch

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

55 JPC13-1 SIDEGATE LEFT Output from S61 used by the CCC to 10.8-13V VM CCC
detect the position of the left sidegate. w/key switch
The VM will prohibit travel if the ON
sidegate is up or the switch is open.

56 JPC13-2 +12VP 12V supply to S61 (Left Sidegate 10.8-13V VM CCC

Switch). w/key switch
ON

57 JPC13-3 DGND B– for S61. <0.3V wrt TP4 VM CCC

58 JPC14-1 SIDEGATE RIGHT Output from S60 used by the CCC to <1V with S60 CCC
detect the position of the right sidegate. sidegate down;
The VM will prohibit travel if the approx. 10V
sidegate is up or the switch is open. w/sidegate up

59 JPC14-2 +12VP 12V supply to S60 (Right Sidegate 10.8-13V VM S60

Switch). w/key switch
ON

60 JPC14-3 PGND B– for S60. <0.3V wrt TP4 VM CCC

61 JPC15-1 Not Used

62 JPC15-15 DGND B– for the Carriage Control Light <0.3V wrt TP4 VM Light
Display Card. Display
Card

63 JPC15-16 5.3V Supply voltage for the Carriage Control >5V CCC Light
Light Display Card. Display
Card

64 JPC15-24 Not Used

65 JPC16-1 B+EPO Present when both the Key Switch and B+ CCC Fuse/
EPO switch are closed. Supplies B+ Relay
EPO to the Fuse/Relay Card where it is Card
used by the K1, K2, and K3 relays.

66 JPC16-2 B–FUSEDS B– for the Spare Power Connector <0.3V wrt TP4 Fuse/Relay CCC
(JPC12-2) on the CCC. Supplies B– for Card (FU8)
the optional lights, fan, and RF unit.

67 JPC16-3 B+FUSEDS B+ for the Spare Power Connector B+ wrt TP4 Fuse/Relay CCC
(JPC12-1) on the CCC. Supplies B+ for w/battery Card (FU7)
the optional lights, fan, and RF unit. connected

68 JPC16-4 B–FUSED B– for the CCC from the Fuse/Relay <0.3V wrt TP4 Fuse/Relay CCC
Card. Card (FU6)

69 JPC16-5 B+EPO B+EPO Spare. B+ CCC Spare

70 JPC16-6 B+KEY B+ that is switched by the Key Switch B+ w/S1 closed CCC Fuse/
(S1) and sent from the CCC to supply Relay
B+ Key to the Fuse/Relay Card. Card

71 JPC16-7 B+FUSEDS B+ Fused Spare. B+ CCC Spare

72 JPC16-8 B+FUSED Main B+ supply to the CCC and is fused B+ wrt TP4 Fuse/Relay CCC
through FU5 on the Fuse/Relay Card. Card (FU5)

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

73 JPC21-1 +5.3V Supplies +5.3V to the E2 Steering >5V CCC E2

Request Encoder. It is dependent on the Steering
+12VP from the VM at JPC11-1. Request
Encoder

74 JPC21-2 DGND B– for the circuits of the E2 Steering <0.3V wrt TP4 CCC E2
Request Encoder. Steering
Request
Encoder

75 JPC21-3 CHA–E2 One part of the steering request from 0-5V nominal E2 Steering CCC and
the E2 Steering Request Encoder when w/tiller moving; Request VM
the steering tiller is moved. It is a square >4.5V or <0.5V Encoder
wave signal (0V and 5V) identical to w/tiller
CHB-E2 but different phase. The CCC stationary
sends this information to the VM.

76 JPC21-4 CHB-E2 One part of the steering request from 0-5V nominal E2 Steering CCC and
the E2 Steering Request Encoder when w/tiller moving; Request VM
the steering tiller is moved. It is a square >4.5V or <0.5V Encoder
wave signal (0V and 5V) identical to w/tiller
CHA-E2 but different phase. The CCC stationary
sends this information to the VM.

77 JPC21-5 CD SUPPLY 5.3V output from the CCC power >4V CCC CCC
supply. This voltage is dependent on
+12VP from the VM at JPC11-1. This
voltage goes back to the CCC
microprocessor to let the CCC know that
JPC21 is connected. If not connected,
Code G0 is displayed.

78 JPC21-6 CD +5.3V output from the CCC power >5V CCC CCC
supply. This voltage is dependent on
+12VP from the VM at JPC11-1. This
voltage goes back to the CCC
microprocessor to let the CCC know that
JPC21 is connected. If not connected,
Code G0 is displayed.

79 JPF1-1 B– B– for FU8 (15A/5A) Fuse for optional <0.5V TP4 Aux
Aux power. Power

80 JPF1-2 B– B– for FU8 (15A/5A) Fuse for optional <0.5V TP4 Aux
Aux power. Power

81 JPF1-3 Not Used

82 JPF1-4 B–F B–F from FU8 for optional Aux Power. <0.5V FU8 to B– Aux
Power

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Section 8. Theory of Operation Models 5300/5500/5600 Maintenance Manual

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

83 JPF1-5 B+F or B–F Provides either B+F or B–F to B+K3 on B– w/K3 FU5 when LPA and
the Lift and Travel Power Amplifiers. At De-energized; K3 is TPA
Startup the K3 coil is energized, B+ w/K3 energized;
providing B+ to the precharge circuit Energized FU6 when
and logic circuits in the power K3 is
amplifiers. With the K3 coil de-energized
de-energized, JPF1-6 is at B– to
discharge the amplifier precharge
circuits.

84 JPF1-6 B+K2 B+ to JPB1-1 for Lift motor fan B+ FRC Lift motor
fan

85 JPF2-1 B+K2 B+ that is present when the K2 relay tips B+ w/K2 closed Fuse/Relay LPC Coil
close (DC lift only). Card

86 JPF2-2 B+K2 B+K2 to power the horn. B+ with K2 K2 tips Horn

energized

87 JPF2-3 B+K2 B+K2 when the K2 relay tips are closed. B+ K2 tips VM

88 JPF2-4 N/A

89 JPF2-5 B+K2 B+K2 to power Load Holding Solenoid. B+ with K2 K2 tips L/H Sol.
energized.

90 JPF2-6 B+K2 B+K2 when the K2 relay tips are closed. B+ K2 tips VM

91 JPF2-7 B+K2 B+K2 when the K2 relay tips are closed. B+ K2 tips VM

92 JPF2-8 N/A

93 JPF2-9 B+KEY B+ Key for warning light when K1 tips B+ CCC Warning
are closed. Light

94 JPF3-1 B– B– for FU6 (15A) that provides B– to the <0.5V TP4 VM

Vehicle Manager.

95 JPF3-2 B– B– for FU6 (15A) that provides B– to the <0.5V TP4 VM

Vehicle Manager.

96 JPF3-3 B–F B–F for DGND on the VM. <0.5V FU6 VM

97 JPF3-4 B–F B–F for DGND on the VM. <0.5V FU6 VM

98 JPF3-5 B–F B–F for the VM. <0.5V FU6 VM

99 JPF3-6 B–F B–F for the VM. <0.5V FU6 VM

100 JPF3-7 B–F B–F for the VM. <0.5V FU6 VM

101 JPF3-8 B–F B–F for S10 (150 or 120 in. Limit <0.5V FU6 S10
Switch) on the mast.

102 JPF3-9 B–F B–F for wire guidance. <0.5V Fuse/Relay Guidance
Card (FU6) Manager

103 JPF3-11 B–F B–F for the Lift Motor Fan. <0.5V FU6 Lift Motor
Fan

104 JPF3-12 B–F B–F for the CCC. <0.5V FU6 CCC

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

105 JPF4-1 B+ B+ from TP1 to FU5 (15A) to supply K2, B+ TP1 VM and
K4 relay tips. This also supplies FU5
Battery_Sense_In on the VM.

106 JPF4-2 B+ B+ from TP1 to FU5 (15A) to supply K2, B+ TP1 FU5 and
K4 relay tips. This also supplies VM
Battery_Sense_In to the VM.

107 JPF4-3 B+ B+ from TP1 to FU7 (15A/5A) to supply B+ TP1 FU7 and
Aux power option. Aux
Power

108 JPF4-4 B+ B+ from TP1 to FU7 (15A/5A) to supply B+ TP1 FU7 and
Aux power option. Aux
Power

109 JPF4-5 B+EPO B+ supply from EPO to K1, K2 and K3. EPO EPO K1, K2,
All functions associated with these Closed: B+; K3
relays are inoperable when the EPO is Open: 0.05V
open.

110 JPF4-6 B+EPO B+ to the EPO_Sense on the VM. Tells EPO EPO VM, EPO
the VM if the EPO is open or closed. Closed: B+; Sense
Open: 0.05V

111 JPF4-7 B+ B+ present when the battery is plugged B+ (there should TP1 VM
in. It is supplied through a thermistor on be no voltage
the Relay Control Fuse Panel. This is drop)
used by the VM to determine that the
correct battery is connected. It will
accept between 28 and 45V (36V
Battery) or 18 and 30V (24V Battery). If
the correct battery is sensed,
Relay_Enable is energized during
startup. After startup, this voltage is used
to determine BSOC.

112 JPF4-8 B+KEY B+ Key from the CCC. B+ CCC VM

113 JPF4-10 B+ B+ Fused to the CCC. B+ FU5 CCC

114 JPF4-11 B+KEY B+ Key for VM. B+ CCC VM

115 JPF4-12 Not Used

116 JPF4-13 RELAY ENABLE Return path for relays K1, K2, K3, and B+ w/Key VM K1, K2,
K4. This is dependent on Switch ON and K3 and
Battery_Sense_In being between 28 all relays K4
and 45V (36V Battery). de-energized;
<0.5V w/Key
Switch OFF or
ON and any
relay energized

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

117 JPF4-14 RELAY ENABLE Return path for relays K1, K2, K3, and B+ w/Key VM K1, K2,
K4. This is dependent on Switch ON and K3 and
Battery_Sense_In being between 18 all relays K4
and 30V (24V Battery). de-energized;
<0.5V w/Key
Switch OFF or
ON and any
relay energized

118 JPF4-15 B+ B+ for battery connected Aux Power. B+ FU7 Aux

Power

119 JPLA1-1 B+K3 B+ present when K3 is energized. This B+ w/K3 K3 LPA

is used to power the control circuits of energized
the LPA.

120 JPLA1-6 TPC Control path for the LPC. The LPA LPC LPA LPC
CONTACTOR supplies a path for B– for the contactor de-energized;
by way of the B– terminal. B+
energized:
14.7V

121 JPLA1-7 L VEL SENSOR Return path for the bearing encoder in <0.5V LPA Lift
the lift motor. 5500 and 5600 only. Velocity
Sensor

122 JPLA1-8 L TEMP+ Analog voltage that varies with the lift 75°F (24°C) Lift Motor LPA
motor temperature. Used by the LPA to approx. 1V Temp.
adjust motor performance. Sensor

123 JPLA1-11 ID0 B+ present at the LPA with K3 tips B+ w/K3 K3 LPA
energized. It is used as an identifier to energized
determine correct connection.

124 JPLA1-12 Not Used

125 JPLA1-13 B+K3 B+ for the LPC. The LPA supplies B+ for B+ LPA LPC
the LPC.

126 JPLA1-23 BUS+ Carries the positive component of 3.0V CCC LPA, VM
digital communications between the
LPA, VM, and CCC.

127 JPLA1-25 Not Used

128 JPLA1-26 L VEL SENSOR + 5V supply to the bearing encoder on the 4.98V LPA Lift
lift motor. This voltage is produced by Velocity
the Lift Power Amp from B+K3. Sensor

129 JPLA1-28 Not Used

130 JPLA1-29 Not Used

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

131 JPLA1-31 L VEL PHASE A Generated when there is movement of Motor Lift Velocity LPA
the bearing encoder in the lift motor. It is Stationary: Sensor
a square wave that is either high (>3V) 4.06 or 0.03V;
or low (<1V). The frequency varies Motor Turning:
directly with motor speed. Identical to 2.3V
L VEL Phase B except for phase. The LPA
uses the relationship between phases to
determine lift speed.

132 JPLA1-32 L VEL PHASE B Generated when there is movement of Motor Lift Velocity LPA
the bearing encoder in the lift motor. It is Stationary: Sensor
a square wave that is either high (>3V) 4.06 or 0.03V;
or low (<1V). The frequency varies Motor Turning:
directly with motor speed. Identical to 2.3V
L VEL Phase A except for phase. The LPA
uses the relationship between phases to
determine lift speed.

133 JPLA1-35 BUS– The wire that carries the negative 2.3V CCC LPA, VM
component of the digital
communications between the LPA, VM,
and the CCC.

134 JPS2-11 B+EPO B+EPO is present when both the key B+ with S1 and VM Guidance
switch and EPO switch are closed. It is EPO closed. Manager
supplied to the Guidance Manager from
B+K2 on the VM. If the key switch or
EPO are open, K2 is de-energized.

135 JPS2-24 B–F B– for the Guidance Manager. It is <0.5V wrt TP4 Guidance VM
fused through FU6 on the Fuse/Relay Manager
Card.

136 JPS4-6 BUS+ Carries the positive component of the Not Usable VM Guidance
digital communications between the VM Manager
and the Guidance Manager.

137 JPT4-2 DGND DGND for Slack chain switch option <0.3V wrt TP4 VM S29, S30
S29 and S30

138 JPT4-3 LIFT DECEL Voltage from S124 (Lift Decel Switch) Open: 4.8V; S124 VM
that indicates the open or closed state of Closed: <0.3V
the switch.

139 JPT6-1 NEUTRAL_PULSE This input tells the VM that the Steer Deadman up: Steer Power VM
Power Amplifier is connected and 4.8V; Amplifier
functioning. CCW steer:
0.2V;
CW steer:
4.8V;
No steering:
voltage varies

140 JPT6-2 CW_PWM This is a control voltage used to rotate At rest: 11.9V; VM Steer
the drive unit in the CW direction. The CW fast: 4V; Power
average DC value will vary depending CW slow: Amplifier
on the amount and speed of steering 11.8V
requested.

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

141 JPT6-3 STEER_CURRENT Analog voltage that varies with the steer Steering Steer Power VM
motor current and is sent from the Steer CW: 2.9V; Amplifier
Power Amplifier to the VM. This voltage At rest: 2.5V;
is used by the VM to establish current Steering
reading for current limit. CCW: 2.1V

142 JPT6-4 DGND Reference for the control circuits in the <0.5V VM Steer
Steer Power Amplifier. If missing, the Power
Steer Power Amplifier will not be Amplifier
powered up.

143 JPT6-5 CCW_PWM This is a control voltage used to rotate At rest: 11.9V; VM Steer
the drive unit in the CCW direction. The CCW fast: 4V; Power
average DC value will vary depending CCW slow: Amplifier
on the amount and speed of steering 11.8V
requested.

144 JPT6-6 +12VP Operating voltage from the VM for the 10.7-13V VM Steer
control circuits in the Steer Power Power
Amplifier. If missing, steering is Amplifier
inoperable.

145 JPT10-2 SENSOR 1 Voltage from the S46A and S46B (Aisle 10.8-13V when VM S46A/B
Detect Sensors) that indicates a magnet is not Aisle
transition over a floor magnet. sensed; Detect
<1V for Sensors
0.1 sec. after
magnet is
sensed, then
10.8-13V

146 JPT10-4 DGND Return path for the Power Source Limit <0.5V VM Power
Source
Limit

147 JPT10-6 +12VP 12V supply to S46A and S46B (Aisle 10.8-13V VM S46A and
Detect Sensors). B

148 JPT10-7 +12VP 12V supply to S47A and S47B (Aisle 10.8-13V VM S47A and
Detect Sensors). B

149 JPT10-8 SENSOR 2 Voltage from S47A and S47B (Aisle 10.8-13V when S47A and S46A/B
Detect Sensors) that indicates a magnet is not S47B Aisle
transition over a floor magnet. sensed; Detect
<1V for Sensors
0.1 sec. after
magnet is
sensed, then
10.8-13V

150 JPT10-9 DGND Reference for the steer motor encoder. <0.5V VM Steer
Motor
Encoder

151 JPT12-5 LIFT L/L pendant connector. VM S112

(down)

152 JPT12-6 LOWER L/L pendant connector. VM S111 (up)

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

153 JPT12-8 CUTOUT Voltage from resistor K510 for Power <0.5V Open VM Power
Source Limit. 5V Closed Source
Limit.

154 JPT12-12 DGND L/L pendant connector. VM VM

155 JPT14-1 B–F This connects B–F on the VM to TP4(B–) <0.5V Fuse/Relay VM
through FU6 on the Fuse/Relay Card. Card
These B– provide the return for
everything not using DGND or AGND
as reference.

156 JPT14-2 DGND This connects DGND on the VM to TP4 <0.5V Fuse/Relay VM
(B–) through FU6 on the Fuse/Relay Card
Card. This is the reference for all circuits
on the lift truck that reference DGND.

157 JPT14-3 DGND This is the negative path for the 12V <0.5V VM CCC
supply to the CCC. If this is not present,
the CCC will not function. 5V is made
from the 12V on the CCC.

158 JPT14-4 BUS_I– The wire that carries the negative 2.3V VM LPA, TPA
component of the digital and CCC
communications between the VM, TPA,
LPA, and CCC.

159 JPT14-5 +12VP This is the positive path for the 12V 10.8-13V VM CCC
supply to the CCC. If this is not present,
the CCC will not function. 5V is made
from the 12V on the CCC.

160 JPT14-6 RELAY_ENABLE Control path for K1, K2, K3 and K4 on Relays VM K1, K2,
the Fuse/Relay Card. After S1 is closed, OFF: B+, K3, K4
all relays are energized simultaneously Relays
during SelfTest if the voltage at ON: <0.5V
Battery_Sense_In is between 28 and
45V (36V Battery) or 18 and 30V (24V
Battery).

161 JPT14-7 B+K2 B+ provided to the VM when the K2 B+ K2 Relay VM,

relay tips are closed. They are Brake
de-energized when the EPO is open. Coil
Note: Also used by the VM for Brake
Coil Suppression.

162 JPT14-8 B–F This connects B–F on the VM to TP4 (B–) <0.5V Fuse/Relay VM
through FU6 on the Fuse/Relay Card. Card
These B– provide the return for
everything not using DGND or AGND
as reference.

163 JPT14-9 B–F This connects B–F on the VM to TP4 (B–) <0.5V Fuse/Relay VM
through FU6 on the Fuse/Relay Card. Card
These B– provide the return for
everything not using DGND or AGND
as reference.

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

164 JPT14-10 DGND This connects DGND on the VM to TP4 <0.5V Fuse/Relay VM
(B–) through FU6 on the Fuse/Relay Card
Card. This is the reference for all circuits
on the lift truck that reference DGND.

165 JPT14-11 BUS_I+ The wire that carries the positive 3.0V VM LPA, TPA
component of the digital and CCC
communications between the VM, TPA,
LPA, and CCC.

166 JPT14-12 B+KEY B+ that is switched by S1 (Key Switch) S1 closed: B+; S1 VM

and used to power functions on the VM S1 open: 0.3V
that are initiated after S1 is closed and
are not affected by the EPO. This
includes the VM power supplies, the
operation of the microprocessor, and
execution of the firmware.

167 JPT14-13 B+K2 B+ provided to the VM when the K2 B+ K2 Relay VM

relay tips are closed. They are
de-energized when the EPO is open.

168 JPT14-14 B+K2 B+ provided to the VM when the K2 B+ K2 Relay VM

relay tips are closed. They are
de-energized when the EPO is open.

169 JPT18-3 +12V 12V supply for the Power Source Limit 10.8-13V VM Power
Source
Limit

170 JPT18-4 +12VP 12V supply for S15 (Rail Sense Switch). 10.8-13V VM S15

171 JPT18-7 DGND Return path for S124, Lift Cutout Switch <0.5V S124 VM
(DECEL).

172 JPT18-9 LIFT_ B– for the LPC coil (DC lift only). 24V Lift Truck: VM LPC Coil
CONTACTOR B+ w/coil
de-energized;
1V w/coil
energized
36V Lift Truck:
B+ w/coil
de-energized;
11-12V w/coil
energized

173 JPT18-10 L/H Control path for the load holding B+ VM L/H Sol.
solenoid that is switched to B– by the de-energized;
VM to energize the L/H solenoid coil. 12.7V
energized

174 JPT18-12 AUX L/H Negative path for the Aux Mast L/H <1V Aux. L/H VM
Solenoid. Sol.

175 JPT18-14 MAIN SEL Negative path for the Aux Mast Main <1V Aux.Main VM
Select Solenoid. Select Sol.

176 JPT18-15 AUX SEL Negative path for the Aux Mast Select <1V Aux. Select VM
Solenoid. Solenoid

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

177 JPT18-16 HORN Control path for the horn that is B+ VM Horn
switched to B– by the VM. de-energized;
<0V energized

178 JPT18-18 ALARM_TRAVEL Return path for Travel Alarm. B+ Travel Alarm VM
de-energized;
<0V energized

179 JPT20-1 +12VF 12V supply to S10 (120/150 in. +10.7 -13V VM S10
Switch).

180 JPT20-2 +12VP 12V supply for the Flow Sensor. 10.8-13V Flow Sensor VM

181 JPT20-3 +12VP 12V supply for S29 10.8-13V VM S29

182 JPT20-4 +12VP 12V supply for S30 10.8-13V VM S30

183 JPT20-5 +12VP 12V supply to the Pressure Transducer. 10.8-13V VM Pressure
Trans-
ducer

184 JPT20-6 +12VP 12V supply to S27 (Travel Cutout 10.8-13V VM S27
Switch) and Battery Gate Sensors.

185 JPT20-7 +12VP 12V supply for the steer motor encoder. 10.8-13V VM Steer
Motor
Encoder

186 JPT20-8 +12VP 12V supply to S124 Lift Cutout (DECEL). 10.8-13V VM S124

187 JPT20-9 +12VP 12V supply to the Home Sensor Prox by +10.7-13V VM Home
the VM. Sensor
Prox

188 JPT20-10 +12VP 12V supply to the S24 (Lift Inhibit 10.8-13V VM S24
Switch).

189 JPT20-14 BRAKE Control path for the electrically released B+ VM Brake
brake on the traction motor. de-energized:
26V energized

190 JPT20-15 B+L/L B+ supplied to lift/lower solenoid when B+ VM L/L

K2 tips are closed.

191 JPT20-16 L/L Control path for the lift/lower De-energized: VM L/L
proportional solenoid. B+;
Full Lift: 28V;
Full Lower:11V;
Feather Lift:
34V;
Decel: 27.7V

192 JPT20-17 B+ALARM B+ supplied to the lift/lower alarm when B+ VM Alarm

K2 tips are closed. Travel/Lift

193 JPT20-18 ALARM_LIFT Control path for the lift/lower alarm. B+ Alarm_Lift VM
de-energized;
<0.0V
energized

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

194 JPT20-19 B+K2 B+ supplied to the Guidance Manager B+ VM Guidance

when the K2 tips are closed. Manager

195 JPT22-1 120/150 IN. Input to the VM from S10. Open: 4.8V; S10 VM
LIMIT Closed: <0.03V

196 JPT22-2 LIFT INHIB Voltage from S24 that indicates the Open: 4.8V; S24 VM
open/closed state of the switch. Closed: <0.03V

197 JPT22-3 HOMESENSE Voltage that the VM uses to determine Off Metal: Home VM
on or off metal. 5.2V; Sensor Prox
On Metal:
0.03V

198 JPT22-4 180_LIM Voltage from S100 (180 in. Limit Open: 4.8V; S100 VM
Switch) that indicates the open/closed Closed: <0.03V
state of the switch.

199 JPT22-5 Not Used

200 JPT22-6 TRVL CUTOUT Voltage from S27 that indicates the Open: 4.8V; S27 VM
open/closed state of the switch. Closed: <0.03V

201 JPT22-7 BRAKE Voltage from CCC to VM that indicates 6.1V released; S2 VM
DEADMAN the open/closed state of switch S2. 0.1V pressed

202 JPT22-8 CARRIAGE Voltage from CCC to VM that indicates 4.8V released; S23 VM
DEADMAN the open/closed state of switch S23. 0.1V pressed

203 JPT22-9 CHANNELA_4 Part of the steering position feedback Not Turning: Steer Motor VM
from the steer motor encoder when the either 0V or 5V; Encoder
drive unit is rotated. It is a square wave Turning either
signal identical to Channel B_4 but direction: 2.4V
different phase. The VM uses the phase
relationship of the two channels to
determine that the direction and speed
of the steering response is the same as
that requested.

204 JPT22-10 CHANNELB_4 Part of the steering position feedback Not Turning: Steer Motor VM
from the steer motor encoder when the either 0V or 5V; Encoder
drive unit is rotated. It is a square wave Turning either
signal identical to Channel A_4 but direction: 2.4V
different phase. The VM uses the phase
relationship of the two channels to
determine that the direction and speed
of the steering response is the same as
that requested.

205 JPT22-11 DGND B– for the Home Sensor Prox. <0.5V Home VM
Sensor Prox

206 JPT22-12 Slack Sw1 Used to determine the status of S29. Approx. S29 VM
0.0V - 5V

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

207 JPT22-13 CHANNEL_A Square waves generated whenever Approx. 2.7V Flow Sensor VM
there is movement of the turbine in the during lift at
flow sensor. The frequency varies 1/3 speed or
directly with the speed of the turbine greater;
that is driven by fluid flowing through >5V or <0.5V
the sensor. The VM uses the quadrature when stopped
phase relationship between Flow_A
and_B to determine flow direction and
speed to calculate carriage height.

208 JPT22-14 CHANNEL_B Square waves generated whenever Approx. 2.7V Flow Sensor VM
there is movement of the turbine in the during lift at
flow sensor. The frequency varies 1/3 speed or
directly with the speed of the turbine greater;
that is driven by fluid flowing through >5V or <0.5V
the sensor. The VM uses the quadrature when stopped
phase relationship between Flow_A
and_B to determine flow direction and
speed to calculate carriage height.

209 JPT22-19 FU1_SENSE B+ when there is not an open between Closed: B+; PC1 VM
battery positive and PC1. This voltage is Open: voltage
used by the VM to determine the state of drops very
FU1 and the PC1 contactor tips. slowly

210 JPT22-20 FU3 SENSE B+ when there is not an open between Closed: B+; PC2 VM
B+ and PC2. This voltage is used by the Open: voltage
VM to determine the state of FU3 and drops slowly to
the LPC contactor tips (DC lift only). 0V

211 JPT22-21 EPO_SENSE Sense wire used by the VM to determine EPO closed: B+; EPO VM
when the EPO is open. This is used to EPO open:
initiate braking and display a message. <0.5V

212 JPT22-22 RAIL_SEN Read by the VM to determine if the lift closed:<1V; S15 VM
truck is in or out of the rail. The VM open: approx.
communicates lift truck position to the 10V
CCC, limiting travel speed based on lift
truck location and position of the
Auto/Manual switch. When the lift truck
is in the rail, S15 is closed.

213 JPT24-1 +12VP 12V supply for S100 (180 in. Limit 10.8-13V S100 VM
Switch).

214 JPT24-3 DGND Return path for S24 (Lift Inhibit Switch). <0.5V S24 VM

215 JPT24-5 DGND Return path for S15 (Rail Sense Switch). <0.5V S15 VM

216 JPT24-6 DGND Return path for S27 (Travel Cutout <0.5V S27 VM
Switch).

217 JPT24-7 DGND Return path for S100 (180 in. Limit <0.5V S100 VM
Switch).

218 JPT24-8 DGND Return path for S46A and S46B (Aisle <0.5V S46A and VM
Detect Sensors). S46B

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Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

219 JPT24-9 DGND Return path for S47A and S47B (Aisle <0.5V S47A and VM
Detect Sensors). S47B

220 JPT24-10 DGND Return path for Pressure Transducer A. <0.5V Pressure VM
transducer

221 JPT24-11 DGND Return path for the intellispeed Flow <0.5V Flow Sensor VM
Sensor.

222 JPT24-16 Slack Sw2 Used to determine the status of S30. Approx. S30 VM
0.0V - 5V

223 JPT24-18 P/T_A Analog DC voltage that varies directly 1V with forks Pressure VM
with the weight on the carriage. fully lowered Transducer
Approx. 0.5V per 1000 lbs. (454 kg). It
is necessary to have the VM supply
approx. 12V as well as DGND in order
for the transducer to function correctly.

224 JPT24-19 FS_TEMP Variable voltage that is representative of 0.2-4.86V; Flow Sensor VM
the temperature of the fluid in the lift approx. 3.2V
system. @86°F

225 JPT24-24 BATTERY_ B+ present when the battery is plugged B+ (there should TP1 VM
SENSE_IN in. It is supplied through a thermistor on be no voltage
the Relay Control Fuse Panel. This is drop)
used by the VM to determine that the
correct battery is connected. It will
accept between 28 and 45V (36V
Battery) or 18 and 30V (24V Battery). If
the correct battery is sensed, Relay
Enable is energized during start-up.
After start-up, this voltage is used to
determine BSOC.

226 JPTA1-1 B+K3 B+ present when K3 is energized. This B+ w/K3 K3 TPA

is used to power the control circuits of energized
the TPA.

227 JPTA1-6 TPC Control path for the TPC. The TPA TPC TPA TPC
CONTACTOR supplies a path for B– for the contactor de-energized:
by way of the B– terminal. B+
energized:
14.7V

228 JPTA1-7 DGND Return path for the bearing encoder in <0.5V Travel TPA
the traction motor. Velocity
Sensor

229 JPTA1-8 T TEMP+ Analog voltage that varies with the Approx. 1V Traction TPA
traction motor temperature. Used by the @75°F (24°C) Motor Temp.
TPA to adjust motor performance. Sensor

230 JPTA1-11 ID0 Not Used by the Traction Power Amp.

231 JPTA1-12 ID1 B+ present at the TPA with K3 tips B+ w/K3 K3 TPA
energized. It is used as an identifier to energized
determine correct connection.

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Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

232 JPTA1-13 B+K3 B+ for the TPC. The TPA supplies B+ for B+ TPA TPC
the TPC.

233 JPTA1-14 Not Used

234 JPTA1-23 BUS+ The wire that carries the positive 3V CCC TPA, VM
component of the digital
communications between the TPA, VM,
and CCC.

235 JPTA1-25 Not Used

236 JPTA1-26 T VEL SENSOR + 5V supply to the bearing encoder on the 4.95V TPA Travel
traction motor. This voltage is produced Velocity
by the Traction Power Amp from B+K3. Sensor

237 JPTA1-28 Not Used

238 JPTA1-29 Not Used

239 JPTA1-31 T VEL PHASE A This is generated when there is Motor Travel TPA
movement of the bearing encoder in the Stationary: Velocity
traction motor. It is a square wave that is 4.06 or 0.03V; Sensor
either high (>3V) or low (<1V). The Turning: 2.3V
frequency varies directly with the speed
of the traction motor. Identical to T VEL
Phase B, except for phase. The TPA uses
the relationship between phase A and B
to determine travel speed and direction.

240 JPTA1-32 T VEL PHASE B This is generated when there is Motor Travel TPA
movement of the bearing encoder in the Stationary: Velocity
traction motor. It is a square wave that is 4.06 or 0.03V; Sensor
either high (>3V) or low (<1V). The Turning: 2.3V
frequency varies directly with the speed
of the traction motor. Identical to T VEL
Phase A, except for phase. The TPA uses
the relationship between phase A and B
to determine travel speed and direction.

241 JPTA1-35 BUS– The wire that carries the negative 2.3V CCC TPA, VM
component of the digital
communications between the TPA, VM,
and CCC.

242 LPA (+) LPA B+ B+ to the LPA used to produce the AC B+ with LPC LPC LPA
phases U,V, and W when the LPC is closed
closed to power the lift motor.

243 LPA (–) LPA B– B– from TP4 on the power panel. It is <0.5V TP4 LPA
used for the power circuits on the LPA.
Without B–, U, V, and W cannot be
produced and the lift motor will not turn.

Publication: 1301126/001A, Issued: 12 Nov 2018 8-39

Section 8. Theory of Operation Models 5300/5500/5600 Maintenance Manual

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

244 LPA (U) Lift Motor Phase One of three phases from the LPA to the VAC between LPA Lift Motor
U Lift Motor. This AC voltage is produced two phases:
by the LPA and is dependent on B+ at Stationary:
the + terminal and B– on the LPA. This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full RPM. Stall: approx.
4VAC

245 LPA (V) Lift Motor Phase One of three phases from the LPA to the VAC between LPA Lift Motor
V Lift Motor. This AC voltage is produced two phases:
by the LPA and is dependent on B+ at Stationary:
the + terminal and B– on the LPA. This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full RPM. Stall: approx.
4VAC

246 LPA (W) Lift Motor Phase One of three phases from the LPA to the VAC between LPA Lift Motor
W Lift Motor. This AC voltage is produced two phases:
by the LPA and is dependent on B+ at Stationary:
the + terminal and B– on the LPA. This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full RPM. Stall: approx.
4VAC

247 TPA (+) TPA B+ B+ to the TPA used to produce the AC B+ w/TPC B+ from TPC TPA
phases U, V and W when the TPC is closed
closed to power the traction motor.

248 TPA (B–) TPA B– B– from TP4 on the power panel. It is <0.5V TP4 TPA
used for the power circuits on the TPA.
Without B–, U, V and W cannot be
produced and the traction motor will not
turn.

249 TPA (U) Traction Motor One of three phases from the TPA to the VAC between TPA Traction
Phase U traction motor. This AC voltage is two phases: Motor
produced by the TPA and is dependent Stationary:
on B+ at TPA (+) and B– at TPA (B–). This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full acceleration. Stall: approx.
4VAC

250 TPA (V) Traction Motor One of three phases from the TPA to the VAC between TPA Traction
Phase V traction motor. This AC voltage is two phases: Motor
produced by the TPA and is dependent Stationary:
on B+ at TPA (+) and B– at TPA (B–). This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full acceleration. Stall: approx.
4VAC

8-40 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section 8. Theory of Operation

Pin-Out Matrix

Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User

251 TPA (W) Traction Motor One of three phases from the TPA to the VAC between TPA Traction
Phase W traction motor. This AC voltage is two phases: Motor
produced by the TPA and is dependent Stationary:
on B+ at TPA (+) and B– at TPA (B–). This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full acceleration. Stall:
approx. 4VAC

Publication: 1301126/001A, Issued: 12 Nov 2018 8-41

Section 8. Theory of Operation Models 5300/5500/5600 Maintenance Manual

Pin-Out Matrix

8-42 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section A. Appendix

Section A. Appendix

Publication: 1301126/001A, Issued: 12 Nov 2018 A-1

Section A. Appendix Models 5300/5500/5600 Maintenance Manual

Lubrication Specification Chart

Lubrication Specification Chart

Approved Raymond Lubricants

Where Used Type Specification Raymond Part Number

75W-90 Synthetic
Drive Unit Gear Case Gear 990-655/001 (1 qt./0.9 liters)
Gear Oil
(all applications) Lubricant 990-655/003 (1 gal./3.8 liters)
API Service GL-5

Hydraulic Reservoir 990-616/04 (1 qt./0.9 liter)

(Non-CS trucks) 990-616/01 (1 gal./3.8 liters)
Hydraulic Fluid ISO 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
(CS trucks - in and out of
1266010
freezer) Hydraulic Fluid ISO VG 32
Note: Do not add any additives.
0° to +80°F
(–18° to +27°C)

Hydraulic Reservoir
(Freezer trucks) 990-618/01 (1 gal./3.8 liters)
Hydraulic Fluid MIL-H-5606E
–20° to +32°F 990-618/01 (1 gal./3.8 liters)
(–29° to 0°C)

NOTE: For ambient temperature ranges of 0° to +32°F (-18° to 0°C) and +50° to +80°F (+10° to +27°C),
specific environmental, application, and operating conditions should be considered when selecting a
hydraulic fluid.

Mast Uprights, Bearings,

and so forth
(all-weather) Grease NLGI 2 1012992
–20° to +120°F
(–29° to +49°C)

High Performance/
1151877/001 (Rexoil)
Lift Chains High Load Chain Aerosol
1151877/002 (Rocol)
Spray

Steering Reducer Grease NLGI 2 1012992

A-2 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section A. Appendix

Thread Adhesives, Sealants, and Lubricants

Thread Adhesives, Sealants, and Lubricants

Loctite*
Raymond P/N Application
Number/Color

990-403 Thread-locking 1/4 in. and below 222/Purple

990-411 Anaerobic Gasket Maker 518

990-445 Cold Storage Silicone Sealing Compound

990-452 Anti-Seize Lubricant, Heavy Duty High Temperature

990-463 Thread-locking 1 in. and under, contamination tolerant 603/Green

990-533 Thread-locking Primer T7471

990-538 Thread-locking Cleaner 707

990-544 Thread-locking 1 in. and under 271/Red

990-552 Hydraulic Sealant 569

990-556 Gasket Sealant Compound

990-571 Thread-locking 1 in. and over 277/Red

990-638 Molybdenum Anti-Seize Compound (Molykote) /Silver

990-644 Corrosion Inhibitor Coating

990-659 RTV Silicone Sealant 5900/Black

990-666 Thread-locking Primer 7649 (19269)

990-669 Thread-locking, primerless high strength 2760

243 or 2440
1013829 Thread-locking 1/4 to 3/4 in. medium strength
7242 (Cyberbond)

Note: *Loctite is a registered trademark of the Loctite Corporation. Brand endorsement is not implied
here, but listed only as a commonly identified product.

Publication: 1301126/001A, Issued: 12 Nov 2018 A-3

Section A. Appendix Models 5300/5500/5600 Maintenance Manual

Component Specific Service/Torque Chart

Component Specific Service/Torque Chart

Thread-Locking Torque to:
Compound (use Dry values for hardware with
pre-applied thread-locking compound)
(not applicable if using
Component Sub-Component(s) hardware with
pre-applied Lubricated Dry
thread-locking
compound) ft. lb. (Nm) ft. lb. (Nm)

Adjust the switch so it is flush with outside

switch
Battery Gate edge.

bracket P/N 1013829 8 (11.3) 11 (15.1)

Brake traction motor P/N 1013829 12 (16)

Drive Unit - Standard mounting bolts P/N 1013829 180 (244)

N/A
250 to 275
Drive Unit - Heavy Duty mounting bolts P/N 1013829
(339 to 373)

Drive Unit Housing Cover mounting bolts P/N 1013829 16 (22) 17 (23)

Drive Wheels mounting bolts N/A 170 (230)

Finger tighten, then use socket to tighten an

EPO N/A
additional 1/4 turn.

Refer to
Horn N/A “Torque Chart - Thread-Forming Screws” on
page A-12

threaded end caps 200 (271)

Lift Cylinders bleed screws N/A 40 in. lb. (4.5)

staging screws 60 in. lb. (6.8)

mounting bolts P/N 1013829 20( 27) 27 (37)

Top Nut:
Lift Motor - AC - Apply anti-seize 17 to 18.4
compound (P/N 990-638) to pump (23 to 25)
spline and mating surfaces. power cables N/A
Bottom Nut:
10.7 to 11
(14.5 to 15)

mounting bolts P/N 1013829 20 (27) 27 (37)

Top Nut:
Lift Motor - DC - Apply anti-seize 8.3 to 10
compound (P/N 990-638) to pump (11.3 to 13.6)
spline and mating surfaces. power cables N/A
Bottom Nut:
11.7 to 13.3
(15.8 to 18.1)

Lift Pump - AC - Apply anti-seize

compound (P/N 990-638) to pump mounting bolts P/N 1013829 49 (67) 66 (90)
spline and mating surfaces.

A-4 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section A. Appendix

Component Specific Service/Torque Chart

Thread-Locking Torque to:

Compound (use Dry values for hardware with
pre-applied thread-locking compound)
(not applicable if using
Component Sub-Component(s) hardware with
pre-applied Lubricated Dry
thread-locking
compound) ft. lb. (Nm) ft. lb. (Nm)

Lift Pump - DC - Apply anti-seize

compound (P/N 990-638) to pump mounting bolts P/N 1013829 15 (20) 19 (26)
spline and mating surfaces.

mounting bolts P/N 1013829 8 (11.3) N/A

Manifold 35 - 40
Valves N/A
(48 - 54)

mounting bolts, rear N/A N/A 22 (30)

Platform Extensions
mounting bolts, front N/A N/A 21 (28)

mounting bolts P/N 1013829 8 (11.3) 11 (15.1)

Power Amplifiers
power cables 8.3 (11.3)

Top Nut:
40 to 50 in.lb.
N/A (4.5 to 5.6)
power cable
Steer Motor Bottom Nut:
50 to 60 in.lb.
(5.6 to 6.8)

mounting bolts P/N 1013829 15 (20) N/A

Steer Reference (Home) Proximity bracket mounting

P/N 1013829 6 (8.2) N/A
Sensor screws (qty 2)

A minimum pressure of 5 tons (4536 kg) is required to press on a new

Tire Replacement
tire. If the minimum pressure is not met, replace the hub.

mounting bolts P/N1013829 21 (28) 28 (38)

Top Nut:
12.5 to 18.4
Traction Motor (23 to 25)
power cables
Bottom Nut:
N/A 10.7 to 11
(14.5 to 15)

hex head bolts 170 (230)

Tractor-to-Mast
socket flathead bolts 130 (176)

Publication: 1301126/001A, Issued: 12 Nov 2018 A-5

Section A. Appendix Models 5300/5500/5600 Maintenance Manual

Torque Chart - Hydraulic Fittings

Torque Chart - Hydraulic

Fittings
JIC SAE Straight Thread Steel Plugs
SAE
Thread (37° Flare Thread)
Dash Hollow Hex Head Plug HP50N Hex Head Plug P50N
Size
Size
ft. lb. Nm ft. lb. Nm ft. lb. Nm

-2 5/16-24 3 ±1 4 ±1 3 ±0.5 4 ±0.6 7.5 ±0.5 10 ±0.6

-3 3/8-24 6 ±1 8 ±1 5 ±0.5 7 ±0.6 14 ±1 19 ±1

-4 7/16-20 12 ±1 16 ±1 11 ±1 15 ±1 18 ±1 24 ±1

-5 1/2-20 15 ±1 20 ±1 15 ±1 20 ±1 22 ±1 30 ±1

-6 9/16-18 21 ±1 28 ±1 18 ±1 24 ±1 27 ±2 37 ±3

-8 3/4-16 45 ±2 61 ±3 46 ±2 62 ±3 48 ±2 65 ±3

-10 7/8-14 60 ±5 81 ±7 75 ±5 102 ±7 90 ±5 122 ±7

-12 1 1/16-12 85 ±5 115 ±7 85 ±5 115 ±7 110 ±5 149 ±7

-14 1 3/16-12 105 ±5 142 ±7 130 ±6 176 ±8 145 ±6 197 ±8

-16 1 5/16-12 120 ±5 163 ±7 135 ±6 183 ±8 160 ±6 217 ±8

-20 1 5/8-12 170 ±10 230 ±14 225 ±12 305 ±16 225 ±12 305 ±16

-24 1 7/8-12 200 ±15 271 ±20 250 ±12 339 ±16 250 ±12 339 ±16

-32 2 1/2-12 270 ±20 366 ±27 325 ±15 441 ±20 325 ±15 441 ±20

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Models 5300/5500/5600 Maintenance Manual Section A. Appendix

Torque Chart - Straight Thread Face Seal O-Rings

Torque Chart - Straight Thread Face Seal O-Rings

SAE Dash Tube Size
ft. lb. Nm
Size Thread Size

-4 9/16-18 18 ±1 24 ±1

-6 11/16-18 27 ±2 37 ±3

-8 13/16-16 40 ±2 54 ±3

-10 1-14 63 ±3 85 ±4

-12 1 3/16-12 90 ±4 122 ±5

-14 1 5/16-32 95 ±6 129 ±8

-16 1 7/16-12 120 ±8 163 ±11

-20 1 11/16-12 140 ±8 190 ±11

-24 2-12 165 ±8 224 ±11

-32 2 1/2-12 360 ±10 488 ±14

Publication: 1301126/001A, Issued: 12 Nov 2018 A-7

Section A. Appendix Models 5300/5500/5600 Maintenance Manual

Torque Chart - Standard (Ferrous)

Torque Chart - Standard (Ferrous)

Grade
None
Marking

SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 7 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque Tightening Torque
Size
Dry** Oiled* Dry** Oiled* Dry** Oiled* Dry** Oiled*
in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm
4-40 5 0.56 4 0.45 8 0.9 6 0.68 11 1.5 8 0.9 12 1.4 9 1.0
4-48 6 0.68 5 0.56 9 1.0 7 0.8 12 1.4 9 1.0 13 1.5 10 1.1
6-32 10 1.1 8 0.9 16 1.8 12 1.4 20 2.2 15 1.7 23 2.6 17 1.9
6-40 12 1.4 9 1.0 18 2.0 13 1.5 22 2.5 17 1.9 25 2.8 19 2.1
8-32 19 2.1 14 1.6 29 3.3 22 2.5 36 4.1 27 3.0 41 4.6 31 3.5
8-36 20 2.2 15 1.7 31 3.5 23 2.6 38 4.3 29 3.3 44 5.0 33 3.7
10-24 27 3.0 21 2.4 42 4.8 32 3.6 52 5.9 39 4.4 60 6.8 45 5.1
10-32 31 3.5 24 2.7 48 5.4 36 4.1 60 6.8 45 5.1 68 7.7 51 5.8
1/4-20 66 7.5 49 5.5 100 11.3 76 8.6 125 14.1 94 10.6 143 16.2 107 12.1
1/4-28 75 8.5 56 6.3 120 13.6 87 9.8 143 16.2 107 12.1 164 18.5 123 13.9
ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm
5/16-18 11 15.1 8 10.9 17 23.0 13 18 21 29 16 22 25 34 18 24
5/16-24 12 16.3 9 12.2 19 26 14 19 24 33 18 24 25 34 20 27
3/8-16 20 27 15 20 30 41 23 31 40 54 30 41 45 61 35 47
3/8-24 23 31 17 23 35 47 25 34 45 61 30 41 50 68 35 47
7/16-14 32 43 24 33 50 68 35 47 60 81 45 61 70 95 55 75
7/16-20 35 47 25 34 55 75 40 54 70 95 50 68 80 109 60 81
1/2-13 50 68 35 47 75 102 55 75 95 129 70 95 110 150 80 109
1/2-20 55 75 40 54 85 115 65 88 105 143 80 109 120 163 90 122
9/16-12 70 95 50 68 110 150 80 109 135 183 100 136 150 203 110 150
9/16-18 80 109 60 81 120 163 90 122 150 203 110 150 170 231 130 177
5/8-11 95 129 70 95 150 203 110 150 190 258 140 190 220 298 170 231
5/8-18 110 150 85 115 170 231 130 177 210 285 160 217 240 326 180 244
3/4-10 170 231 130 177 260 353 200 272 330 448 240 326 380 515 280 381
3/4-16 190 258 140 190 300 407 220 298 370 502 280 381 420 569 320 434
7/8-9 170 231 125 169 430 583 320 434 530 719 400 544 600 813 460 624
7/8-14 185 252 140 190 470 637 350 475 580 786 440 598 660 895 500 680
1-8 250 339 190 258 650 881 480 651 800 1085 600 813 900 1224 680 925
1-12 275 373 205 278 700 949 520 705 860 1166 660 895 1000 1360 740 1003
1 1/8-7 350 475 270 366 800 1085 600 813 1120 1519 840 1139 1280 1136 960 1302
1 1/8-12 400 544 300 407 880 1193 660 895 1260 1708 940 1274 1440 1952 1080 1464
1 1/4-7 500 680 375 509 1120 1523 840 1139 1580 2142 1200 1627 1820 2468 1360 1884
1 1/4-12 550 746 420 569 1240 1681 920 1247 1760 2386 1320 1790 2000 2720 1500 2034
1 3/8-6 650 881 490 664 1460 1980 1100 1491 2080 2820 1560 2115 2380 3227 1780 2413
1 3/8-12 750 1017 560 759 1680 2278 1260 1708 2380 3227 1780 2413 2720 3688 2040 2766
1 1/2-6 870 1180 650 881 1940 2630 1460 1980 2780 3769 2080 2820 3160 4298 2360 3200
1 1/2-12 980 1329 730 990 2200 2983 1640 2224 3100 4203 2340 3173 3560 4857 2660 3606
NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.
NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

A-8 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section A. Appendix

Torque Chart - Metric (Ferrous)

Torque Chart - Metric (Ferrous)

Ferrous Metric Bolts, Coarse Thread
(The grade rating is stamped on the head of the bolt.)
Grade 4.8 Grade 8.8 Grade 10.9 Grade 12.9
Size Dry** Oiled* Dry** Oiled* Dry** Oiled* Dry** Oiled*
in. 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: 1301126/001A, Issued: 12 Nov 2018 A-9

Section A. Appendix Models 5300/5500/5600 Maintenance Manual

Torque Chart - Standard (Brass)

Torque Chart - Standard (Brass)

Brass MS63 Standard Bolts, Coarse Thread
Torque (with bolts oiled*)
Size
in. lb. Nm
0-80 0.5 0.05
1-64 0.9 0.10
1-72 1.0 0.11
2-56 1.5 0.17
2-64 1.6 0.18
3-48 2.3 0.26
3-56 2.5 0.28
4-40 3.3 0.37
4-48 3.6 0.40
5-40 4.8 0.54
5-44 5.3 0.60
6-32 6.1 0.69
6-40 6.8 0.77
8-32 11 1.24
8-36 11 1.24
10-24 14 1.58
10-32 17 1.92
12-24 23 2.59
12-28 25 2.82
1/4-20 35 3.96
1/4-28 40 4.52
5/16-18 73 8.25
5/16-24 81 9.15
3/8-16 130 14.69
3/8-24 147 16.61
NOTE: * Use ”oiled” values for bolts with
thread-locking compound.

A-10 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section A. Appendix

Torque Chart - Metric (Brass)

Torque Chart - Metric (Brass)

Brass MS63 Metric Bolts, Coarse Thread

Diameter Torque (bolts oiled)

(in millimeters) in. lb. Nm

3 4.4 0.5

3.5 7.0 0.79

4 10 1.1

5 19 2.1

6 34 3.8

8 79 9

10 150 17

NOTE: * Use ”oiled” values for bolts with

thread-locking compound.

Publication: 1301126/001A, Issued: 12 Nov 2018 A-11

Section A. Appendix Models 5300/5500/5600 Maintenance Manual

Torque Chart - Thread-Forming Screws

Torque Chart - Thread-Forming Screws

Standard Thread-Forming Screws
Torque
Size
in. lb. Nm
4-40 10 1.1
5-40 16 1.8
6-32 20 2.3
8-32 36 4
10-24 51 5.76
10-32 59 6.7
12-24 81 9.1
1/4-20 123 13.9
5/16-18 253 28.6
3/8-16 450 50.8
7/16-14 736 83.1
1/2-13 1000 113

Metric Thread-Forming Screws

Diameter Torque
(mm) in. lb. Nm
2.5 7 0.8
3 14 1.6
3.5 22 2.5
4 33 3.7
5 47 5.3
6 113 12.7
6.3 147 16.6
7 198 22.3
8 280 31.7
10 554 62.6
12 981 110.9

A-12 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section A. Appendix

Decimal Equivalent Chart

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 .397
1/32 .031 .03 .794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272

Publication: 1301126/001A, Issued: 12 Nov 2018 A-13

Section A. Appendix Models 5300/5500/5600 Maintenance Manual

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400

A-14 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section A. Appendix

Standard/Metric Conversions

Standard/Metric Conversions
To Convert... Multiply, Add, or Subtract...
Area
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Distance
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Mass
Ounces to Grams Ounces x 28.35
Grams to Ounces Ounces x 0.035
Ounces to Kilograms Ounces x 0.028
Kilograms to Ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to Pounds Kilograms x 2.2
Pressure
Pounds per Square Inch (PSI) to kiloPascals PSI x 6.894
kiloPascals to Pounds per Square Inch (PSI) kiloPascals x 0.145
Speed
Miles per hour to Kilometers per hour Miles per hour x 1.609
Kilometers per hour to Miles per hour Kilometers per hour x 0.6214
Temperature
Fahrenheit to Celsius (°F minus 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) plus 32
Torque
Inch Pounds (in. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lb.) Newton Meters x 0.737
Volume
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26

Publication: 1301126/001A, Issued: 12 Nov 2018 A-15

Section A. Appendix Models 5300/5500/5600 Maintenance Manual

Standard/Metric Conversions

A-16 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section I. Index

Index

Index 1K . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Section I. Index

2A . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
2E . . . . . . . . . . . . . . . . . . . . . . . . 6-19
A 2G . . . . . . . . . . . . . . . . . . . . . . . . 6-20
2H . . . . . . . . . . . . . . . . . . . . . . . . 6-20
2M . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Active Maintenance Mode . . . . . . 3-9, 3-24
2T . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
AMP Connectors . . . . . . . . . . . . . . . . 7-83
2U . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Analog Tests . . . . . . . . . . . . . 6-43 to 6-68
2V . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Antenna Cards . . . . . . . . . . . . . . . . . . 8-4
2X . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Audible Alarms . . . . . . . . . . . . . . . . . . 3-8
2Y . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
42 . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
B 43 . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
4C . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Battery 4F . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Cables . . . . . . . . . . . . . . . . . . . . . 7-68 4G . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Charging . . . . . . . . . . . . . . . . . . . 7-69 4H . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Checks . . . . . . . . . . . . . . . . . . . . . 4-6 4K . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Cleaning Exterior . . . . . . . . . . . . . 7-69 50 . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Maintenance . . . . . . . . . . . . . . . . 7-69 51 . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Safety . . . . . . . . . . . . . . . . . . . . . . 2-5 56 . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
State-of-Charge (BSOC) . . . . . 5-5, 7-69 59 . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Testing . . . . . . . . . . . . . . . . . . . . 7-69 5A . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Bearings 5B . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Mast, Shimming . . . . . .7-109 to 7-115 5E . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Bleeding Cylinders . . . . . . . . . . . . . . 7-95 5G . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Brake 5J . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Adjustment . . . . . . . . . . . . . . . . . 7-61 5M . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Rotor Replacement . . . . . . . . . . . 7-62 5P . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Brushes . . . . . . . . . . . . . . . . . . . . . . 7-72 61 . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
BSOC (Battery State-of-Charge) . . 5-5, 7-69 63 . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Lift Cutout Adjustment . . . . . . . . . 5-5 64 . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Bulletins, Service . . . . . . . . . . . . . . . . .1-v 66 . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
67 . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
C 6D . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6F . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6K . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Cables, Power . . . . . . . . . . . . . . . . . . 7-70
6M . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Carriage . . . . . . . . . . . . . . .7-106 to 7-108
6N . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Carriage Control Card Replacement . . 7-80
6P . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Caution, Definition . . . . . . . . . . . . . . . 2-2
7E . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Chains
7F . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Free Lift Cylinder, 3-Stage . . . . . .7-116
7G . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Inspection . . . . . . . . . . . . . . . . . . 4-11
7H . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Main Cylinders, 3-Stage . . . . . . . .7-116
7M . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Maintenance . . . . . . . . . . . . . . . . 4-11
7T . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Chains, Maintenance . . . . . . . . . . . . 4-11
7U . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Cleaning
7V . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Lift Truck . . . . . . . . . . . . . . . . . . . 2-4
7X . . . . . . . . . . . . . . . . . . . . . . . . 6-30
CODE . . . . . . . . . . . . . . . . . . . . . . . . 6-20
7Y . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Code
80 . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
10 . . . . . . . . . . . . . . . . . . . . . . . . 6-19
81 . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
1H . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Publication: 1301126/001A, Issued: 12 Nov 2018 I-1

Section I. Index Models 5300/5500/5600 Maintenance Manual

Index

83 . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Communication Error Code

84 . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Troubleshooting . . . . . . . . . . . . . . 5-22
88 . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Commutator, Motor . . . . . . . . . . . . . . 5-11
8C . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Component Locator Photos . . . . . 7-3 to 7-8
8F . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Configuration Codes . . . . . . . . . . . . . . 3-29
8L . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Configure Mode . . . . . . . . . . . . . . . . . . 3-9
91 . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Connector
92 . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Battery . . . . . . . . . . . . . . . . . . . . . 7-68
93 . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Connectors
94 . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 AMP . . . . . . . . . . . . . . . . . . .7-82, 7-83
9A . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 General . . . . . . . . . . . . . . . ..... 7-81
9B . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Molex . . . . . . . . . . . . . . . . . ..... 7-82
9E . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Power Amp . . . . . . . . . . . . . ..... 7-86
9G . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Repair . . . . . . . . . . . . . . . . ..... 7-81
9H . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Contactor Test
9J . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 PC . . . . . . . . . . . . . . . . . . . . . . . 6-118
9K . . . . . . . . . . . . . . . . . . . . 6-34, 6-35 Contactor Test, P . . . . . . . . . . . . . . . 6-119
A0 . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Contactor Tip Inspection . . . . . . . . . . 4-12
A2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Control Handle
A4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Cleaning . . . . . . . . . . . . . . . . . . . . 7-23
AH . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Inspection . . . . . . . . . . . . . . . . . . 7-23
AL . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Installation . . . . . . . . . . . . . . . . . . 7-24
AP . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Lift/Lower Knob . . . . . . . . . . . . . . 7-23
AT . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Removal . . . . . . . . . . . . . . . . . . . . 7-19
F8 . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Repair/Replacement
FE . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Procedures . . . . . . . . . 7-19 to 7-24
FG . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Soldering Procedures . . . . ...... 7-24
FH . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Travel Pot Repair/Replace ...... 7-21
FN . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Control Handle Assembly . . . . ...... 7-79
FP . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Conversion
FT . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Decimal to Fraction . . . . . . . . . . . A-13
G0 . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Fraction to Decimal . . . . . . . . . . . A-13
G2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Conversions, Standard/Metric . . . . . . A-15
G3 . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Cylinder
G4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Storage Preparation . . . . . . . . . . . 3-29
G5 . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Cylinders
G7 . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Bleeding . . . . . . . . . . . . . . . . . . . . 7-95
GD . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Center . . . . . . . . . . . . . . . . . . . . 7-101
GE . . . . . . . . . . . . . . . . . . . . . . . . 6-40
GF . . . . . . . . . . . . . . . . . . . . . . . . 6-40 D
J2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
J4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
DC Motor
VC . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Brushes . . . . . . . . . . . . . . . . . . . . 7-72
X3 . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Troubleshooting . . . . . . . . . . . . . . 5-11
X4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
DC Motor Test . . . . . . . . . . . . . . . . . . 5-14
X5 . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
DC Motor Troubleshooting . . . . . . . . . 5-11
Codes
Deadman Pedal
Power Amplifier . . . . . . . . . . . . . . . .6-2
Pressed, Theory . . . . . . . . . . . . . . . 8-6
Codes and Messages . . . . . . . . . . . . . . .6-9
Rectangular . . . . . . . . . . . . . . . . . 7-25
Codes, Configuration . . . . . . . . . . . . . 3-29
Round . . . . . . . . . . . . . . . . . . . . . 7-25
Cold Storage . . . . . . . . . . . . . . . . . . . . 3-28
Decals and Plates . . . . . . . . . . . . . . . . 7-11
Heater Assemblies . . . . . . . . . . . . . 3-28
Decimal to Fraction Conversion . . . . . A-13

I-2 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section I. Index

Index

Display Messages . . . . . . . . . . . . . . . . 3-7 H

Drive Motor
Install . . . . . . . . . . . . . . . . . . . . . 7-28 Harness
Removal . . . . . . . . . . . . . . . . . . . 7-28 Connectors . . . . . . . . . . . . . . . . . . 7-81
Drive Tire . . . . . . . . . . . . . . . 7-65 to 7-66 Soldering Procedures . . . . . . . . . . 7-81
Drive Unit Heater Assemblies . . . . . . . . . . . . . . . 3-28
Checks . . . . . . . . . . . . . . . . . . . . . 4-6 High Pressure Relief Valve Adjustment 7-93
Heavy Duty . . . . . . . . . . . . . . . . . 7-49 Home Proximity Sensor
Removal . . . . . . . . . . . . . . . 7-29, 7-49 Adjustment . . . . . . . . . . . . . . . . . . 7-18
Standard . . . . . . . . . . . . . . . . . . . 7-29 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Troubleshooting . . . . . . . . . . . . . . 5-21 Hydraulic
Drive Wheel . . . . . . . . . . . . . . 7-65 to 7-66 Bleeding Cylinders . . . . . . . . . . . . 7-95
Flow Sensor Service Notes . . . . . . . 7-90
E System Storage Preparation . . . . . 3-29
Hydraulic Components
Electrostatic Discharge Free Lift Cylinder . . . . . . . . . . . . 7-101
See Static Precautions
Emergency Lower Valve . . . . . . . . . . . 2-11 I
Emergency Lower Valve, Theory . . . . 8-10
End-of-Aisle IETM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Code J2 . . . . . . . . . . . . . . . . . . . . 5-23 Input Tests . . . . . . . . . . . . . . 6-71 to 6-110
Error Messages Inspection
Power Amplifier . . . . . . . . . . . . . . . 6-2 Battery Connector . . . . . . . . . . . . . 7-68
ESD Ground Jack . . . . . . . . . . . . . . . . 2-8 Motor Brushes . . . . . . . . . . . . . . . 7-72
Wiring/Harness . . . . . . . . . . . . . . 7-81
F Installation . . . . . . . . . . . . . . . . . . . . . . 3-7
Interactive Electronic
Fault Codes Technical Manuals . . . . . . . . . . . . . 1-3
Power Amplifier . . . . . . . . . . . . . . . 6-2
FlashWare L
Starting . . . . . . . . . . . . . . . . . . . . 3-25
FlashWare Program . . . . . . . . . . . . . . 3-25 L/L Pot Test . . . . . . . . . . . . . . . . . . . . 6-45
Flow Sensor . . . . . . . . . . . . . . . . . . . 7-90 Learn
Assembly . . . . . . . . . . . . . . . . . . . 7-92 Controls . . . . . . . . . . . . . . . . . . . . 3-19
Disassembly . . . . . . . . . . . . . . . . 7-91 Ht/Wt . . . . . . . . . . . . . . . . . . . . . . 3-19
O-Ring Replacement . . . . . . . . . . 7-90 Mode . . . . . . . . . . . . . . . . . . . . . . . 3-9
Forks When to Run . . . . . . . . . . . . . . . . 3-20
Checks . . . . . . . . . . . . . . . . . . . . . 4-7 LEDs
Installation . . . . . . . . . . . . . . . . .7-119 Wire Guidance . . . . . . . . . . . . . . . . 3-7
Removal . . . . . . . . . . . . . . . . . . .7-119 Lift
Fraction to Decimal Conversion . . . . . A-13 Motor . . . . . . . . . . . . . . . . . . . . . . 7-96
Fuse Relay Card . . . . . . . . . . . . . . . . . 8-4 Pump . . . . . . . . . . . . . . . . . . . . . . 7-96
Lift Chain
G Adjustment . . . . . . . . . . . . . . . . . 7-122
Maintenance . . . . . . . . . . . . . . . . 7-122
Ground Jack, ESD . . . . . . . . . . . . . . . 2-8 Lift Chain Storage Preparation . . . . . . 3-29
Grounded DC Motor Test . . . . . . . . . . 5-14 Lift Chains
Guidance Manager 3-Stage . . . . . . . . . . . . . 7-116 to 7-117
Theory of Operation . . . . . . . . . . . . 8-4 Maintenance . . . . . . . . . . . . . . . . . 4-11
Lift Cylinder

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Section I. Index Models 5300/5500/5600 Maintenance Manual

Index

Three-Stage Center With Cushions AC

Cushion Replacement . . . . . . 7-101 Bearing Encoder . . . . . . . . . . . 7-76
Seal Replacement . . . . . . . . . 7-103 Open Winding . . . . . . . . . . . . . 5-15
Service . . . . . . . . . . . . . . . . . 7-101 Service . . . . . . . . . . . . . . . . . . 7-75
Lift Power Amplifier . . . . . . . . . . . . . . . 7-78 Shorted Winding . . . . . . . . . . . 5-15
Theory of Operation . . . . . . . . . . . . .8-4 Temperature Sensor . . . . . . . . 7-75
Lift/Lower Commutator . . . . . . . . . . . . . . . . . 5-11
Knob Installation/Adjustment . . . . 7-23 DC . . . . . . . . . . . . . . . . . . . . . . . . 5-11
System Theory . . . . . . . . . . . . . . . 8-10 Field Winding Test . . . . . . . . . 5-14
Valve . . . . . . . . . . . . . . . . . . . . . . . 7-94 Grounded Motor Test . . . . . . . 5-14
Lights Open Circuit Test . . . . . . . . . . 5-14
Steering Indicator . . . . . . . . . . . . . .3-7 Short Circuited Armature . . . . 5-14
Wire Guidance LEDs . . . . . . . . . . . .3-7 Tests . . . . . . . . . . . . . . . . . . . . 5-14
Load Holding Valve . . . . . . . . . . . . . . . 7-94 winding . . . . . . . . . . . . . . . . . . 5-14
Load Wheels . . . . . . . . . . . . . . . . . . . 7-121 Power Cable Terminals . . . . . . . . . 7-72
Locator Photos . . . . . . . . . . . . . .7-3 to 7-8 Troubleshooting
Loctite® DC . . . . . . . . . . . . . . . . . . . . . 5-11
See Thread Adhesives
Lubrication Specification Chart . . . . . . .A-2 O

M Open Circuit DC Motor Test . . . . . . . . 5-14

Open Winding AC Motor . . . . . . . . . . . 5-15
Maintenance Minder . . . . . . . . . . . . . . .4-3 Operator Display . . . . . . . . . . . . . . . . . 3-7
Disabling . . . . . . . . . . . . . . . . . . . . .4-4 Steering Indicator Lights . . . . . . . . . 3-7
Enabling . . . . . . . . . . . . . . . . . . . . .4-3 Output Tests . . . . . . . . . . . 6-117 to 6-134
Maintenance Mode . . . . . . . . . . . 3-9, 3-23
Active . . . . . . . . . . . . . . . . . . 3-9, 3-24 P
Static . . . . . . . . . . . . . . . . . . 3-9, 3-23
Mast
Pallet Clamp . . . . . . . . . . . . . . . . . . 7-120
Bearing
Password . . . . . . . . . . . . . . . . . . . . . . . 3-8
Shimming . . . . . . . . 7-109 to 7-115
How to Change . . . . . . . . . . . . . . . 3-13
Inner Tele to Carriage . . . . 7-114
Photos, Locator . . . . . . . . . . . . . 7-3 to 7-8
Main Frame to
Pin Extraction
Outer Telescopic . . 7-112
AMP Connectors . . . . . . . . . . . . . . 7-83
Outer Tele to Inner Tele . . 7-113
Pin Insertion
Bearing Replacement
AMP Connectors . . . . . . . . . . . . . . 7-84
Upper . . . . . . . . . . . . . . . . . . 7-111
Pin-Out Matrix . . . . . . . . . . . . 8-21 to 8-41
Checks . . . . . . . . . . . . . . . . . . . . . .4-8
Power Amplifier
Disassembly . . . . . . . . . . . . . . . . 7-112
Connectors . . . . . . . . . . . . . .7-82, 7-86
Messages and Codes . . . . . . . . . . . . . . .6-9
LED Diagnostics . . . . . . . . . . . . . . . 6-2
Power Amplifier . . . . . . . . . . . . . . . .6-2
Replacement . . . . . . . . . . . . . . . . . 7-78
Modes of Operation
Power Amplifier Replacement . . . . . . . 7-78
Program Mode . . . . . . . . . . . . . . . . .3-9
Power Cables . . . . . . . . . . . . . . . . . . . 7-70
Run Mode . . . . . . . . . . . . . . . . . . . .3-8
Power Cables, Motor . . . . . . . . . . . . . . 7-72
Motor
Program Mode . . . . . . . . . . . . . . . . . . . 3-9
Checks . . . . . . . . . . . . . . . . . . . . . .4-8
Configure Mode . . . . . . . . . . . . . . . 3-9
Drive, Install . . . . . . . . . . . . . . . . . 7-28
LEARN . . . . . . . . . . . . . . . . . . . . . . 3-9
Drive, Remove . . . . . . . . . . . . . . . . 7-28
Maintenance . . . . . . . . . . . . . . . . . . 3-9
Lift . . . . . . . . . . . . . . . . . . . . . . . . 7-96
Pump
Storage Preparation . . . . . . . . . . . . 3-29
Lift . . . . . . . . . . . . . . . . . . . . . . . . 7-96
Motors . . . . . . . . . . . . . . . . . . 7-72 to 7-77

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Models 5300/5500/5600 Maintenance Manual Section I. Index

Index

R Steering and Controls . . . . . . . . . . . . . 7-15

Storage
Relief Valve Hydraulic Cylinders . . . . . . . . . . . 3-29
Adjustment . . . . . . . . . . . . . . . . . 7-93 Hydraulic System . . . . . . . . . . . . . 3-29
Run Mode . . . . . . . . . . . . . . . . . . . . . . 3-8 Lift Chains . . . . . . . . . . . . . . . . . . 3-29
Motors . . . . . . . . . . . . . . . . . . . . . 3-29
Warranty Issues . . . . . . . . . . . . . . 3-29
S SuperWord . . . . . . . . . . . . . . . . . . . . . . 3-8
How to Change . . . . . . . . . . . . . . . 3-13
Safety Switch Adjustment . . . . . . . . . . . . . . . . A-4
Battery . . . . . . . . . . . . . . . . . . . . . 2-5 Switch Gap . . . . . . . . . . . . . . . . . . . . . . A-4
Decals . . . . . . . . . . . . . . . . . . . . . 7-11 Switches
Definitions . . . . . . . . . . . . . . . . . . . 2-2 Deadman Replacement . . . . . . . . . 7-25
Emergency Lower Valve . . . . . . . . 2-11 Tests
ESD . . . . . . . . . . . . . . . . . . . . . . . . 2-8 S10 . . . . . . . . . . . . . . . . . . . . 6-103
General . . . . . . . . . . . . . . . . . . . . . 2-3 S11 . . . . . . . . . . . . . . . . . . . . . 6-74
Static Precautions . . . . . . . . . . . . . 2-8 S15 . . . . . . . . . . . . . . . . . . . . . 6-99
Welding . . . . . . . . . . . . . . . . . . . . 2-14 S2 . . . . . . . . . . . . . . . . . . . . . . 6-73
Scheduled Maintenance S21 . . . . . . . . . . . . . . . . . . . . . 6-89
360 Day . . . . . . . . . . . . . . . . . . . . 4-10 S23 . . . . . . . . . . . . . . . . . . . . . 6-72
60 Day . . . . . . . . . . . . . . . . . . . . . 4-6 S24 . . . . . . . . . . . . . . . . . . . . . 6-77
Guidelines . . . . . . . . . . . . . 4-2 to 4-10 S25 . . . . . . . . . . . . . . . . . . . . 6-108
Sealants, Specifications . . . . . . . . . . . . A-3 S27 . . . . . . . . . . . . . . . . . . . . 6-102
Sensor S28 . . . . . . . . . . . . . . . . . . . . . 6-75
Flow . . . . . . . . . . . . . . . . . . . . . . 7-90 S3 . . . . . . . . . . . . . . . . . . . . . . 6-78
Sensors S4 . . . . . . . . . . . . . . . . . . . . . 6-100
Home Prox Adjustment . . . . . . . . 7-18 S46 . . . . . . . . . . . . . . . . . . . . 6-106
Service Bulletins . . . . . . . . . . . . . . . . . .1-v S47 . . . . . . . . . . . . . . . . . . . . 6-104
Service/Torque Chart, S60 & 61 . . . . . . . . . . . . . . . . 6-101
Component Specific . . . . . . . . . . . . A-4 S7 . . . . . . . . . . . . . . . . . . . . . . 6-76
Shimming Mast Bearings . .7-109 to 7-115 System Architecture . . . . . . . . . . 8-2 to 8-5
Inner Tele to Carriage . . . . . . . . .7-114 Systems
Main Frame to Outer Telescopic . .7-112 Theory of Operation . . . . . . . . . . . . 8-3
Outer Tele to Inner Tele . . . . . . . .7-113
Shorted Winding AC Motor . . . . . . . . 5-15
T
Shorted Winding on AC Motor . . . . . . 5-15
Shorts to Frame Test . . . . . . . . . . . . . . 5-2
Soldering Procedures . . . . . . . . . . . . . 7-81 Terminals, Motor Power Cable . . . . . . 7-72
Solenoid Tests
Main Load Hold A04 (VR1) . . . . . . . . . . . . . . . . . . . 6-44
Test . . . . . . . . . . . . . . . . . . . .6-120 A05 (VR2) . . . . . . . . . . . . . . . . . . . 6-45
Special Tools . . . . . . . . . . . . . . . . . . . 7-10 A08 (TM Temp) . . . . . . . . . . . . . . . 6-46
Specification Tag . . . . . . . . . . . . . . . . . 3-3 A09 (LM Temp) . . . . . . . . . . . . . . . 6-47
Specifications, Vehicle . . . . . . . . . . . . . 3-3 A10 (TPA Temp) . . . . . . . . . . . . . . 6-48
Standard/Metric Conversions . . . . . . A-15 A11 (TM Current) . . . . . . . . . . . . . 6-49
Static A13 (Press Sensor) . . . . . . . . . . . . 6-50
Precautions . . . . . . . . . . . . . . . . . . 2-8 A14 (VM +12V) . . . . . . . . . . . . . . . 6-51
Static Maintenance Mode . . . . . . 3-9, 3-23 A15 (Batt) . . . . . . . . . . . . . . . . . . . 6-52
Steer Motor/Gearbox . . . . . . . . . . . . . 7-16 A19 (LPA Temp) . . . . . . . . . . . . . . 6-53
Encoder Bearing Replacement . . . 7-16 A20 (LM Current) . . . . . . . . . . . . . 6-54
Steering A22 (Traction Request) . . . . . . . . . 6-55
Indicator Lights . . . . . . . . . . . . . . . 3-7 A23 (Lift Request) . . . . . . . . . . . . . 6-56
A34 (L/L Current) . . . . . . . . . . . . . 6-58

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Section I. Index Models 5300/5500/5600 Maintenance Manual

Index

A35 (Brake) . . . . . . . . . . . . . . . . . . 6-59 Guidance Manager . . . . . . . . . . . . . 8-4

A37 (Steer PA Current) . . . . . . . . . 6-60 Intellispeed . . . . . . . . . . . . . . . . . . . 8-5
A51 (Left Tractor Guidance Coil) . . 6-62 Lift Power Amplifier . . . . . . . . . . . . 8-4
A52 (Right Tractor Guidance Coil) . 6-63 Lift/Lower System . . . . . . . . . . . . 8-10
A53 (Left Load Guidance Coil) . . . . 6-64 Emergency Lower . . . . . . . . . . 8-10
A54 (Right Load Guidance Coil) . . . 6-65 Lower . . . . . . . . . . . . . . . . . . . 8-12
A55 (Tractor Near Wire Coil) . . . . . 6-66 Variable Speed DC Lift . . . . . . 8-10
A56 (Load Near Wire Coil) . . . . . . . 6-67 Variable Speed with AC Lift . . . 8-11
Analog . . . . . . . . . . . . . . . . 6-43 to 6-68 Operator Interface Card . . . . . . . . . 8-4
DC Motor . . . . . . . . . . . . . . . . . . . 5-14 Pin-Out Matrix . . . . . . . . . 8-21 to 8-41
I00 (S23) . . . . . . . . . . . . . . . . . . . . 6-72 Steering . . . . . . . . . . . . . . . . . . . . . 8-8
I01 (S2) . . . . . . . . . . . . . . . . . . . . . 6-73 Systems Overview . . . . . . . . . . . 8-8
I02 (S11) . . . . . . . . . . . . . . . . . . . . 6-74 Systems Overview . . . . . . . . . . . . . . 8-3
I03 (S28) . . . . . . . . . . . . . . . . . . . . 6-75 Traction Power Amplifier . . . . . . . . . 8-4
I04 (S7) . . . . . . . . . . . . . . . . . . . . . 6-76 Vehicle Manager . . . . . . . . . . . . . . . 8-3
I05 (S24) . . . . . . . . . . . . . . . . . . . . 6-77 Wire Guidance . . . . . . . . . . . . . . . 8-13
I15 (S3) . . . . . . . . . . . . . . . . . . . . . 6-78 Systems Overview . . . . . . . . . . 8-14
I38 (S21) . . . . . . . . . . . . . . . . . . . . 6-89 Thread Adhesives, Specifications . . . . . A-3
I65 (S15) . . . . . . . . . . . . . . . . . . . . 6-99 Throttle Pot Test . . . . . . . . . . . . . . . . . 6-44
I66 (S4) . . . . . . . . . . . . . . . . . . . . 6-100 Tie-Down for Transport . . . . . . . . . . . 2-12
I67 (S60 & 61) . . . . . . . . . . . . . . . 6-101 Tire, Drive . . . . . . . . . . . . . . . 7-65 to 7-66
I68 (S27) . . . . . . . . . . . . . . . . . . . 6-102 Tools, Special . . . . . . . . . . . . . . . . . . . 7-10
I69 (S10) . . . . . . . . . . . . . . . . . . . 6-103 Torque Chart
I72 (S47) . . . . . . . . . . . . . . . . . . . 6-104 Brass, Standard . . . . . . . . . . . . . . A-10
I73 (S46) . . . . . . . . . . . . . . . . . . . 6-106 Face Seal O-Rings . . . . . . . . . . . . . A-7
I74 (S25) . . . . . . . . . . . . . . . . . . . 6-108 Ferrous, Metric . . . . . . . . . . . . . . . . A-9
Input . . . . . . . . . . . . . . . . 6-71 to 6-110 Hydraulic Fittings . . . . . . . . . . . . . . A-6
O00 (TPC) . . . . . . . . . . . . . . . . . . 6-118 Metric (Brass) . . . . . . . . . . . . . . . . A-11
O02 (LPC) . . . . . . . . . . . . . . . . . . 6-119 Thread-Forming Screws . . . . . . . . A-12
O11 (SOL1) . . . . . . . . . . . . . . . . . 6-120 Towing . . . . . . . . . . . . . . . . . . . . . . . . 2-13
O12 (Ramp L/L SOL) . . . . . . . . . . 6-121 Traction Motor
O18 (Horn) . . . . . . . . . . . . . . . . . 6-122 Power Cable Terminal Nuts . . . . . . 7-72
O19 (Audible Alarm) . . . . . . . . . . 6-123 Traction Power Amplifier . . . . . . . . . . 7-78
O20 (Travel Alarm) . . . . . . . . . . . 6-124 LED Diagnostics . . . . . . . . . . . . . . . 6-2
O28 (Ramp LM) . . . . . . . . . . . . . . 6-125 Theory of Operation . . . . . . . . . . . . 8-4
O29 (Ramp TM) . . . . . . . . . . . . . . 6-126 Traction Power Amplifiers . . . . . . . . . . 7-78
O30 (Brake SOL) . . . . . . . . . . . . . 6-127 Traction System
O32 - Toggle Relay Enable . . . . . . 6-128 Functional Operation . . . . . . . 8-5, 8-6
O39 (OD Lights) . . . . . . . . . . . . . 6-129 Travel Pot (VR1) Replacement . . . . . . . 7-21
O40 (L/L Alarm) . . . . . . . . . . . . . 6-130 Travel, Theory . . . . . . . . . . . . . . . . . . . 8-6
O41 (Aux Sel SOL) . . . . . . . . . . . . 6-131 Troubleshooting
O42 (Main Sel SOL) . . . . . . . . . . . 6-132 Aisle Exit Error Code J2 . . . . . . . . 5-23
O43 (Aux Load Hold SOL) . . . . . . 6-133 Chains . . . . . . . . . . . . . . . . . . . . . 4-11
Output . . . . . . . . . . . . . 6-117 to 6-134 Communication Error Codes . . . . 5-22
Shorts to Frame . . . . . . . . . . . . . . .5-2 DC motors
Wire Guidance . . . . . . . . . 6-62 to 6-67 short-circuited winding . . . . . . 5-14
Theory of Operation Drive Unit . . . . . . . . . . . . . . . . . . . 5-21
Antenna Cards . . . . . . . . . . . . . . . .8-4 Electrical . . . . . . . . . . . . . . . . . . . . 5-2
BSOC . . . . . . . . . . . . . . . . . . . . . . .5-5 Electrical Symptoms . . . . . 5-29 to 5-30
Carriage Control Card . . . . . . . . . . .8-3 Hydraulic Functions . . . . . 5-25 to 5-27
Emergency Lower Valve . . . . . . . . . 8-10 Motors . . . . . . . . . . . . . . . 5-11 to 5-15
Fuse/Relay Card . . . . . . . . . . . . . . .8-4 DC . . . . . . . . . . . . . . . . . . . . . 5-11

I-6 Publication: 1301126/001A, Issued: 12 Nov 2018

Models 5300/5500/5600 Maintenance Manual Section I. Index

Index

Pin-Out Matrix . . . . . . . . 8-21 to 8-41

Shorts to Frame Test . . . . . . . . . . . 5-2
Travel Functions . . . . . . . . . . . . . 5-28

Valve
High Pressure Relief
Adjustment . . . . . . . . . . . . . . 7-93
Valves
Emergency Lower . . . . . . . . . . . . 2-11
High Pressure Relief Adjustment . 7-93
Lift/Lower . . . . . . . . . . . . . . . . . . 7-94
Load Holding . . . . . . . . . . . . . . . . 7-94
Vehicle
Specifications . . . . . . . . . . . . . . . . 3-3
Vehicle Manager
Theory of Operation . . . . . . . . . . . . 8-3
VR1 Test . . . . . . . . . . . . . . . . . . . . . . 6-44
VR2 Test . . . . . . . . . . . . . . . . . . . . . . 6-45

Warning, Definition . . . . . . . . . . . . . . . 2-2

Warranty
Storage Issues . . . . . . . . . . . . . . . 3-29
Welding Safety . . . . . . . . . . . . . . . . . 2-14
Wheels
Drive . . . . . . . . . . . . . . . . 7-65 to 7-66
Load . . . . . . . . . . . . . . . . . . . . . .7-121
Wire Guidance . . . . . . . . . . . . . . . . . 3-27
End-of-Aisle Configurations . . . . . 8-15
End-of-Aisle Control, Theory . . . . 8-15
End-of-Aisle Magnet Installation . 8-16
End-of-Aisle Slow Down, Theory . 8-18
LEDs . . . . . . . . . . . . . . . . . . . . . . . 3-7
Setup . . . . . . . . . . . . . . . . . . . . . 3-27
Tests . . . . . . . . . . . . . . . . 6-62 to 6-67
Wiring
Connectors . . . . . . . . . . . . . . . . . 7-81
Soldering Procedures . . . . . . . . . . 7-81
Wrist strap, ESD . . . . . . . . . . . . . . . . . 2-8

Publication: 1301126/001A, Issued: 12 Nov 2018 I-7

Section I. Index Models 5300/5500/5600 Maintenance Manual

Index

I-8 Publication: 1301126/001A, Issued: 12 Nov 2018

 1301126/001A
Printed by the Digital Print Center,
The Raymond Corporation, Greene, NY
 Schematics

Models Serial Numbers

5300 00001 and Up This publication applies to all subsequent releases of this product until otherwise
indicated in new editions or bulletins. Changes occur periodically to the information in
5500, 5600 44001 and Up this publication.

If you need assistance with your lift truck, or to order additional copies of this document,
contact your local authorized Raymond Sales and Service Center. To locate your local
authorized Raymond Sales and Service Center, go to www.raymondcorp.com.

Publication:1301126/001A Issued: 12 Nov 2018

©2018 The Raymond Corporation.

Models 5300/5500/5600 High-Level Orderpicker Lift Truck Schematics
Section A. Appendix

Figure 1. Power Distribution Diagram Sheet 1 (DC Lift)

JPTA1
TPC -6
CONTACTOR
CARRIAGE
-13
TPC SUPPLY
(B+K3)
CONTROL IDENT. DESCRIPTION
CARD BRAKE ELECTRIC BRAKE
TA JPC5
CONTACTOR -1 CD COIL DRIVER CIRCUIT
PANEL
TPC
TO
TP1 -2
OPTIONS FU1 POWER FUSE FOR STEER
2 1
FU2 POWER FUSE FOR TRACTION
B- -3
-4 FU3 POWER FUSE FOR LIFT
1
FU5 CONTROL FUSE FOR VEHICLE MANAGER B+ 15A
LPC FU2
FU1 2 (350A) FU6 CONTROL FUSE FOR VEHICLE MANAGER B- 15A
(100A)
FU7 CONTROL FUSE FOR AUX. POWER B+ 15A/5A
TP2 FU3 TP5
JP U FU8 CONTROL FUSE FOR AUX. POWER B- 15A/5A
(500A) U -1
B+
JPS1-1, -2 X Y JPS1-8 V B+K3
TP3 TPC TM V
-3, -4 W +
W S1 JPC6
2 1 -1

JPS1-11 -2

-3
NC
1
S21 H (HRN) HORN
2
NO -4

JP10 CONNECTOR FOR WARNING LIGHT

JPB- BATTERY CONNECTOR -
JPB+ BATTERY CONNECTOR +
JPBR CONNECTOR FOR BRAKE
JPC5 CONNECTOR ON C.C.C. FOR LIGHTS/FANS
JPC6 CONNECTOR ON C.C.C. FOR LIFT/LOWER BYPASS SWITCH
VEHICLE JPC12 CONNECTOR ON C.C.C. FOR SPARE POWER
X
LPC
Y JPS1-9 MANAGER TO TS12-1
JPC12
-1 JPC16 CONNECTOR ON C.C.C. FOR OVER THE MAST CABLE #2
OPTIONS -2 JPF1 B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY CARD
TS12-2 JPF2 B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD

JPS1-10 JPF3 B- CONNECTOR ON FUSE/RELAY CARD

JPF4 KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/RELAY CARD

JPS1 CONTACTOR PANEL INTERFACE CONNECTOR

JP +12V
JPS2 CONNECTOR ON TRUCK TRACKER FOR POWER
B-
+5V

DGND JPS26 CONNECTOR FOR OVER THE MAST CABLE #2

JPS29 CONNECTOR FOR 10 AMP POWER HOOKUP OPTION ON TRACTOR

A1 +
JPT20
-15 JPT14 B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM
TP4 TP2
A2 JPT18 COIL DRIVERS CONNECTOR ON VM
MS+ -16 CD
LM L/L
+ 1 2 JPT20 PROPORTIONAL COIL DRIVERS CONNECTOR ON VM
JPT22 DIGITAL INPUTS CONNECTOR ON VM
MS SA S1 -
JPT18-9
- CD JPTA1 TRACTION AMP CONNECTOR
MS-
TP4
K1 KEYSWITCH RELAY-OPTIONS
JPT14-2, -10 DGND
K2 KEYSWITCH RELAY-SOLENOIDS, ATTACHMENTS, HORN

-1, -8, -9 B-F K3 KEYSWITCH RELAY-POWER AMPS

K4 KEYSWITCH RELAY-AUX. VM POWER

L/H LOAD/HOLD SOLENIOD

L/L LIFT/LOWER SOLENOID
JPF3-3, -4

TS10-1
LA LIFT POWER AMPLIFIER
-5, -6, -7

TO
JPF1-3

JPF1-5

JPF2-1

JPF1-6

OPTIONS

-2
-12
-11

LM AC LIFT MOTOR OR DC LIFT MOTOR

LPC LIFT POWER CONTACTOR
HRN
FU6 (15A) -NEG JPT18
JPF3-1, -2
H -IN H-1 -16 MS STEER MOTOR
1 2
K3 -POS H-2

JPF1-1, -2 FU8 (15A/5A) JPF1-4 S1 KEY SWITCH

1 2 JPF4-15 S21 EPO SWITCH
FU7 (15A/5A) K1 JPBR-2
JPF4-3, -4
JPF2-9 JPT20
1 2 -1 -14
BRAKE CD
JPF2-2

JPT18
-5 -10 JPC16
L/H CD -1
1 2 JPT14 -2 SA STEER POWER AMPLIFIER
JPF4-13 -6
CD -3
JPT22
-6 -21 -4
TA TRACTION POWER AMPLIFIER
K4 K3 K2 K1 JP10-1
-5 WARNING LIGHT TM AC TRACTION MOTOR
-6
-12 -2 TP1 TIE POINT ON B+
JPT14
-11 -12 -8 TP2 TIE POINT ON STEER MOTOR FUSE
-8 TP3 TIE POINT ON LIFT MOTOR FUSE
JPF4-1, -2 FU5 (15A)
-10 TP4 TIE POINT ON B-
1 2
K2 TP5 TIE POINT ON TRACTION MOTOR FUSE
K4
JPT14
-7,-13,-14 TPC TRACTION POWER CONTACTOR
JPF2-3,-6,-7,
TS12 TERMINAL STRIP FOR SPARE POWER

MODEL 5300
FUSE/ JPS26
-4
DC LIFT
RELAY -2
CARD -3
-1
-6
-8

Publication:1301126/001A, Issued: 12 Nov 2018 2

Models 5300/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 2. Power Distribution Diagram Sheet 2 (AC Lift)
JPTA1
TPC -6
CONTACTOR
CARRIAGE
-13
TPC SUPPLY
(B+K3)
CONTROL IDENT. DESCRIPTION
CARD BRAKE ELECTRIC BRAKE
TA JPC5
CONTACTOR -1 CD COIL DRIVER CIRCUIT
PANEL
TPC
TO
TP1 OPTIONS -2 FU1 POWER FUSE FOR STEER
2 1
FU2 POWER FUSE FOR TRACTION
B- -3
-4 FU3 POWER FUSE FOR LIFT
1
FU5 CONTROL FUSE FOR VEHICLE MANAGER B+ 15A
LPC FU2
FU1 2 (350A) FU6 CONTROL FUSE FOR VEHICLE MANAGER B- 15A
(100A)
FU7 CONTROL FUSE FOR AUX. POWER B+ 15A/5A
TP2 FU3 TP5
JP U FU8 CONTROL FUSE FOR AUX. POWER B- 15A/5A
(500A) U -1
B+
JPS1-1, -2 X Y JPS1-8 V B+K3
TP3 TPC TM V
-3, -4 W +
W S1 JPC6
2 1 -1

JPS1-11 -2

-3
JPLA1 NC
LPC -6 1
CONTACTOR S21 H (HRN) HORN
-13 2
LPC SUPPLY NO -4
(B+K3)
JP10 CONNECTOR FOR WARNING LIGHT
JPB- BATTERY CONNECTOR -

LA JPB+ BATTERY CONNECTOR +

JPBR CONNECTOR FOR BRAKE
JPC5 CONNECTOR ON C.C.C. FOR LIGHTS/FANS
JPC6 CONNECTOR ON C.C.C. FOR LIFT/LOWER BYPASS SWITCH
VEHICLE JPC12 CONNECTOR ON C.C.C. FOR SPARE POWER
X JPC12
LPC
Y JPS1-9 B- MANAGER TO TS12-1 -1 JPC16 CONNECTOR ON C.C.C. FOR OVER THE MAST CABLE #2
OPTIONS -2 JPF1 B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY CARD
TS12-2 JPF2 B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD

JPS1-10 JPF3 B- CONNECTOR ON FUSE/RELAY CARD

U JPF4 KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/RELAY CARD

U -1
B+K3 JPLA1 LIFT AMP CONNECTOR
LM V
V
JPS1 CONTACTOR PANEL INTERFACE CONNECTOR
W + +12V
JP W JPS2 CONNECTOR ON TRUCK TRACKER FOR POWER
B-
+5V
DGND JPS26 CONNECTOR FOR OVER THE MAST CABLE #2
JPS29 CONNECTOR FOR 10 AMP POWER HOOKUP OPTION ON TRACTOR

JPT20
-15 JPT14 B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM
TP4 TP2
CD JPT18 COIL DRIVERS CONNECTOR ON VM
MS+ -16
L/L
+ 1 2 JPT20 PROPORTIONAL COIL DRIVERS CONNECTOR ON VM
JPT22 DIGITAL INPUTS CONNECTOR ON VM
MS SA

- JPTA1 TRACTION AMP CONNECTOR

MS-
TP4
K1 KEYSWITCH RELAY-OPTIONS
JPT14-2, -10 DGND
K2 KEYSWITCH RELAY-SOLENOIDS, ATTACHMENTS, HORN

-1, -8, -9 B-F K3 KEYSWITCH RELAY-POWER AMPS

K4 KEYSWITCH RELAY-AUX. VM POWER

L/H LOAD/HOLD SOLENIOD

L/L LIFT/LOWER SOLENOID
JPF3-3, -4

TS10-1
LA LIFT POWER AMPLIFIER
-5, -6, -7

TO
JPF1-3

JPF1-5

JPF2-1

JPF1-6

OPTIONS

-2
-12
-11

LM AC LIFT MOTOR OR DC LIFT MOTOR

LPC LIFT POWER CONTACTOR
HRN
FU6 (15A) -NEG JPT18
JPF3-1, -2
H -IN H-1 -16 MS STEER MOTOR
1 2
K3 -POS H-2

JPF1-1, -2 FU8 (15A/5A) JPF1-4 S1 KEY SWITCH

1 2 JPF4-15 S21 EPO SWITCH
FU7 (15A/5A) K1 JPBR-2
JPF4-3, -4
JPF2-9 JPT20
1 2 -1 -14
BRAKE CD
JPF2-2

JPT18
-5 -10 JPC16
L/H CD -1
1 2 JPT14 -2 SA STEER POWER AMPLIFIER
JPF4-13 -6
SEE CD -3
-14 DETAIL JPT22
-6 -21 -4
A TA TRACTION POWER AMPLIFIER
K4 K3 K2 K1 JP10-1
-5 WARNING LIGHT TM AC TRACTION MOTOR
-6
-12 -2 TP1 TIE POINT ON B+
JPT14
-11 -12 -8 TP2 TIE POINT ON STEER MOTOR FUSE
-8 TP3 TIE POINT ON LIFT MOTOR FUSE
JPF4-1, -2 FU5 (15A)
-10 TP4 TIE POINT ON B-
1 2
K2 TP5 TIE POINT ON TRACTION MOTOR FUSE
K4
JPT14
-7,-13,-14 TPC TRACTION POWER CONTACTOR
JPF2-3,-6,-7,
TS12 TERMINAL STRIP FOR SPARE POWER
JPF4-13
-14

36V TRUCKS MODEL 5500, 5600

JPF4-13
-14 FUSE/ JPS26
-4 AC LIFT
24V TRUCKS
RELAY -2
CARD -3
-1
DETAIL A -6
-8

Publication:1301126/001A, Issued: 12 Nov 2018 3

Models 5300/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 3. Electrical Schematic Sheet 1 (AC Lift)

A B C D E F G H
MOTOR VELOCITY JPTA4-6
JPTA1
NOTES: RED JPTA2-1 JPTA1-26
-1
T VEL SENSOR +
SEE PAGE 8. BLACK -4 -5 -7
B+K3
TME T VEL SENSOR - -12

2 WHITE -3 -4 -31 ID1

T VEL PHASE A JPSC3-1
-2 -3 -32 -2
BLUE
T VEL PHASE B
CONTACTOR RED JPTA3-2 -8
-8
T TEMP+ -23
PANEL TMT RED/BLK -1 -7
BUS+
-35
-6 BUS-
TPC MOTOR TEMPERATURE TPC CONTACTOR
TP1 -13
TPC SUPPLY
VEHICLE
2 1 (B+K3) MANAGER JPS25-1 JPC11-1
+12V
B- -2 -2 BUS-
-3 -3 BUS+
1
LPC FU2 AC TRACTION JPT22-7 -4 -4 OTM CABLE B
JPS1-11 BRAKE DEADMAN
FU1 2 (350A) AMPLIFIER 6 BRAKE DEADMAN SEE SHEET 3
(100A) -2 JPT22-8 -5 -5
CARRIAGE DEADMAN CARRIAGE DEADMAN
SPL10

BUS_I+
FU3 TP5

BUS_I-
TP2 U -6 -6
JP JPS1-2 (500A) U DGND
B+ -1
-1 X Y JPS1-8 V
TP3 TPC TM V 9 JS31-1 JS27-1
-4

-6
JPSC1-2 8 9

JS4-5
+ JPSC1-1
-3 W W -2 -2

3
-2
SPL2
-1

MOTOR VELOCITY VEHICLE MANAGER

RED JPLA2-1 JPLA1-26
JPLA1-1 JPT10-6 JPS54-1
L VEL SENSOR +
B+K3 +12V
-7 +12VP JPT20-8 JPS57-1 S124-3

LIFT DECEL
BLACK -4 SPL11 -2 -2
LME L VEL SENSOR - -11 JPT4-3 -2 -2 SENSOR 1
LIFT DECEL S124
-3 -31 ID1 JPT24-8 -3
WHITE DGND
JPT18-7 -3 -1 13

END OF AISLE
L VEL PHASE A DGND 6
JPT10-7 JPS55-1
-2 -32 JPT14 +12V
BLUE -2
L VEL PHASE B -5 -8
SENSOR 2
RED -8 +12VP JPT24-9 -3
JPLA3-2
L TEMP+ -23 JPSC2-2 -11 DGND
LMT RED/BLK -1 BUS+ BUS_I+
-35 JPSC2-1 -4
-6 BUS- BUS_I-
+12V
MOTOR TEMPERATURE LPC CONTACTOR -3 JPT22-4 -2
-13 DGND SLACK SW1

CHAIN SWITCHES
LPC SUPPLY JPT4-2 -3
DGND
(B+K3)

SLACK
X Y JPS1-9 JPT24-1 JS59-1 6
LPC B- +12V
JPT22-4 -2
SLACK SW2
-3
AC LIFT
AMPLIFIER JIO-2 JPT24-4
DGND

4 JPS1-5 JPS1-10 -5 -13

+12VP JPT10-5
+12V
JPT18-4
JPT22-22
JPS53-3
-2

RAIL SENSE
PSC3A-1
U -6 JPT12-11 BUS_2- RAIL_SEN 7
U CUSTOM IN 1 -10 -2
BUS_2+ JPT24-3 -1
V -1 -9 DGND
LM V CUSTOM IN 2
-3 JPT18-2
W + CUSTOM OUT JIPM-1
JP W M SEL2
-4 JPT18-14
B- -2 MAIN SEL
-15 A SEL2

AUX L/L
AUX SEL
A L/H2
7
-12
AUX L/H

SPL1 JPT20-11 J3CB-1

BUS_3+ JPT20-5 JPS50-1
JPT18-13 -2 7 +12V

TRANSDUCER
-1 -2 BUS_3- JPT24-18 -2

PRESSURE
P/T A 7
TP4 JPT6-6 JPT24-10 -3
TP2 DGND
+12VP
MS+ -5
CCW_PWM JPT20
+ -2 -16 JPT22-13 JPS51-1
CW_PWM L/L L/L CHANNEL A
SA -3 2 1 JPT22-14 -2

MAIN LIFT ENCODER

MS CHANNEL B

FLOW SENSOR
STEER_CURRENT -15 JPT24-11 -3
(B+K2)B+L/L
-4 DGND 7
DGND JPT24-19 -4
- -1 FS TEMP
MS- NEUTRAL_PULSE JPT20-2 -5
+12V
TP4
JPT22-19 FU1_SENSE

GUIDANCE
JPS15-1

MANAGER
5
JPT14-10 JPT18-18
ALARM_TRAVEL
DGND JPT20-19 JPS2-11 -2
-2 B+K2 6 B+K2
JPT20-17

ALARM OPTIONS
DGND
-1
JPS52-1 6
-8
-18 -2
-9 B-F ALARM_L/L

JPT24-1 JPS28-1
S10-3 JPS8-1 JPT20-1 +12V
+12V JPT22-4 -2

120 IN. LIMIT

150 IN. LIMIT
S10-2 JPS8-2 JPT22-1 JPT22 JPA7 180_LIM
13

180 IN. LIMIT

S10
150_LIM -3 -1 0 7

HOME SENSOR
6 JB1-2 HOMESENSE
6 S10-1 JPS8-3 -3
JPF1-3

JPF1-5

JPF2-1

JPF1-6

JPT24-7
JPF3-9
JPF3-3

-1 -11 -2 - HOME DGND

DGND SENSOR
-12
-11

JPT20
-4
-5
-6
-7
-8

+ PROX
TS10-1

TS10-2 -9 -3
+12VF
JPT20-10 JPS10-1
JPF3-1 +12V
HRN JPT22-2 -2
FU6 (15A) -NEG LIFT INHIB
6

LIFT LIMIT
-2
-IN H-1 JPT18-16 HORN
1 2 H JPT24-3 -3
K3 -POS H-2 DGND
JPF1-1
FU8 (15A/5A) JPF1-4
-2
1 2 JP10-1 JPT20-6 JPS16-1
JPF4-15 +12V
WARNING

GATES SENSOR/
TRAVEL LIMIT
11 -2

BATTERY
LIGHT JPBR-2 JPXBR-2 JPT22-6
JPF4-3 FU7 (15A/5A) K1
-2 JPT20-7 JPE4-1 RED
BGS/TL 6
JPF2-9 +12VP
-4 1 2 -1 -1 JPT20-14 JPT22-9 JPT24-6
BRAKE BRAKE -3 WHT STEER -3

6
JPF2-2 CHANNELA_4 DGND
MOTOR
-10 -2 BLU ENCODER
-3 CHANNELB_4
-5 JPT10-9 -4 BLK
JPT18-10 DGND
L/H L/H
JPT18-3 JPPL1-1
1 2
JPF4-13 SEE JPT14-6 +12V
RELAY_ENABLE JPT12-8 -2

SOURCE LIMIT
DETAIL PSL

POWER
7

COMMUNICATIONS
-14
-6 A JPT22-21
EPO_SENSE TXD JPT9-2 7 JPT10-4 -3
K4 K3 K2 K1 DGND

SERIAL
-5 RXD -3
DGND -5 8
-12
JPT14-12 JPT12-5 J1-4
-11 LIFT
B+KEY
-8 -6 -3

LIFT PENDANT
FU5 (15A) LOWER
-1 JPT2

COMMUNICATIONS
-10
1 2 VBUS -1 -12 -9
K2 K4 D+ -2 DGND
-2 JPF2-4 JPT14-7

USB
B+K2 D- -3
-6 -13
B+K2 -4
-14 DGND
-7
B+K2
T JPF4-7 JPT24-24
JPF4-13 BATTERY_SENSE_IN
-14

36V TRUCKS
JPF2-8
AC LIFT - OPR
7 JPF4-13
JPS26-4
-2
JPC16-4
-2
B-FU6

FUSE/RELAY CARD
B-FU8 TABLE A
-14 -3 -3 B+FU7 OTM CABLE A 11 AUX. POWER
-1 -1 SEE SHEET 3
24V B+EPO OPTION STD C.S.
-6 -6
TRUCKS B+KEY FU7 5A 15A
-8 -8
B+FU5 FU8 5A 15A
DETAIL A JPS30-1 JPS29-1
6 -2 -2

Publication:1301126/001A, Issued: 12 Nov 2018 4

Models 5300/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 4. Electrical Schematic Sheet 2 (DC Lift)

A B C D E F G H
MOTOR VELOCITY JPTA4-6
JPTA1
RED JPTA2-1 JPTA1-26
-1
T VEL SENSOR +
B+K3
BLACK -4 -5 -7
TME T VEL SENSOR - -12
WHITE -3 -4 -31 ID1

2 T VEL PHASE A JPSC3-1

-2 -3 -32 -2
BLUE
T VEL PHASE B
CONTACTOR RED JPTA3-2 -8
-8
T TEMP+ -23
PANEL TMT RED/BLK -1 -7
BUS+
-35
-6 BUS-
TPC MOTOR TEMPERATURE TPC CONTACTOR
TP1 -13
TPC SUPPLY
VEHICLE
2 1 (B+K3) MANAGER JPS25-1 JPC11-1
+12V
B- -2 -2 BUS-
-3 -3 BUS+
1
LPC FU2 AC TRACTION JPT22-7 -4 -4 OTM CABLE B
JPS1-11
AMPLIFIER 6 BRAKE DEADMAN BRAKE DEADMAN SEE SHEET 3
FU1 2 (350A)
(100A) -2 JPT22-8 -5 -5
CARRIAGE DEADMAN CARRIAGE DEADMAN
SPL10

BUS_I+
FU3 TP5

BUS_I-
TP2 U -6 -6
JP JPS1-2 (500A) U DGND
B+ -1
-1 X Y JPS1-8 V 9
TP3 TPC TM V JS31-1 JS27-1
-4

-6
JPSC1-2

JS4-5
+ JPSC1-1 8 9
-3 W W -2 -2
-2

3 -1
SPL2

X
LPC
Y JPS1-9 VEHICLE MANAGER
S124
JPS57
+12VP JPT20-8 -1 -3

LIFT DECEL
JPT4-3 -2 -2 JPT10-6 JPS54-1
LIFT DECEL S124 +12V
-2 -2
DGND JPT18-7 -3 -1 13 SENSOR 1
JPS1-5 JPS1-6 JPS1-10 JPT14 JPT24-8 -3
DGND

END OF AISLE
-5
JPT10-7 JPS55-1 6
+12VP +12V
-8 -2
-11 SENSOR 2
BUS_I+ JPT24-9 -3
A1 + -4
BUS_I- DGND
-3 JPT24-1 JS58-1
DGND +12V
A2 JPT22-4 -2
SLACK SW1

CHAIN SWITCHES
LM JPT4-2 -3
DGND

SLACK
JPT24-1 JS59-1 6
+12V
JPT18-9 JPT22-4 -2
S1 - LIFT CONTACTOR SLACK SW2
-3
JIO-2 JPT24-4
DGND

4 -5
-6 JPT12-11
-13
+12VP
BUS_2-
JPT10-5 PSC3A-1 +12V
JPT18-4
JPT22-22
JPS53-3

RAIL SENSE
-2
CUSTOM IN 1 -10 -2 RAIL_SEN 7
-9
BUS_2+
-1 JPT24-3 -1
CUSTOM IN 2 DGND
-3 JPT18-2
CUSTOM OUT JIPM-1
JP
-4 JPT20-5 JPS50-1
B- -2 +12V

TRANSDUCER
JPT24-18 -2

PRESSURE
P/T A 7
JPT24-10 -3
DGND
JPT22-20 JPT20-11 J3CB-1
LIFT CONTACTOR BUS_3+
JPT18-13 -2 7 JPT22-13 JPS51-1
BUS_3- CHANNEL A
JPT22-14 -2

MAIN LIFT ENCODER

CHANNEL B

FLOW SENSOR
TP4 TP2 JPT6-6 JPT24-11 -3
+12VP DGND 7
MS+ -5 JPT24-19 -4
CCW_PWM JPT20 FS TEMP
+ -2 -16 JPT20-2 -5
CW_PWM L/L L/L +12V
MS SA -3
STEER_CURRENT -15
2 1
-4 (B+K2)B+L/L
JPT18-18 JPS15-1
DGND ALARM_TRAVEL
- -1 JPT20-17 -2
MS- B+K2

ALARM OPTIONS
NEUTRAL_PULSE
TP4 JPT22
-19 FU1_SENSE JPS52-1 6
JPT14

GUIDANCE
MANAGER
-10 -18 -2

5 JPT20-19 JPS2-11 ALARM_L/L

DGND
-2 B+K2 6
DGND
-1 JPT24-1 JPS28-1
+12V
-8 JPT22-4 -2
180_LIM

180 IN. LIMIT

-9 B-F 7
JPT24-7 -3
DGND
S10-1 JPS8-1 JPT20-1
+12V

120 IN. LIMIT

150 IN. LIMIT
JPT22 JPA7
6 13 S10 -2 -2 JPT22-1
150_LIM -3 -1 0

HOME SENSOR
HOMESENSE JPT20-10 PS10-1
-3 -3 +12V
JPF1-3

JPF1-5

JPF2-1

JPF1-6
JPF3-3

JPF3-9

-11 -2 - HOME JPT22-2 -2

DGND SENSOR LIFT INHIB
6
-12
-11

LIFT LIMIT
JPT20
-4
-5
-6
-7
-8

+ PROX
TS10-1

TS10-2

+12VF -9 -3 JPT24-3 -3
DGND
JPF3-1 HRN
FU6 (15A) -NEG
-2 JPT20-6 JS16-1
-IN H-1 JPT18-16 +12V
H HORN

GATES SENSOR/
1

TRAVEL LIMIT
2

BATTERY
JPT22-6 -2
K3 -POS H-2 BGS/TL 6
JPF1-1
FU8 (15A/5A) JPF1-4 JPT24-6 -3
-2
DGND
1 2 JPF4-15 JP10-1
WARNING
11 LIGHT JPBR-2 JPXBR-2
JPF4-3 FU7 (15A/5A) K1 JPT20-7 JPE4-1
JPF2-9 -2 RED
+12VP
-4 1 2 -1 -1 JPT20-14 JPT22-9 JPT18-3
BRAKE BRAKE -3 WHT STEER JPPL1-1
JPF2-2 CHANNELA_4 +12V

6
MOTOR JPT12-8 -2
-10 -2 BLU ENCODER

SOURCE LIMIT
CHANNELB_4 PSL

POWER
-3 7
-5 JPT10-9 -4 BLK
JPT18-10 DGND JPT10-4 -3
L/H L/H DGND
1 2
JPF4-13 JPT14-6
RELAY_ENABLE

COMMUNICATIONS
-14
-6 JPT22-21
EPO_SENSE TXD JPT9-2
K4 K3 K2 K1

SERIAL
-5 RXD -3
7
DGND -5
-12 8
-11 JPT14-12
B+KEY JPT12-5 J1-4
LIFT
-8
FU5 (15A)
-1

COMMUNICATIONS
-10 JPT2 -6 -3

LIFT PENDANT
VBUS LOWER
1 2 -1
K2 K4 D+ -2 -12 -9
-2 JPF2-4 JPT14-7

USB
B+K2 -3 DGND
-13 D-
-6 B+K2
DGND -4
-7 -14
B+K2
T JPF4-7 JPT24-24
BATTERY_SENSE_IN
JPF2-8
DC LIFT - OPR
FUSE/
7 RELAY
CARD
JPS26-4
-2
-3
JPC16-4
-2
-3
B-FU6
B-FU8
11 TABLE A
B+FU7 OTM CABLE A AUX. POWER
-1 -1 SEE SHEET 3
B+EPO OPTION STD C.S.
-6 -6 B+KEY FU7 5A 15A
-8 -8
B+FU5 FU8 5A 15A
JPS30-1 JPS29-1
6 -2 -2

Publication:1301126/001A, Issued: 12 Nov 2018 5

Models 5300/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 5. Electrical Schematic Sheet 3

A B C D E F G H

2
JPC1-1
+5.3V
-2
DGND
-3
CHA
-4
CHB

INPUT STEER ENCODER

JPS25-2 JPC11-2 -8
BUS- BRKDMAN
-3 -3 -9
BUS+ DEADMAN STEERING
-1 -1 ENCODER
+12V

OVER THE MAST CABLE

-6 -6 JPC21-1
+5.3V
DGND -2
DGND
OTM CABLE B -3
SEE SHEETS 1 & 2 -4 -4 CHA-E2
BRAKE DEADMAN -4
CHB-E2
-5 -5 CARRIAGE DEADMAN -5
CD SUPPLY
-6
CD
JPS31-1 JPS27-1
8 9
-2 -2
CARRIAGE
3 CONTROL
CARD

JPC12-1 TS12-1

POWER
B+FU7

SPARE
6 7 8 9
-2 -2
B+FU8

JPC6-1 1 2
B+F
-2 S1
B+KEY
-3
B+EPO NC

EPO/ KEY
4 -4
1

2
S21
B+ KEY NO

JPC8-2 S11-3
6-12VF
-1 -2
24" LIMIT
S11

24" LIMIT
13
DGND -3 -1
-1 JPC15-1

CARRIAGE CONTROL
CARRIAGE CONTROL

LIGHT DISPLAY CARD

LIGHT DISPLAY

ALL PINS USED

-15 -15 DGND

CARD
JPC7-2
-16 -16 +5.3V +12VF
-1 S2-2 NO C S2
BRK DEADMAN

DEADMAN SWITCHES
5
13
-24 -24 -3 -1
DGND

-5
+12VF
-1 JPC2-1 DGND -4 S23-2 NO C
CARRIAGE DEADMAN S23

INTERFACE CARD
-2 -2 UP ARROW

OPERATOR
13

OPERATOR

ALL PINS USED

INTERFACE
-3 -3 DN ARROW -6 -1
DGND
-4 -4 ETR/SHFT

-17 -17
6-12VF JPC3-2 S28-3
-1 -2 S28

60" LIMIT
60" LIMIT
5

-3 -1 13
PGND

CONTROL HANDLE
JPC9-8

6
+5.3V
-9 TRAVEL
TRAVEL
VR1
-7
DGND

CONTROL HANDLE
-5
+5.3V
-6 LIFT/LOWER
L/L
VR2
-4
DGND
S3
-3 + +VS

-3 -2 0
JPS26-1 JPC16-1 HORN
B+EPO OUT S3
-2 -2 -1 - GND HORN
B-FU8
-3 -3
B+FU7

OVER THE MAST CABLE

-4 -4
B-FU6

OTM CABLE A -6 -6
B+KEY
SEE SHEETS 1 & 2
-8 -8

7
B+FU5

JPS30-1 JPS29-1
-2 -2 6

Publication:1301126/001A, Issued: 12 Nov 2018 6

Models 5300/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 6. Electrical Schematic Sheet 4

A B C D E F G H

CARRIAGE VEHICLE
CONTROL MANAGER
2 TS12-1
B+FU7 FU9
(2A)
CARD
+12VP
JPC14-2 S60-3
+12VP
JPT20-3 JPS58-1 S29-2
13
-1 -2 JPT22-12 -2 -3
SIDEGATE R S60 SLACK SW1 S29
13 VEHICLE
-3 -1 JPT4-2 -3 -1
DGND DGND MANAGER
TS12-2 JPT20-10 JPS10-1 S24-3
B-FU8 FU10 +12V 13
(2A) JPC13-2 S61-3 JPT20-4 JPS59-1 S30-2 13 JPT22-2 -2 -2
+12VP +12VP LIFT INHIBIT S24
-1 -2 JPT24-16 -2 -3
2 AMP POWER HOOKUP OPTION SIDEGATE L S61 SLACK SW2 S30 JPT24-3 -3 -1
DGND
-3 -1
13 -3 -1
DGND LIFT INHIBIT
OTM CABLE A
SIDEGATE SWITCH OPTION SLACK CHAIN SWITCH OPTION
VEHICLE
MANAGER JPS16 JPBGS2 S15B
JPS30 JPS29 JPT20-6 -1 -1 +
+12V
-1 -1 -2
3 -1 -2
CUTOUT
JPT22-6
JPT24-6
-2
-3 -3
0
-
TP1 DGND
B+ FU30 FU11
(15A) (10A) JPBGS1 S15A
-1 +
-2 -2
-1 -2 -2 0

TP4 JPW2 JP1T -3 -

B- FU31 FU12 -1 -1 RIGHT
(15A) (10A) VEHICLE GUIDANCE
MANAGER MANAGER -2 -2 NEAR WIRE
-3 -3 LEFT CARRIAGE
JPT20-19 JPS2-11 -5 -5 T0 CONTROL VEHICLE
10 AMP POWER HOOKUP OPTION B+K2 B+K2 CARD MANAGER
-6 -6 T1 S40 JPT20-6 JPS16-1 S27-3
FU22

TRACTOR
S40-2 +12V 13

SENSOR
-7 -7 T2 JC5-1 + S40-1
B+KEY
FUSE/ JPT22-6 -2 -2
-8 -8 T3 FU23 TRVL CUTOUT S27
RELAY -14 -14 AGRD JPT24-6 -3 -1
CARD DGND
JPS2 JC5-2 - LED1-2 LED1-1
VEHICLE -15 -15 +12VF B-F
JPF3-9 -24
MANAGER
4 B+K2 B-FU6 -13
JPT20-17 JPS52-1 AL+ LED2-2 LED2-1 TRAVEL LIMIT OPTION OR BATTERY GATE SENSOR OPTION
B+K2
A FUF1
-18 -2 AL- -2
ALARM L/L
SPL20
JPS4-5
LIFT/LOWER ALARM OPTION JPSCx-1 BUS- JPW1 JP1L -1
LED3-1
-1 -1 RIGHT LED3-2
-6
JPSCx-2 BUS+ -2 -2 NEAR WIRE
LED4-2 LED4-1
-3 -3 LEFT
VEHICLE

LOAD SENSOR
MANAGER -5 -5 T0
JPT20-17 JPS15-1 AL+ -6 -6 T1
B+K2 OPERATOR LIGHT OPTION
JPT18-18 -2 AL- A -7 -7 T2
ALARM_TRAVEL CARRIAGE -8 -8 T3
TRAVEL ALARM OPTION CONTROL
-14 -14 AGRD
CARD
JPC9-1 1 2 -15 -15 +12VF
AUTO/MAN -13 S81
S4 HTRC
-2 1 2 1 2
DGND TS12-1
1

5 FU21 10A
RAYMOND
WIRE GUIDANCE CARRIAGE
2
TS12-2
HEIGHT REF PROX MANAGER
HTRDM FUDM
+ JPFP-1 JPRCM-24 HTR3-1 HTR2-1 1 2 HTR2-2 1 2
B+COIL
S46A-1 0 JPFP-2 JPRCM-23 5A 1
RIGHT REF_SW_DIN
-2 S80
- JPFP-3 JPRCM-10
-3 CARRIAGE DGND HTR3-2 2

-4 CONTROL
CARD
-6 JPC6-6
L/L BYPASS COLD STORAGE OPTION
-8
1

FREE LIFT ENCODER

JPB1-1
CARRIAGE CONTROL CARD AND DEADMAN HEATERS
JPF1-6 + S7
S46B JPFLE-3 JPRCM-17
-5 2 ENC CH A
-1 FAN DGND -2 JPRCM-11
RIGHT
-3 ENC CH B
(LEFT) -4 JPRCM-9
JPB1-2 DGND CARRIAGE
-5 JPF3-11 - LIFT/LOWER BYPASS SWITCH
6 -7 LIFT MOTOR FAN
-1 JPRCM-14
5V OUT CONTROL
CARD
-8 (36V UL-EE ONLY)
JPC4-2 S25-3
+12V 13
-1 -2
LOWER LIMIT S25
S47A-1 HSUP -3 -1
LEFT SEE SHEET 7 DGND
-2 (RIGHT)
VEHICLE ZONE H3

JTC1-1

JTC1-2
MANAGER JPT10 JPS54 -3
-6 -1 LOWER LIMIT OPTION
H(+)
H(-)

-4 CARRIAGE
(+)

+12VP
(-)

-2 -2 -6 FUSE/RELAY CONTROL
SENSOR 1
-8
CARD CARD
-6 -4 -2 -1
JPT24-8 -3 JPC10-8
DGND DGND
JPF2-2 H-2 IH-1 JPC10-9
B+K2
12VDC
S47B-1 JPC10-6 JPRCM-21
JPT10 JPS55 LEFT BUS+ BUS+
-7 -1 -3 JPC10-7 JPRCM-15
+12VP BUS- BUS-
-8 -2 -5 VEHICLE JPC10-5
SENSOR 2 DGND
MANAGER HRES
7
-7 JPC5-4 JPRCM-13
B+KEY B+KEY
JPT24-9 -3 -8 JPC5-3 JPRCM-1
DGND JPT18-16 H-1 IH-2 1 H1 B-F B-F
HORN
END OF AISLE OPTION
(ALTERNATE CONFIGURATION SHOWN IN PARENTHESIS)
ELECTRONIC HORN OPTION PROGRAMMABLE LIFT LIMIT

Publication:1301126/001A, Issued: 12 Nov 2018 7

Models 5300/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 7. Electrical Schematic Sheet 5

A B C D E F G H
SF
JFAN-1 PFA-1 SF-2 SF-1
TS12-1
+

2 VEHICLE
MANAGER SBX BATTERY JFAN-2 PFA-2 F-B
-
FAN

TS12-2
JPT20-11 JP3CB-1 JPSI-1 JPAB-B
BUS_3+
OPERATOR FAN OPTION
JPT18-13 JP3CB-2 -2 JPAB-C
BUS_3-
JPS1T-1 -3 JPAB-A
JPS1T-2 -4 JPAB-D

KEYSWITCH OTM CABLE B

TS12-1 J12-1 RD
S1-1 JPS1C-1 J13-1 RD
WAKE VEHICLE
-3 JPS1C-2 MANAGER
WAKE RTN
SWL JPT24-1 JPS28-1 S100-3
-5
+12V 13
B+KEY TS12-2 J12-2 BK -1 -2 BK JPT22-4 -2 -2
S100
3
180_LIM
-6
B+ J13-2 BK -1 -2 BK JPT24-7 -3 -1
DGND
SEE SHEET 3
ZONE G4 FC/AUX-TRACTOR-1 BK FX/AUX-CARRIAGE-1
WORK LIGHT OPTION 180 INCH LIMIT OPTION
-2 WT -2
5500/5600 E-PORT OPTION
-3 RD -3
-4 GN -4
-5 OR -5
CARRIAGE
VEHICLE CONTROL -6 BL -6
S32
MANAGER FLOW SENSOR BASED INTELLISPEED CARD -7 WT/BK -7
JPC19-1 -1 -2
JPT20-5 JPS50-1 + LIFT -8 RD/BK -8
+12VP
S33
JPT24-18 -2 0
P/T PRESS A FUEL CELL/AUX OTM CABLE OPTION
-2 -1 -2
JPT24-10 -3 - LOWER
DGND S31
JPY7-1 P A
4 VR
IN2
-2 B
DGND
-3 -2 -1

-3 JPC20-2 S34-3
13
FLOW MODULE

JPC22-13 JPS51-1 JPY1-1 SHLD +12VP

FLOW A -1 -2
JPT22-14 -2 -2 JPY6-1 P AUX LIMIT S34
FLOW B VR -3 -1 VEHICLE
JPT24-11 -3 -3 -2 A DGND
MANAGER
DGND IN1
JPT24-19 -4 -4 -3 FLOW SENSOR JPC24-2 S36-3 JPT18-2 JPS53-2 JPS53A-2 S15-3
FS_TEMP SHLD +12VP 4 13 +12VP
JPT20-2 -5 -5
B JPT22-22 -1 -1 -2
JPY2-1 -1 -2 RAIL SENSE S15
+12VP SLACK AUX1 S36
GND -3 -1
-2 DGND
13
JPT24-5 -3 -3 -1
F/S_TEMP DGND
JPC22-2 S37-3
+12VP 4 13 JPS53B-2 S16-3
-1 -2
SLACK AUX2 S37 -1 -2
S16
-3 -1
DGND CARRIAGE 13
CONTROL -3 -1
CARD

5
JPC9-1 1 2
VEHICLE AUTO/MAN
MANAGER MAIN LIFT ENCODER (FOR HEIGHT
SENSE AND INTELLISPEED) S4
-2
JPT20-5 JPS50-1 + DGND
+12VP
JPF2-8
JPT24-18 -2 0 B+K2 RAIL SENSE OPTION
P/T PRESS A
X X X
JPT24-10 -3 - FUSE/RELAY
DGND AUX AUX AUX
L/H L/H L/H CARD
D510-2 D510-3
SOL SOL SOL CONNECTOR TO CONNECTOR TO
VEHICLE SBX AUX-RD
THIRD PARTY DEVICE RAYMOND TM
MANAGER Y Y Y BATTERY D510
JPT18-12 RXD TXD
AUX L/H JRDP1-1 PT9-2
JPT22-13 JPS51-1 JPMLE-3 MAIN LIFT -15
CHANNEL A AUX SEL TXD RXD D510-5 A
JPT22-14 -2 -2 ENCODER -2 -3
CHANNEL B -14 D510 K510
MAIN SEL
JPT24-11 -3 -4 SHLD D510-4 B
DGND -5
DGND
AUX LIFT/LOWER OPTION (36V ONLY) -3
JPT20-2 -5 -1 AUX-BK
+12VP BATT-
6 -5
BATT+
-6 K510
FU35 VEHICLE 1 JPSX16-2
MANAGER

TP1

TP4
2 AMP
INTELLISPEED OPTION 5 125VDC JPT18-3 JPL1-1 7
BATT- +12V
BATT+
JPT12-8 -2 4
CUTOUT
iPORT SUPPLIER WIRELESS MODULE
JPT10-4 -3
DGND
JPSX16-3
S90 POWER SOURCE LIMIT OPTION
SPL22
CARRIAGE JP10-1 JPBL10-1 JPBL11-1 JPBL12-1
CONTROL S1-2 JP10-1
CARD 1 JPC6-2 3 4 (SHEET 3)
B+KEY
JPC5-3 SPL5 JP10-2 JPBL10-2 FU50 (2A)
B-F A 6 1 2 JPBL11-2 JPBL12-2
HTRES CARRIAGE K12 DA60 4 JP10-2
7
HTRH CONTROL B 1 BLUE LIGHTS
S75 1
CARD K12
FU51 (2A)

7 B+KEY
JPC5-4 1 2 -4 -3 -1 1 2 JPBL13-2 JPBL14-2

CONTROL HANDLE HEATER TS12-2 SEE SHEET 1,2 SUP6

ZONE D6
JPBL13-1 JPBL14-1
SECURITY START SWITCH
BLUE LIGHT OPTION 12

Publication:1301126/001A, Issued: 12 Nov 2018 8

Models 5300/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 8. Electrical Schematic Sheet 6, iWarehouse

A B C D E F G H

2 CARRIAGE
TERM/ZAP
JP27A
-1 BUS+

-2 BUS-

3 SPM/GC
JP42C
PS27 JS27
-1 BUS+ BUS+ -1
-1
B+ OTM CABLE
-1 -2 -2 -2
-2 BUS- BUS-
BUS+ SPLI1

BUS- -3

RX -4
-1 -2
-5 SPLI2
B-
-7
DGND

-8
TX

JS31 PS31
-1 BUS+ BUS+ -1

4 -2 BUS- BUS- -2
TP1

IPM2 JP57C
-1 FU39
-2 -1 TS12-1
-1 -2
B+ SPLI4 B+FU7
2A -1
BUS+ -2
FU40
BUS- -3 2A
-1 -2 TS12-2
-4
B- SPLI3 B-FU8
IPM1 JP57T -2
TRACTOR
-5 -1
SEL B+ TERM/ZAP
SEE SHEET 3 BUS+ -2 JPS31A
ZONE G3 -1 BUS+
-1

BUS- -3
SPLI5

-1

-4
B-
5
SPLI6

-2 BUS-
-2

-2

JPBD1
EVO4.3 SPM/GC
-1 JP42T
DGND PROGRAM
PORT -1
PC9 B+
-2 -2
TX 1 TX -2
BUS+
-3 -3
RX 0 -3 BUS- JPC9
-4
RX -2 VM
DGND RX -4
TX
-5
-7 DGND -5 -3
B+ B-
RX
-8 -6
SEL
RX 1
-7 -5
-9 DGND DGND
TX 0
-8
-10 TX
DGND

6
-11
SEL
-14
DGND
-17
BUS+

DGND -20

-21
PLC B+

BUS- -23

CARRIAGE TRACTOR
TP4

7
OPR iWAREHOUSE MONITOR

Publication:1301126/001A, Issued: 12 Nov 2018 9

Models 5300/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 9. Electrical Schematic Sheet 7, Navigation Solutions Option

A B C D E F G H

2
OPTIONAL
SEE SHEET 1
ZONE C2
SEE SHEET 4
ZONE B3
CARRIAGE
JPDCI JPDCI CONVERTER PID CONTROL
JPDCO JPDCO JPPID JPPID JPTC1 JPTC1 JPC10 CARD
-1 -1 -1 -1 -35 -23 -2 -2 -9
FU11-2 IN+ OUT+ 12VDC INP. AWAKE/SUSPEND +12VF
FUDC
-2 -2 -2 -2 -12 -4 -1 -1 -8
FU12-2 IN- OUT- GND
CAN GND GND
JPTA4 JPTA4
-1 -1
JPS27 JPS27
-1 -1 -3
-2 -2
3 -2 -2 -5
INP. CAN1 H

-3 -3 INP. CAN1 L

-4 -4
TO TRACTION
TO TRACTION -5 -5 MOTOR/BRAKE
AMPLIFIER
-6 -6
-7 -7 JPTC2
-1
-8 -8
-2

SEE SHEET 1 -3
ZONE D3
-4
OVER-THE-MAST CABLE
4 -1
JPDM
DIODE
JPDM
-2
SPLD1
RESISTOR
-3 JPTA1-25
MODULE
-6 SPLD2
-4

JPS31-1 -2

SEE SHEET 1
RFID READ/WRITE HEAD
JPRF1 JPRF2 JPZA ZPU JPZA ZONE E3

-1 -1 -17
RS232 CTS (DETECT) RS232 CTS (DETECT) -13
SPEED SENSOR
-2 -2 -18 CH A
RS232 RX RS232 RX -6 APM PSC1-1 PSC1-2
-3 -19 SPEED SENSOR
-3 CH B
RS232 RTS RS232 RTS
-20
5 RS232 TX
-4 -4
RS232 TX
JPZSC1 JP56 JP55
-15 -1 -3 -2 JSC1-1
CAN1_L INT_CAN4_L INT_CAN0_L
JPZB
-9 -23 -2 -2
-5 -5 CAN1_H INT_CAN4_H -1 JSC1-2
12V 12V INT_CAN0_H
JP55
-6 -6 -16 -9
GND GND -1
B+ B+
1
FUZ
2A
JPANT1 2
ANT
1
JPANT2 TP1
ANT
1
-8
B-
6 B-
-4 SPLZ
-10
B-
-2 -1

JPF3-11

FUSE/RELAY
CARD

NAVIGATION SOLUTIONS
7 OPTION

Publication:1301126/001A, Issued: 12 Nov 2018 10

Models 5300/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 10. Electrical Schematic Sheet 8, Legend
LEGEND
IDENT. SHEET ZONE DESCRIPTION IDENT. SHEET ZONE DESCRIPTION
IDENT. SHEET ZONE DESCRIPTION
NOTES: A 4 B4,B5 ELECTRONIC ALARM JPC19 5 D4 AUX MAST LIFT/LOWER CONNECTOR
LPC 1,2 B3,C4,C3 LIFT POWER CONTACTOR
APM 7 E5 AUX PROCESS MODULE JPC20 5 D4 AUX MAST LIMIT SWITCH CONNECTOR LOAD/HOLD SOLENIOD
1. 36V TRUCK ONLY. L/H 1,2 D6
AUX L/H SOL 5 E6 AUX MAST LOAD HOLD SOLENOID JPC21 3 F3 STEERING ENCODER CONNECTOR LIFT/LOWER SOLENOID
L/L 1,2 F5
2. WRITTEN REQUEST FOR CHANGE MUST BE SUBMITTED TO RAYMOND AUX SEL SOL 5 E6 AUX MAST SELECTOR SOLENOID JPC22 5 D5 AUX MAST SLACK CHAIN SWITCH

ENGINEERING FOR APPROVAL PRIOR TO ANY CHANGE IN CONSTRUCTION, A L/H2 1 H4 AUX MAST LOAD HOLD SOLENOID CONNECTOR JPC24 5 D5 AUX MAST SLACK CHAIN SWITCH
MAIN SEL SOL 5 E6 MAIN LIFT SELECTOR SOLENOID
MATERIALS, COMPONENTS AND/OR PROCESS. A SEL2 1 H4 AUX MAST SELECTOR SOLENOID CONNECTOR JPDCI 7 D3 POWER CONVERTER INPUT CONNECTOR
MS 1,2 B5 STEER MOTOR
JPDCO 7 E3 POWER CONVERTER OUTPUT CONNECTOR
M SEL2 1 H4 MAIN LIFT SELECTOR SOLENOID CONNECTOR
3. SCHEMATIC SHOWS TRUCK SWITCHED OFF, DEADMAN SWITCHED OFF, AND BRAKE 1,2 E6 ELECTRIC BRAKE JPDM 7 C4 NAV SOLUTIONS DIODE MODULE CONNECTOR
CARRIAGE FULLY LOWERED. JPE4 1,2 F6 STEER MOTOR ENCODER CONNECTOR
PID 7 F3 POSITIONING INFORMATION DISPLAY
DA60 5 C7 RECIRCULATING DIODE FOR THE SECURITY START SWITCH JPF1 1,2,4 MULTI FUSE/RELAY CARD AMP AND AUX POWER CONNECTOR
PRESS A 5 B4,B5 INTELLISPEED PRESSURE SENSOR
4. AUSTRALIAN OPR ONLY.
D510 5 H6 RECIRCULATING DIODE FOR THE POWER SOURCE LIMIT SWITCH JPF2 1,2,4,5 MULTI FUSE/RELAY CARD RELAY CONNECTOR
PSC3A 1,2 G4 2ND CANBUS SPLICE CONNECTOR
JPF3 1,2,4 MULTI FUSE/RELAY B- CONNECTOR
5. 60 INCH LIMIT SWITCH NOT USED ON INTELLISPEED TRUCKS.
FC/AUX-CARR 5 H2 AUX OTM CABLE CARRIAGE CONNECTOR JPF4 1,2 MULTI FUSE/RELAY B+ AND KEYSWITCH CONTROL CONNECTOR
S1 3,5 G4,A3 KEY SWITCH
OPERATOR FAN CONNECTOR
6. SEE PAGE 4 FOR CONNECTED CIRCUITS. FC/AUX-TRAC 5 G2 AUX OTM CABLE TRACTOR CONNECTOR JPFAN 5 D2 S2 3 G5 DEADMAN SWITCH
FU1 1,2 B3 POWER FUSE FOR STEER JPFLE 4 F6 FREE LIFT ENCODER CONNECTOR
S3 3 G6 CONTROL HANDLE HORN SWITCH
7. SEE PAGE 5 FOR CONNECTED CIRCUITS. FU2 1,2 B3 POWER FUSE FOR TRACTION JPFP 4 F5 HEIGHT REFERENCE SWITCH CONNECTOR
S4 4,5 C5,F5 AUTO/MANUAL SWITCH
FU3 1,2 B3 POWER FUSE FOR LIFT JPLA1 1 D3,D4 LIFT POWER AMPLIFIER CONNECTOR
S7 4 D6 LIFT/LOWER BYPASS SWITCH
8. SEE PAGE 6 FOR CONNECTED CIRCUITS. FU5 1,2 B6 B+ CONTROL FUSE FOR VEHICLE MANAGER AND CARRIAGE CONTROL CARD JPLA2 1 C3 LIFT MOTOR ENCODER CONNECTOR
S10 1,2 E5 120/150 INCH MAST HEIGHT SWITCH
FU6 1,2 B6 B- CONTROL FUSE FOR VEHICLE MANAGER AND CARRIAGE CONTROL CARD JPLA3 1 C3 LIFT MOTOR TEMPERATURE SENSOR CONNECTOR
S11 3 G5 24 INCH MAST HEIGHT SWITCH
9. SEE PAGE 7 FOR CONNECTED CIRCUITS.
FU7 1,2 B6 B+ CONTROL FUSE FOR WARNING LIGHTS AND OPTIONS JPMLE 5 B6 LIFT MOTOR TEMPERATURE SENSOR CONNECTOR
S15 5 H4 RAIL SENSE SWITCH
10. THIS PART SHALL COMPLY WITH RESTRICTED SUBSTANCES QAP FU8 1,2 B6 B- CONTROL FUSE FOR WARNING LIGHTS AND OPTIONS JPP 6 C5 iWAREHOUSE PROGRAM PORT CONNECTOR
S15A 4 H4 BATTERY GATE SENSOR
D20014464. FU9 4 B2 B+ CONTROL FUSE FOR 2A POWER OPTION JPPID 7 F3,G3 NAV SOLUTIONS PID CONNECTOR
S15B 4 H3 BATTERY GATE SENSOR
11. FOR FUSES 7 AND 8 SEE TABLE A. FU10 4 B2 B- CONTROL FUSE FOR 2A POWER OPTION JPPL1 1,2,5 H6,G6 POWER SOURCE LIMIT SWITCH CONNECTOR
S16 5 H5 RAIL SENSE SWITCH
FU11 4 B3 CARRIAGE B+ CONTROL FUSE FOR 10A POWER OPTION JPRCM 4 F5-6 RAYMOND CARRIAGE MANAGER CONNECTOR
S21 3 G4 EPO SWITCH
12. FUSES MAY NOT BE INSTALLED FU12 4 B4 CARRIAGE B- CONTROL FUSE FOR 10A POWER OPTION JPRF1 7 B5 RFID R/W MODULE CONNECTOR
S23 3 F5 DEADMAN SWITCH (CARRIAGE DEADMAN)
FU21 4 H5 CONTROL FUSE FOR CARRIAGE CONTROL CARD HEATER JPRF2 7 B5 RFID R/W HARNESS CONNECTOR
S24 4 H2 LIFT INHIBIT SWITCH
13. SOME SWITCHES MAY HAVE THE FOLLOWING CONFIGURATION. FU22 4 F3 CONTROL FUSE FOR OPERATOR LIGHTS JPS1 1,2 B3-4,C3-4 CONTACTOR PANEL CONNECTOR
S25 4 H6 LOWER INHIBIT SWITCH
FU23 4 F3 CONTROL FUSE FOR OPERATOR LIGHTS JPS1C 5 B3 EPORT OTM CABLE CARRIAGE CONNECTOR
S27 4 H4 TRAVEL CUTOUT SWITCH
FU30 4 A3 TRACTOR B+ CONTROL FUSE FOR 10A POWER OPTION JPS1T 5 B2 EPORT OTM CABLE TRACTOR CONNECTOR
S28 3 G6 60 INCH MAST HEIGHT SWITCH
+ +VS FU31 4 A4 TRACTOR B- CONTROL FUSE FOR 10A POWER OPTION JPS2 1,2,3 MULTIPLE GUIDANCE MANAGER POWER CONNECTOR
S29 5 F2 SLACK CHAIN SWITCH
FU35 5 F6 CONTROL FUSE FOR 3RD PARTY iPORT SOLUTIONS JPS4 1,2,4 E3,C4 GUIDANCE MANAGER CANBUS CONNECTOR
S30 5 F3 SLACK CHAIN SWITCH
O OUT FU39 4 C4 CARRIAGE CONTROL FUSE FOR iWARHOUSE JPS8 1,2 E5 120/150 INCH SWITCH HARNESS CONNECTOR
S31 5 E4 AUX LIFT LEFTHAND DEADMAN
FU40 5 F4 TRACTOR CONTROL FUSE FOR iWARHOUSE JPS10 1,2,4 H5,G2 LIFT LIMIT SWITCH CONNECTOR
S32 5 E4 AUX LIFT
12 FU50 5 E7 CONTROL FUSE FOR BLUE LIGHT OPTION JPS15 1,2,4 H5,B5 TRAVEL ALARM CONNECTOR
S33 5 E4 AUX LOWER

- GND 12 FU51
FUDC
5
7
E7
E3
CONTROL FUSE FOR BLUE LIGHT OPTION
CONTROL FUSE FOR DC CONVERTER
JPS16
JPS25
1,2,4
1,2,3
H6,G3,G4
G3,E3
TRAVEL LIMIT OR BATTERY GATE SENSOR HARNESS CONNECTOR
TRACTOR CONNECTOR FOR OTM CABLE B
S34 5 E4 AUX MAST LIMIT SWITCH
S36 5 E5 AUX MAST SLACK CHAIN SWITCH
FUDM 4 H5 CONTROL FUSE FOR COLD STORAGE DEADMAN HEATER JPS26 1,2,3 D7,E7 TRACTOR CONNECTOR FOR OTM CABLE A
S37 5 E5 AUX MAST SLACK CHAIN SWITCH

DETAIL A
FUF1 4 D4 CONTROL FUSE FOR GUIDANCE MANAGER JPS27 1,2,3 G3,E3 CARRIAGE OTM B AUX WIRE CONNECTOR
S40 4 F3 SWITCH FOR OPERATOR LIGHTS
FUZ 7 D6 CONTROL FUSE FOR ZPU AND APM JPS27A 6 C2 iWAREHOUSE CARRIAGE CANBUS TERMINATOR CONNECTOR
S46A 4 B6 AISLE DETECT SENSOR 1
F-B 5 D2 OPERATOR FAN B- TERMINAL JPS28 1,2,5 H5,E3 180 INCH LIMIT SWITCH CONNECTOR
S46B 4 B6 AISLE DETECT SENSOR 1
JPS29 1,2,3,4 E7,B3 CARRIAGE OTM A AUX WIRE/10A OPTION CONNECTOR
S47A 4 B6 AISLE DETECT SENSOR 2
H 1,2,4 D6,C7 HORN CONNECTOR JPS30 1,2,3,4 D7,E7,B3 TRACTOR OTM A AUX WIRE/10A OPTION CONNECTOR
S47B 4 B7 AISLE DETECT SENSOR 2
H1 4 D7 ELECTRONIC HORN JPS31 1,2,3 G3,E3 TRACTOR OTM B AUX WIRE CONNECTOR
S60 4 D2 SIDEGATE RIGHT SWITCH
HRES 4 D7 POWER RESISTOR FOR THE ELECTRONIC HORN JPS31A 6 G4 iWAREHOUSE TRACTOR CANBUS TERMINATOR CONNECTOR
S61 4 D3 SIDEGATE LEFT SWITCH
HRN 1,2 F3,G3 STANDARD HORN JPS50 1,2,5 H4,C4,C5 INTELLISPEED PRESSURE SENSOR CONNECTOR
S75 5 H5 CONTROL HANDLE HEATER THERMOSTAT
HSUP 4 F3,G3 SUPPRESSOR MODULE FOR THE ELECTRONIC HORN JPS51 1,2,5 H4,C4,C5 FLOW MODULE/MAIN LIFT ENCODER CONNECTOR
S80 4 H3 DEADMAN HEATER THERMOSTAT
HTR2 4 F3,G3 DEADMAN PEDAL HEATER CONNECTOR JPS52 1,2,4 H5,B4 LIFT/LOWER ALARM CONNECTOR
S81 4 F2 C.C.C. HEATER THERMOSTAT
HTR3 4 F3,G3 DEADMAN PEDAL HEATER CONNECTOR JPS53 1,2,5 H4,G4 RAIL SENSE SWITCH CONNECTOR
S90 5 H4 SECURITY START SWITCH
HTRC 4 F2 HEATER FOR THE CARRIAGE CONTROL CARD JPS53B 5 G5 RAIL SENSE SWITCH CONNECTOR
S100 5 D4 180" LIMIT SWITCH
HTRDM 4 G2 HEATER FOR THE DEADMAN PEDAL JPS54 1,2,4 H3,A6 END OF AISLE HARNESS CONNECTOR
S124 1,2 B4 LIFT DECEL SWITCH
HTRES 5 H5 POWER RESISTOR FOR THE CONTROL HANDLE HEATER JPS55 1,2,4 H2,A7 END OF AISLE HARNESS CONNECTOR
SA 1,2 B5 STEER POWER AMPLIFIER
HTRH 5 H5 HEATER FOR THE CONTROL HANDLE JPS58 1,2,5 H3,E2 SLACK CHAIN SWITCH CONNECTOR
SBX-AUX 5 G6 POWER SOURCE LIMIT BATTERY CONNECTOR
JPS59 1,2,5 H3,E3 SLACK CHAIN SWITCH CONNECTOR
SF 5 D2 OPERATORS FAN SWITCH
IH 4 D7 ELECTRONIC HORN HARNESS CONNECTOR JPSC1 1,2 E3 CANBUS SPLICE CONNECTOR
SPL1 1 D4 SPLICE FOR LIFT AMP LOGIC POWER
IPM 6 B4,E5 IMPACT SENSOR MODULE JPSC2 1 E3 CANBUS SPLICE CONNECTOR
SPL2 1,2 D3 SPLICE FOR TRACTION AMP LOGIC POWER
JPSC3 1,2 F2 CANBUS SPLICE CONNECTOR
SPL5 5 B7 SPLICE FOR HANDLE HEATER
J1 1,2 H6 LIFT PENDANT CONNECTOR JPSI 5 B2 EPORT SBX HARNESS CONNECTOR
SPL10 1,2 E3 REFERENCE SPLICE FOR CANBUS SHIELD
J12 5 D3 WORK LIGHT HARNESS CONNECTOR JPSX16 5 H6 POWER SOURCE LIMIT RELAY CONNECTOR
SPL11 1 E3 REFERENCE SPLICE FOR CANBUS SHIELD
J13 5 D3 WORK LIGHT HARNESS CONNECTOR JPT2 1,2 F6 VEHICLE MANAGER USB PORT
SPL20 4 E4 REFERENCE SPLICE FOR OPERATOR LIGHTS
JIO 1,2 E4 CUSTOM I/O CONNECTOR JPT4 5 F3,H3,E2 VEHICLE MANAGER GENERAL PURPOSE I/O CONNECTOR
SPL22 5 E7 REFERENCE SPLICE FOR BLUE LIGHTS
JIPM 1,2 G4 2ND CANBUS CONNECTOR JPT6 1,2 E5 VEHICLE MANAGER ELECTRIC STEER CONNECTOR
SPLD1 7 C4 SPLICE FOR DIODE MODULE
JP1L 4 D4 GUIDANCE MANAGER LOAD SENSOR CONNECTOR JPT9 1,2 F6 VEHICLE MANAGER RS-232 SERIAL PORT
SPLD2 7 C4 SPLICE FOR DIODE MODULE
JP1T 4 D3 GUIDANCE MANAGER TRACTOR SENSOR CONNECTOR JPT10 1,2,3,4,5 MULTIPLE VEHICLE MANAGER CANBUS AND DIGITAL I/O CONNECTOR
SPLI1 6 C3 BUS+ SPLICE FOR iWAREHOUSE
JP3CB 1,2,5 G4,B2 EPORT CANBUS CONNECTOR JPT12 1,2,3,4,5 MULTIPLE LIFT PENDANT CONNECTOR
SPLI2 6 C4 BUS- SPLICE FOR iWAREHOUSE
JP10 1,2,5 D6,E7 WARNING LIGHT/BLUE LIGHT CONNECTION JPT14 1,2,3,4,5 MULTIPLE VEHICLE MANAGER POWER AND CANBUS CONNECTOR
SPLI3 6 C5 REFERENCE SPLICE FOR iWAREHOUSE
JP42C 6 E5 iWAREHOUSE TRANSMITTER CARRIAGE MODULE CONNECTOR JPT18 1,2,3,4,5 MULTIPLE VEHICLE MANAGER COIL DRIVER CONNECTOR
SPLI4 6 C4 SPLICE FOR iWAREHOUSE POWER
JP42T 6 B3 iWAREHOUSE TRANSMITTER TRACTOR MODULE CONNECTOR JPT20 1,2,3,4,5 MULTIPLE VEHICLE MANAGER COIL DRIVER CONNECTOR
SPLI5 6 C5 REFERENCE SPLICE FOR iWAREHOUSE
JP55 7 E6,F5 APM POWER AND TRUCK CANBUS CONNECTOR JPT22 1,2,3,4,5 MULTIPLE VEHICLE MANAGER DIGITAL I/O CONNECTOR
SPLI6 6 C5 SPLICE FOR iWAREHOUSE POWER
JP56 7 E5 APM NAV CANBUS CONNECTOR JPT24 1,2,3,4,5 MULTIPLE VEHICLE MANAGER ANALOG I/O CONNECTOR
SPLZ 7 D6 REFERENCE SPLICE ZPU
JP57C 6 E5 iWAREHOUSE IMPACT SENSOR CARRIAGE MODULE CONNECTOR JPTA1 1,2,7 D2,D4 TRACTION POWER AMPLIFIER CONNECTOR
SPM/GC 6 B3,E5 COMMUNICATIONS TRANSLATOR MODULE
JP57T 6 B4 iWAREHOUSE IMPACT SENSOR TRACTOR MODULE CONNECTOR JPTA2 1,2 C2 TRACTION MOTOR ENCODER CONNECTOR
SUP6 5 E7 SUPPRESSOR FOR BLUE LIGHT(S)
JPA7 1,2 F5 HOME SENSE PROXIMITY SWITCH CONNECTOR JPTA3 1,2 C2 TRACTION MOTOR TEMPERATURE SENSOR CONNECTOR
SWL 5 D3 SWITCH FOR WORK LIGHTS
JPAB 5 B2 EPORT SBX HARNESS CONNECTOR JPTA4 1,2 C2,B3 TRACTION AMP SENSOR HARNESS CONNECTOR

JPANT1 7 B6 ZPU ANTENNA CONNECTOR JPTC1 4,7 F6,H3 TRUCKCOM WAKE SIGNAL CONNECTOR
TP1 1,2,3,4,5 MULTIPLE TIE POINT ON B+
JPANT2 7 B6 ZPU ANTENNA CONNECTOR JPTC2 7 H4 TRUCKCOM CONNECTOR
TP2 1,2 B3 TIE POINT ON STEER MOTOR FUSE
JPB1 1,4 C5,C6 36V UL EE LIFT MOTOR FAN CONNECTOR JPW1 4 D4 GUIDANCE MANAGER TRACTOR HARNESS CONNECTOR
TP3 1,2 B3 TIE POINT ON LIFT MOTOR FUSE
JPBD1 6 B5 iWAREHOUSE EVOLUTIONS DISPLAY CONNECTOR JPW2 4 D3 GUIDANCE MANAGER LOAD HARNESS CONNECTOR
TP4 1,2 MULTIPLE TIE POINT ON B-
JPBGS1 4 F3 BATTERY GATE SENSOR CONNECTOR JPXBR 1,2 E6 BRAKE HARNESS CONNECTOR
TP5 1,2 B3 TIE POINT ON TRACTION MOTOR FUSE
JPBGS2 4 F2 BATTERY GATE SENSOR CONNECTOR JPY1 5 B4 FLOW MODULE CONNECTOR
TPC 1,2 B2,C3 TRACTION POWER CONTACTOR
JPBL10 5 E7 CONNECTOR FOR BLUE SPOT LIGHT(S) JPY2 5 B4 FLOW MODULE TEMP SENSOR CONNECTOR
TM 1,2 C3 TRACTION MOTOR
JPBL11 5 E7 CONNECTOR FOR BLUE SPOT LIGHT(S) JPY6 5 B4 FLOW MODULE FLOW SENSOR CONNECTOR
TME 1,2 C2 TRACTION MOTOR ENCODER
JPBL12 5 F7 CONNECTOR FOR BLUE SPOT LIGHT(S) JPY7 5 B4 FLOW MODULE FLOW SENSOR CONNECTOR
TMT 1,2 C2 TRACTION MOTOR TEMPERATURE SENSOR
JPBL13 5 E7 CONNECTOR FOR BLUE SPOT LIGHT(S) JPZA 7 C5 ZPU MODULE CONNECTOR
TS10 1,2 D5 TRACTOR AUX POWER TERMINAL STRIP
JPBL14 5 F7 CONNECTOR FOR BLUE SPOT LIGHT(S) JPZB 7 C5 ZPU MODULE CONNECTOR
TS12 3,4,5 G3, MULTI CARRIAGE AUX POWER TERMINAL STRIP
JPBR 1,2 E6 BRAKE CONNECTOR JPZSC1 7 D5 NAV SOLUTIONS CANBUS CONNECTOR

JPC1 3 F2 STEERING ENCODER CONNECTOR JRDP 5 F6 CONNECTOR FOR 3RD PARTY IPORT OPTIONS
VR1 3 G6 CONTROL HANDLE TRAVEL POTENTIOMETER
JPC2 3 E5 OPERATOR INTERFACE CONNECTOR VR2 3 G6 CONTROL HANDLE LIFT/LOWER POTENTIOMETER
JPC3 3 F6 60 INCH LIMIT SWITCH CONNECTOR K1 1,2 C6 RELAY FOR WARNING LIGHT AND OPTIONS

JPC4 4 G6 LOWER LIMIT CONNECTOR K2 1,2 C6 RELAY FOR SOLENOIDS, ATTACHMENTS AND ALARMS
ZPU 7 C5 ZONING AND POSITIONING MODULE
JPC5 4,5 E3,A7 OPERATOR LIGHT HARNESS AND CONTROL HANDLE HEATER CONNECTOR K3 1,2 C6 RELAY FOR POWER AMPS

JPC6 3,4 F4,D6 KEYSWITCH/EPO/BYPASS CONNECTOR K4 1,2 C6 NOT USED

JPC7 3 F5 DEADMAN SWITCH CONNECTORS K12 5 C7,D7 RELAY FOR THE SECURITY START SWITCH

JPC8 3 F5 24 INCH LIMIT SWITCH CONNECTOR K510 5 H6 RELAY FOR THE POWER SOURCE LIMIT SWITCH

JPC9 3 F6 CONTROL HANDLE CONNECTOR

JPC10 4 F6 PROGRAMMABLE LIFT LIMIT CONNECTOR LED1 4 F4 OPERATOR LIGHT CONNECTOR

JPC11 1,2,3 H3,E3 CARRIAGE CONNECTOR FOR OTM CABLE B LED2 4 F4 OPERATOR LIGHT CONNECTOR

JPC12 3 F3 CARRIAGE SPARE POWER CONNECTOR LED3 4 F4 OPERATOR LIGHT CONNECTOR

JPC13 4 C3 SIDEGATE SWITCH CONNECTOR LED4 4 F4 OPERATOR LIGHT CONNECTOR

JPC14 4 C2 SIDEGATE SWITCH CONNECTOR LM 1,2 C4,B4 LIFT MOTOR

JPC15 3 E5 OPERATOR DISPLAY CONNECTOR LME 1 C3 LIFT MOTOR ENCODER

JPC16 1,2,3 E7 CARRIAGE CONNECTOR FOR OTM CABLE A LMT 1 C4 LIFT MOTOR TEMPERATURE SENSOR

Publication:1301126/001A, Issued: 12 Nov 2018 11

Models 5300/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 11. Hydraulic Schematic, Standard Lift

Publication:1301126/001A, Issued: 12 Nov 2018 12

Models 5300/5500/5600 High-Level Orderpicker Lift Truck Schematics
Figure 12. Hydraulic Schematic, Auxiliary Lift

Publication:1301126/001A, Issued: 12 Nov 2018 13

RAYMOND SERVICE INFORMATION

The Raymond Corporation

Corporate Headquarters
P O Box 130
Greene, New York 13778-0130

RSI OPR-19-001A Model

February 20, 2019 5300 Serial Number 00001 and Up
5500, 5600 Serial Number 44001 and Up

SUBJECT: New Software Release

GENERAL There is an amplifier load improvement with Vehicle Manager (VM) software
INFORMATION: version 1.05

SERVICE An improvement has been made to the amplifier software load procedure.
INFORMATION: The new VM software version is 1.05 (106500105.s19).

1. Verify the FlashWare version on your computer is 8.1 or higher.

2. Verify that the most current software is installed on the computer as listed on the
SAP Portal.
Note: The preferred connections to update software on lift trucks equipped with
the 1045780-201 VM is USB to USB.
3. Using cable 1120332/00X, connect the computer to the JPT2 port on the VM.
4. Turn the key switch ON.
5. Save the lift truck FlashWare configuration settings.
6. Update VM software to version 1.05.
7. Verify the lift truck FlashWare configurations are correct after the update.
8. Test the lift truck operation.

PARTS Now available through the Raymond Portal.

AVAILABILITY:

FILING File this notice in Maintenance Manual 1301126/001A next to page 3-25.
INSTRUCTIONS:

Raymond ® is a registered trademark of The Raymond Corporation RSI OPR-19-001A

©2019 The Raymond Corporation. D20055536A
1306777/001 Page 1 of 1
RAYMOND SERVICE INFORMATION

The Raymond Corporation

Corporate Headquarters
P O Box 130
Greene, New York 13778-0130

RSI MUL-18-003 Model

December 18, 2018 FlashWare

SUBJECT: FlashWare 8.0 Functionality and Enhancements

GENERAL Highlights of FlashWare 8.0

INFORMATION:
• New OPR LPA and TPA P/N 1301836/002 load/upload functionality.
• New Model 7X30 Aux Power Amplifier P/N 1239519/007 and
LPA P/N 1077913/010 load/upload functionality.

SERVICE Perform the following steps:

INFORMATION: 1. Download FlashWare 8.0 from the Raymond Portal.
2. Select one of the following:
• “FlashWare Application Package” (includes FlashWare and all truck files)
• “FlashWare Application” (includes the FlashWare application only)
3. Select “Run” or “Save.”
• Choose “Run” to automatically extract the file into the C:\Download folder.
• Choose “Save” to launch the application later.
4. After the version downloads, launch the self-extracting Zip file. This will install the
files into the C\:Download folder. Open the Readme.txt file located in the
C:\Download folder and follow the instructions.

Note: Use of the serial-to-serial connection is not recommended due to the slow transmit
time when communicating with the amplifiers. This may cause timeout issues while trying
to load an amplifier.

AVAILABILITY: Now available through the Raymond Portal. Customers must contact their local Raymond
Sales and Service Center to obtain the current FlashWare version.

FILING File this notice in the Appendix of all applicable maintenance manuals.
INSTRUCTIONS:

®
Raymond is a registered trademark of The Raymond Corporation RSI MUL-18-003
2018 The Raymond Corporation. Page 1 of 1
FOTP-0060/1-2-17/H