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Raymond EASi Reach-Fork Lift Truck Maintenance Manual PDMM-0080 - EZ ET ES DS DT EF DZ Series

Raymond EASi Reach-Fork Lift Truck Maintenance Manual PDMM-0080 – EZ ET ES DS DT EF DZ Series

Name: Raymond EASi Reach-Fork Lift Truck Maintenance Manual PDMM-0080 - EZ ET ES DS DT EF DZ Series
SKU: RAY-EASIREACH-PDMM0080-HD
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Complete Raymond EASi Reach-Fork lift truck maintenance manual PDMM-0080 for Series EZ-A, ET-A, ES-B, ET-B, DS-B, DT-B, EF, EZ-B and DZ-B. Covers scheduled maintenance, troubleshooting, fault codes, component procedures, theory of operation, electrical schematics and hydraulic schematics in 746 pages.

SKU: RAY-EASIREACH-PDMM0080-HD Category: Forklift & Material Handling Manuals Tags: easireach fork truck repair guide, raymond easi reach-fork maintenance manual, raymond ez et ds dt dz series manual, raymond reach forklift service manual pdmm-0080 Vendor: Gear Head Docs

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Description

Raymond EASi Reach-Fork Lift Truck Maintenance Manual – PDMM-0080

This is the complete Raymond EASi Reach-Fork Lift Truck Maintenance Manual, document number PDMM-0080 (PDMM-0080-01), originally issued 7-31-00 and revised 9-1-01. It is the full-service reference used to keep EASi Reach-Fork trucks running correctly, from routine scheduled maintenance through component-level repair, electrical fault diagnosis and hydraulic system troubleshooting. Every chapter needed to service the truck is here: safety, systems overview, scheduled maintenance intervals, symptom-based troubleshooting, fault codes and electrical tests, step-by-step component procedures, theory of operation and full schematics in the appendix.

File Details

Manual type: Maintenance Manual
Brand: Raymond (The Raymond Corporation)
Model line: EASi Reach-Fork Lift Truck
Series covered: EZ-A, ET-A, ES-B, ET-B, DS-B, DT-B, EF, EZ-B, DZ-B
Language: English
Page count: 746 pages
File format: PDF
Document number: PDMM-0080 / PDMM-0080-01
Issued: 7-31-00
Revised: 9-1-01

Chapters Covered

The Raymond EASi Reach-Fork Lift Truck Maintenance Manual PDMM-0080 is organized into the following top-level chapters, each with their own sub-sections:

How to Use This Manual – Map of the Manual, Manual Design, Page Revision Record, Service Bulletins Included, Product Improvement Notices Included, START Page
Safety – Definitions, General Safety, Battery Safety, Static Precautions, Jacking Safety, Tie-down for Transport, Welding Safety
Systems Overview – Introduction, Lift Truck Specifications, Operator Displays, Modes of Operation
Scheduled Maintenance – Maintenance Guidelines, Operator’s Daily Checklist, Every 60 Days/250 Deadman Hours, Every 90 Days/600 Hours, Every 180 Days/1500 Hours, Every 360 Days/3000 Hours, Scheduled Maintenance Points, Motor Maintenance, Maintenance Minder Tool, Lubrication Points
Troubleshooting – How to Use This Chapter, Electrical Troubleshooting Guidelines, Electrostatic Discharge, Shorts to Frame Test, Hydraulic Troubleshooting Guidelines, Troubleshooting Procedure, Symptom Tables for Hydraulic Functions, Travel Functions and Electrical Symptoms
Messages, Codes, and Tests – Firmware Changes, Modes of Operation, Messages and Codes Summary List, Messages and Codes Summary Tables, Electrical Codes, Electrical Connector Locator Chart, Circuit Card Connectors, Electrical Test Summary List, Analog Tests, Digital Input Tests, Digital Output Tests
Component Procedures – Component Locator Photos, Covers and Finish, Steering and Controls, Drive and Brake, Electrical Components, Hydraulic Components, Mast/Chain/Hose and Cable, Options
Theory of Operation – Traction System Functional Operation, Operation of the Travel System, Brake System, Steering System, Lift/Lower System Functional Operation, Auxiliary System, 4-D Control
Appendix – Lubrication Specification Chart, Thread Adhesives/Sealants/Lubricants, Torque Charts (Standard Ferrous, Metric Ferrous, Standard Brass), Decimal Equivalent Chart, Standard/Metric Conversions, Electrical Schematics, Hydraulic Schematics
Index

In practice, this Raymond EASi Reach-Fork maintenance manual gives a technician a single reference for the entire truck platform. The electrical fault-code chapter alone covers dozens of codes – from Code 12 (lift motor temperature hot) through the PC, P, B and X contactor codes, VFC and System Card faults, and 4-D caster/steer faults – each with alarm behaviour, system response, how to clear, and the specific tests to run. The analog, digital input and digital output tests give measurable values so diagnosis is not guesswork. On the mechanical side, the component procedures walk through real teardown and reassembly of the drive unit, drive motor, brake, control handle, lift pump, auxiliary pump, steering pump, main manifold, reach cylinder, tilt cylinder, sideshift cylinder, lift cylinders and the full mast assembly. The appendix schematics and torque charts mean every fastener and hose can be reassembled to Raymond’s original specifications.

What This Manual Helps You Do

With the Raymond EASi Reach-Fork service information in this PDF you can carry out scheduled maintenance on all covered EASi Reach-Fork series, read and clear fault codes correctly, troubleshoot travel, lift, lower, steer, reach, tilt, sideshift and 4-D caster issues using the symptom tables and tests, remove and reinstall major components, replace brake pads and rotors to the published gaps, adjust caster height and mast backlash, service the hydraulic system and bleed it properly, and check electrical shorts to frame before they damage the System Card or VFC. Correct procedures and published torque and gap values matter on reach trucks: an over-shimmed mast binds, a mis-adjusted brake drags and overheats the drive motor, and a wrong brake rotor/pad gap can turn a routine repair into a component replacement. This document exists so those values are on hand rather than guessed.

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “Raymond EASi Reach-Fork Lift Truck Maintenance Manual PDMM-0080 – EZ ET ES DS DT EF DZ Series” are as follows:

EASi Reach-Fork® Lift Truckp. 1

How to Use This Manualp. 3

Map of the Manualp. 4

Design of the Manualp. 5

Page Revision Recordp. 7

Service Bulletins Includedp. 9

Product Improvement Notices Includedp. 10

Table of Contentsp. 13

How to Use This Manual 1-1p. 13

Safety 2-1p. 13

Systems Overview 3-1p. 13

Scheduled Maintenance 4-1p. 13

Troubleshooting 5-1p. 13

Messages, Codes, and Tests 6-1p. 14

Component Procedures 7-1p. 14

Theory of Operation 8-1p. 14

Appendix A-1p. 14

Index I-1p. 15

START Pagep. 17

Safetyp. 19

Definitionsp. 20

General Safetyp. 21

Battery Safetyp. 25

Static Precautionsp. 29

Figure 2-1: ESD Ground Jackp. 29

Figure 2-2: Anti-Static Kit with Wrist Strap and Matp. 30

Jacking Safetyp. 31

Figure 2-3: Verify A-frame Down-Travel Adjustment Boltp. 31

Figure 2-4: Correct Jacking Locationsp. 32

To elevate the rear of the lift truck:p. 32

To elevate either side of the lift truck:p. 32

Tie-down for Transportp. 32

Welding Safetyp. 33

Systems Overviewp. 35

Introductionp. 36

Lift Truck Specificationsp. 37

Figure 3-1: Lift Truck Specification Platep. 37

Battery Specificationsp. 38

Figure 3-2: Battery Specifications by Seriesp. 38

Optional Battery Gatesp. 38

Operator Displaysp. 39

Figure 3-3: Operator Display, Series ES/ET/EZ/EFp. 39

Main Operator Displayp. 39

Figure 3-4: Operator Display, Series DS/DT/DZp. 39

Setting Default Displaysp. 39

Selecting “Off Deadman” defaultp. 39

Selecting “On Deadman” defaultp. 40

4-D® Display (Series EF only)p. 41

Figure 3-5: 4-D Control Panel, Series EFp. 41

Figure 3-6: 4-D Display, Series EFp. 41

Modes of Operationp. 42

Overview of Modesp. 42

Run Modep. 42

Program Modep. 42

Learn Modep. 42

Configure Modep. 43

Maintenance Modep. 43

Passwordsp. 43

Passwordp. 43

Superwordp. 43

Scheduled Maintenancep. 45

Maintenance Guidelinesp. 46

Operator’s Daily Checklistp. 47

Every 60 Days or 250 Deadman Hours (HD)p. 49

Every 90 Days or 600 Deadman Hours (HD)p. 53

Every 180 Days or 1500 Deadman Hours (HD)p. 54

Every 360 Days or 3000 Deadman Hours (HD)p. 54

Scheduled Maintenance Pointsp. 55

Figure 4-1: Scheduled Maintenance Points, Mast Viewp. 55

Figure 4-2: Scheduled Maintenance Points, Tractor View (DZ-B shown)p. 56

Figure 4-3: Scheduled Maintenance Points, Operator Compartment (DZ-B shown)p. 57

Figure 4-4: Scheduled Maintenance Points, Undersidep. 58

Motor Maintenancep. 59

Motor Cleaningp. 59

Figure 4-5: Motor cleaning with compressed airp. 59

Maintenance Minder™ Toolp. 60

Factory Configurationp. 60

Enablingp. 60

Setting Time Interval and Action Optionp. 61

Changing Time Interval or Action Optionp. 61

Resetting Maintenance Minderp. 62

Disablingp. 62

Lubrication Pointsp. 63

Fluidsp. 63

Lubrication Point Locator Photosp. 64

Figure 4-6: Lubrication Points, Steering Linkage and A-frame (underside view)p. 64

Figure 4-7: Lubrication Points, Steering Linkage and A-frame (top views)p. 64

Figure 4-8: Lubrication Points, Caster Wheel bearing and axlep. 65

Figure 4-9: Lubrication Points, Steering Shaft and Drive Unit; Fork Carriage Pivot Pinp. 65

Figure 4-10: Reach Assembly (Deep-Reach® shown)p. 66

Figure 4-11: Reach Mechanismp. 66

Figure 4-12: Lubrication Points, Reach Cylinderp. 67

Figure 4-13: Lubrication Points, Mast and Carriagep. 68

Figure 4-14: Lubrication Points, Reach Mechanism; Sideshift Carriagep. 68

Troubleshootingp. 69

How to Use This Chapterp. 70

Electrical Troubleshooting Guidelinesp. 71

Electrostatic Dischargep. 73

Shorts to Frame Testp. 74

Hydraulic Troubleshooting Guidelinesp. 80

Troubleshooting Procedurep. 81

Symptom Tables: Hydraulic Functionsp. 85

Auxiliary Functionsp. 85

Multiple Functions Affectedp. 85

No Auxiliary Functions Work (Reach/Retract, Tilt, Sideshift)p. 85

All Auxiliary Functions are Slowp. 86

Tiltp. 86

No Tilt; other Aux Functions OKp. 86

Slow Tilt; other Aux Functions OKp. 87

Sideshiftp. 87

No Sideshift or One Direction Only; Other Aux Functions OKp. 87

Sideshift – Slow Operation; Other Aux Functions OKp. 87

Reachp. 88

Reach – Does Not Work; Other Functions OKp. 88

Reach – Slow Operation; Other Aux Functions OKp. 88

Retractp. 89

Retract – Does Not Work; Other Functions OKp. 89

Retract – Slow Operation; Other Functions OKp. 89

Lift/Lower Systemp. 90

Lift and Lowerp. 90

Intermittent Lift and Lowerp. 90

Lift Functionp. 91

No Liftp. 91

Slow Liftp. 92

Unable to Pick Up a Loadp. 93

Lower Functionp. 94

Slow Lowerp. 94

Intermittent Lowerp. 94

Load Drifting/Settlingp. 95

Symptom Tables: Travel Functionsp. 96

Slow or Sluggish Accelerationp. 96

Slow Travelp. 97

Symptom Tables: Electrical Symptomsp. 98

Electrical Motorsp. 98

Motor Arcingp. 98

Motor Overheatingp. 99

Operator Display Problemsp. 100

Scrambled or Intermittent Displayp. 100

Dead Lift Truckp. 101

Display is Dark; Lift Truck is NOT Operationalp. 101

Messages, Codes, and Testsp. 103

Firmware Changesp. 104

Figure 6-1: EASi Reach-Fork Firmware Changesp. 104

Modes of Operationp. 107

Overview of Modesp. 107

Run Modep. 107

Program Modep. 107

Configure Modep. 107

Learn Modep. 107

Maintenance Modep. 107

Passwordsp. 107

Electronic Operator Keyp. 107

Passwordp. 107

Superwordp. 108

Run Mode Tonesp. 108

Entering Program Modep. 109

Entering a Password or Superwordp. 109

To change Password or Superwordp. 109

Using Configure Modep. 110

To Place the Lift Truck in Configure Modep. 110

To Configure an Itemp. 110

To Configure Additional Itemsp. 110

If You Make a Mistakep. 110

To Save New Valuesp. 110

If You Change Your Mind About Making Changesp. 110

To Reinstate Factory Default Settingsp. 111

Configure Mode Settingsp. 112

Using Learn Modep. 115

Learn Controlsp. 115

Learn Weightp. 115

Using Maintenance Modep. 116

Static Maintenance Modep. 116

To Place the Lift Truck in Static Maintenance Modep. 116

Active Maintenance Modep. 117

To Enable a Test For Active Maintenance Modep. 117

To Clear a Test From the Active Maintenance Listp. 117

To Clear All Active Maintenance Tests At Oncep. 117

Messages and Codes Summary Listp. 119

Messages and Codes Summary Tablesp. 121

Electrical Codesp. 125

Code 12p. 125

Run Test:p. 125

Code 1Hp. 125

Run Tests:p. 125

Code 1Lp. 126

Run Tests:p. 126

Code 1Np. 126

(Optional)p. 126

Run Test:p. 126

Code 1Wp. 127

Run test:p. 127

Code 1Xp. 127

Code 1Yp. 128

Code 1Zp. 128

Code 20p. 129

Run Tests:p. 129

Code 21p. 130

Run Tests:p. 130

Code 23p. 131

Checks:p. 131

Run Tests:p. 131

Code 24p. 132

Run Tests:p. 132

Inspect the following components:p. 132

Code 25p. 133

Run Tests:p. 133

Code 26p. 134

Run Tests:p. 134

Inspect the following components:p. 134

Code 28p. 135

Run Test:p. 135

Code 29p. 136

Run Test:p. 136

Inspect following components:p. 136

Code 2Ap. 137

Run test:p. 137

Code 2Bp. 137

Run Tests:p. 137

Code 2Cp. 138

Run Tests:p. 138

Code 2Dp. 138

Run Test:p. 138

Code 2Ep. 139

Run Test:p. 139

Code 2Fp. 139

Run Tests:p. 139

Check:p. 139

Code 40p. 140

Run Tests:p. 140

Code 41p. 140

Run Tests:p. 140

Code 42p. 141

Run Test:p. 141

Run test:p. 141

Code 43p. 141

Run Test:p. 141

Code 44p. 142

Run Test:p. 142

Code 45p. 142

Code 49p. 143

Run test:p. 143

Run Test:p. 143

Code 4Ap. 143

Run test:p. 143

Run Test:p. 143

Code 5Dp. 144

Check the following:p. 144

Code 6Dp. 144

Check:p. 144

Run Test:p. 144

Code 6Fp. 145

Run Test:p. 145

Additional checks:p. 145

Code 6Gp. 145

Run Test:p. 145

Code 80p. 146

Run Test:p. 146

Code 81p. 146

Run Test:p. 146

Code 84p. 147

Run Test:p. 147

Code 85p. 148

Run Test:p. 148

Code 86p. 148

Run Test:p. 148

Code A0p. 149

Code A1p. 150

Code AGp. 151

Checks:p. 151

Code AHp. 152

Checks:p. 152

Code AKp. 153

Repair:p. 153

Code ECp. 154

Repairp. 154

Code F1p. 155

Diagnosis and Repairp. 155

Code F4p. 156

Diagnosis and Repairp. 156

Code F5p. 157

Diagnosis and Repairp. 157

Code F6p. 158

Diagnosis and Repairp. 158

Code F8p. 159

Repairp. 159

Code FEp. 160

Repairp. 160

Code FGp. 160

Run Test:p. 160

Code FHp. 161

Run Test:p. 161

Code GBp. 161

Code GCp. 162

Electrical Connector Locator Chartp. 163

Terminologyp. 163

Figure 6-2: Molex Jack and Pin Connectorp. 163

Figure 6-3: Electrical Connector Locator Chartp. 163

Circuit Card Connectorsp. 167

Power Cardp. 167

Figure 6-4: Power Card connectorsp. 167

System Cardp. 168

P/N 154-012-438 Used since 9-96p. 168

Figure 6-5: System Card connectorsp. 168

System Cardp. 169

P/N 154-012-390 Used 6-95 to 8-96p. 169

Figure 6-6: System Card connectorsp. 169

System Cardp. 170

P/N 828-004-200 Used 9-93 to 5-95p. 170

Figure 6-7: System Card connectorsp. 170

Vehicle Function Controller (VFC) Cardp. 171

Figure 6-8: Vehicle Function Controller (VFC) Cardp. 171

4-D® Circuit Cardp. 171

Figure 6-9: 4-D Circuit Card connectorsp. 171

Electrical Test Summary Listp. 173

Analog Testsp. 173

Input Testsp. 173

Output Testsp. 174

Analog Testsp. 175

Test A00 – PC Sense Voltagep. 175

Run Testp. 175

Diagnosis and Repairp. 175

Test A01 – Auxiliary Sense Voltagep. 176

Run Testp. 176

Diagnosis and Repairp. 176

Test A02 – Lift Pump Sense Voltagep. 177

Run Testp. 177

Diagnosis and Repairp. 177

Test A03 – BSense/Q1-C Sense Voltagep. 178

Run Testp. 178

Diagnosis and Repairp. 178

Test A04 – Throttle Potentiometer Voltagep. 179

Run Testp. 179

Diagnosis and Repairp. 179

Figure 6-10: JPS4 pin connector orientationp. 179

Test A05 – Lift/Lower Potentiometer Voltagep. 180

Run Testp. 180

Diagnosis and Repairp. 180

Figure 6-11: JPS4 pin connector orientationp. 180

Lift/Lower Potentiometer Adjustment – Wirewoundp. 180

Lift/Lower Potentiometer Adjustment – Solid Statep. 181

Test A06 – Display Remote Lift Sense Voltagep. 182

Run Testp. 182

Diagnosis and Repairp. 182

Test A07 – Display Remote Lower Sense Voltagep. 183

Run Testp. 183

Diagnosis and Repairp. 183

Test A08 – Traction Motor Temperature (v.4.5)p. 184

Firmware version 4.5 and abovep. 184

Run Testp. 184

Diagnosis and Repairp. 184

Firmware version 4.5 and abovep. 184

Test A08 – Traction Motor Temperature Voltage (v.3.6)p. 186

Firmware version 3.6p. 186

Run Testp. 186

Firmware version 3.6:p. 186

Diagnosis and Repairp. 186

Firmware version 3.6p. 186

Test A09 – Lift Pump Motor Temperature (v.4.5)p. 188

Firmware version 4.5 and abovep. 188

Run Testp. 188

Diagnosis and Repairp. 188

Firmware version 4.5 and abovep. 188

Test A09 – Lift Pump Motor Temperature Voltage (v.3.6)p. 190

Firmware version 3.6p. 190

Run Testp. 190

Diagnosis and Repairp. 190

Test A10 – Main Heat Sink Temperature Sensor (v.4.5)p. 192

Firmware version 4.5 and abovep. 192

Run Testp. 192

Diagnosis and Repairp. 192

Firmware version 4.5 and abovep. 192

Test A10 – Main Heat Sink Temperature Sensor Voltage (v.3.6)p. 194

Firmware version 3.6p. 194

Run Testp. 194

Diagnosis and Repairp. 194

Firmware version 3.6p. 194

Test A11 – Armature Current Sensor (v.4.5)p. 196

Firmware version 4.5 and abovep. 196

Run Testp. 196

Diagnosis and Repairp. 196

Test A11 – Armature Current Sensor Voltage (v.3.6)p. 197

Firmware version 3.6p. 197

Run Testp. 197

Diagnosis and Repair Firmware version 3.6p. 197

Test A12 – Field Current Sense (v.4.5)p. 198

Firmware version 4.5 and abovep. 198

Run Testp. 198

Diagnosis and Repairp. 198

Test A12 – Field Current Sense Voltage (v.3.6)p. 199

Firmware version 3.6p. 199

Run Testp. 199

Diagnosis and Repairp. 199

Test A13 – Pressure Sensor Voltagep. 200

Run Testp. 200

Diagnosis and Repairp. 200

Test A14 – Power Supply +12 Voltagep. 201

Run Testp. 201

Diagnosis and Repairp. 201

Test A15 – Battery Voltagep. 202

Run Testp. 202

Diagnosis and Repairp. 202

Test A17 – Remote Lift/Lower Optionp. 203

Diagnosis and Repairp. 203

Test A18 – Drive Motor RMS Current Calculator (v.4.5)p. 204

Firmware version 4.5 and above onlyp. 204

Digital Input Testsp. 205

Test I00 – Deadman Switchp. 205

Run Testp. 205

Diagnosis and Repairp. 205

Test I01 – Remote EPO and/or Unnested Switchp. 206

Run Testp. 206

Diagnosis and Repairp. 206

Test I02 – Mast Switch #1p. 207

Run Testp. 207

Diagnosis and Repairp. 207

Test I03 – Mast Switch #2p. 208

Run Testp. 208

Diagnosis and Repairp. 208

Test I04 – Lift Inhibit Bypass Switchp. 209

Run Testp. 209

Diagnosis and Repairp. 209

Test I05 – Lift Inhibit Mast Switchp. 210

Run Testp. 210

Diagnosis and Repairp. 210

Test I06 – Reach Switchp. 211

Run Testp. 211

Diagnosis and Repairp. 211

Figure 6-12: JPS4 pin connector orientationp. 211

Test I07 – Retract Switchp. 212

Run Testp. 212

Diagnosis and Repairp. 212

Figure 6-13: JPS4 pin connector orientationp. 212

Test I08 – Tilt Up Switchp. 213

Run Testp. 213

Diagnosis and Repairp. 213

Figure 6-14: JPS4 pin connector orientationp. 213

Test I09 – Tilt Down Switchp. 214

Run Testp. 214

Diagnosis and Repairp. 214

Figure 6-15: JPS4 pin connector orientationp. 214

Test I10 – Sideshift Right Switchp. 215

Run Testp. 215

Diagnosis and Repairp. 215

Figure 6-16: JPS4 pin connector orientationp. 215

Test I11 – Sideshift Left Switchp. 216

Run Testp. 216

Diagnosis and Repairp. 216

Figure 6-17: JPS4 pin connector orientationp. 216

Test I12 – Power Panel Temperature Limit Signalp. 217

Run Testp. 217

Diagnosis and Repairp. 217

Test I13 – Armature Current Limit Signalp. 219

Run Testp. 219

Diagnosis and Repairp. 219

Test I16 – Encoder Countp. 220

Run Testp. 220

Diagnosis and Repairp. 220

Test I17 – Drive Wheel Inputsp. 221

Run Testp. 221

Expected Resultsp. 221

Other Failuresp. 221

Diagnosis and Repairp. 221

Test I18 – Caster Wheel Inputsp. 222

Run Testp. 222

Expected Resultsp. 222

Other Failuresp. 222

Diagnosis and Repairp. 222

Digital Output Testsp. 223

Test O00 – Toggle the PC Contactorp. 223

Run Testp. 223

Diagnosis and Repairp. 223

Test O01 – Toggle the X Contactorp. 225

Run Testp. 225

Diagnosis and Repairp. 225

Test O02 – Toggle the P Contactorp. 227

Run Testp. 227

Diagnosis and Repairp. 227

Test O03 – Toggle the B Contactorp. 229

Preparationp. 229

Run Testp. 229

Diagnosis and Repairp. 229

Test O04 – Toggle Solenoid DIRAp. 231

Preparationp. 231

Run Testp. 231

Diagnosis and Repairp. 231

Test O05 – Toggle Solenoid DIRBp. 233

Preparationp. 233

Run Testp. 233

Diagnosis and Repairp. 233

Test O06 – Toggle Reach Solenoidp. 235

Preparationp. 235

Run Testp. 235

Diagnosis and Repairp. 235

Test O07 – Toggle Tilt Solenoidp. 237

Preparationp. 237

Run Testp. 237

Diagnosis and Repairp. 237

Test O08 – Toggle Sideshift Solenoid (all Series except EF)p. 239

Test O08 – Toggle 4-D Caster Wheel Positioner Solenoid (Series EF only)p. 239

All except Series EFp. 239

Series EF onlyp. 239

Preparationp. 239

Run Testp. 239

Diagnosis and Repairp. 239

Test O09 – Toggle Equalizing (EQ) Solenoidp. 241

Preparationp. 241

Run Testp. 241

Diagnosis and Repairp. 241

Test O10 – Toggle 2nd Pump Solenoidp. 243

Preparationp. 243

Run Testp. 243

Diagnosis and Repairp. 243

Test O11 – Toggle Load Hold Solenoidp. 245

Preparationp. 245

Run Testp. 245

Diagnosis and Repairp. 245

Test O12 – Proportional Solenoid PWM Rampp. 247

Preparationp. 247

Run Testp. 247

Diagnosis and Repairp. 248

Figure 6-18: Proportional Solenoid connectionsp. 248

Test O13 – Armature Enable Signalp. 250

Preparationp. 250

Run Testp. 250

Diagnosis and Repairp. 250

Test O14 – Armature PWM (v.4.5)p. 251

Firmware version 4.5 and abovep. 251

Preparationp. 251

Run Testp. 251

Diagnosis and Repair Firmware version 4.5 and abovep. 252

Test O14 – Armature PWM (v.3.6)p. 254

Firmware version 3.6p. 254

Preparationp. 254

Run Testp. 254

Diagnosis and Repairp. 255

Test O15 – Forward Enable Testp. 256

Preparationp. 256

Run Testp. 256

Diagnosis and Repairp. 256

Test O16 – Reverse Enable Testp. 257

Preparationp. 257

Run Testp. 257

Diagnosis and Repairp. 257

Test O17 – Field PWM Ramp (v.4.5)p. 258

Firmware version 4.5 and abovep. 258

Preparationp. 258

Run Testp. 258

Diagnosis and Repair Firmware version 4.5 and abovep. 259

Test O17 – Field PWM Ramp (v.3.6)p. 260

Firmware version 3.6p. 260

Preparationp. 260

Run Testp. 260

Diagnosis and Repair Firmware version 3.6p. 261

Test O18 – Toggle Hornp. 262

Preparationp. 262

Run Testp. 262

Diagnosis and Repairp. 262

Test O19 – Audible Alarm Testp. 263

Run Testp. 263

Diagnosis and Repairp. 263

Test O20 – K1 Travel Option Testp. 264

Run Testp. 264

Diagnosis and Repairp. 264

Figure 6-19: K1 Relay Connections on System Cardp. 264

Test O21 – Regen Enable Circuitp. 266

Preparationp. 266

Run Testp. 266

Diagnosis and Repairp. 266

Component Proceduresp. 267

Component Locator Photosp. 271

Figure 7-1: Tractor, Series DZ-Bp. 271

Figure 7-2: Tractor, Series DZ-Bp. 272

Figure 7-3: Tractor, Series DZ-Ap. 273

Figure 7-4: Tractor, Series EZ-Ap. 274

Figure 7-5: Mast and Carriage, Series DZ-B Deep-Reach®p. 275

Figure 7-6: Underside Componentsp. 276

Covers and Finishp. 277

Right Side Coverp. 278

Figure 7-7: Right Side Cover, Series EZ-Bp. 278

Removalp. 278

Installationp. 278

Figure 7-8: Right Side Cover, Series DZ-Bp. 278

Top Coverp. 279

Series EZ, ES, ET, EFp. 279

Figure 7-9: Top Cover, Series EZ-B Cold Storage shownp. 279

Removalp. 279

Installationp. 279

Series DS, DT, DZp. 280

Figure 7-10: Top Cover, Series DZ-Bp. 280

Removalp. 280

Installationp. 280

OD/SMARTi® Coverp. 281

Series EZ, ES, ET, EFp. 281

Figure 7-11: OD/SMARTi® Cover, Series EZ-Bp. 281

Removalp. 281

Figure 7-12: Control Handle and OD Coverp. 281

Installationp. 281

Steering Wheel Coverp. 282

Series DS, DT, DZp. 282

Figure 7-13: Steering Wheel Cover, Series DZ-Bp. 282

Removalp. 282

Installationp. 282

Figure 7-14: Electronics Compartment Cover, Cold Storagep. 283

Electronics Compartment Coverp. 283

Removalp. 283

Figure 7-15: Electronics Compartment Cover, Cold Storage, Heatersp. 283

Installationp. 283

Drive Motor Compartment Doorp. 284

Figure 7-16: Drive Motor Compartment Doorp. 284

Openingp. 284

Removalp. 284

Installationp. 284

Decalsp. 285

Removalp. 285

Installationp. 285

Locationp. 285

Figure 7-17: Decal Location Chartp. 286

Figure 7-18: Decal and Specification Plate Locations, Tractorp. 287

Figure 7-19: Safety Decalsp. 288

Steering and Controlsp. 289

Steering Wheel and Knobp. 290

Series EZ, ES, ET, EFp. 290

Removalp. 290

Installationp. 290

Series DS, DT, DZp. 290

Removalp. 290

Installationp. 290

Steering Orbitrolp. 291

Figure 7-20: Steering Orbitrol (Series EZ-B shown)p. 291

Removalp. 291

Figure 7-21: Steering Orbitrol (Series DZ shown)p. 292

Installationp. 292

Steering Pumpp. 293

Steering Hydraulic Motorp. 293

Figure 7-22: Steering Hydraulic Motorp. 293

Removalp. 293

Installationp. 293

Steering Shaft and Gearp. 295

Figure 7-23: Steering Shaftp. 295

Removalp. 295

Figure 7-24: Steering Shaft and Gear Assemblyp. 296

Installationp. 296

Steering Electric Motor, Series EZ-B/DZ-B onlyp. 298

Figure 7-25: Steering Electric Motor Location (Series EZ-B Cold Storage shown)p. 298

Testingp. 298

Removalp. 298

Figure 7-26: Terminal Strip TS8 Locationp. 298

Figure 7-27: Hydraulic Filler Bracket, Attached Componentsp. 299

Installationp. 299

Figure 7-28: Steering Electric Motor, Impellerp. 300

Caster Assemblyp. 301

Removalp. 301

Installationp. 302

Steerable Casterp. 303

Figure 7-29: Setting Drive Wheel Parallelp. 303

Initial Adjustmentp. 303

Figure 7-30: Steering Adjustmentsp. 303

Figure 7-31: A-frame Down-Travel Adjustment Boltp. 304

Caster Height Adjustmentp. 304

Figure 7-32: A-frame Spring adjustmentsp. 304

Figure 7-33: A-frame Up-Travel Stop Adjustmentp. 306

Steering Linkagep. 307

Figure 7-34: Steering Linkagep. 307

Figure 7-35: Steering Linkage Exploded Viewp. 308

4-D® Casterp. 309

Figure 7-36: Connector JPS4 at System Cardp. 310

Control Handle, Series EZ/ES/ET/EFp. 310

Control Handle Shellp. 310

Removalp. 310

Figure 7-37: Control Handle Cable Retainer (EZ/ES/ET/EF)p. 310

Disassemblyp. 310

Figure 7-38: Control Handle Retaining Ring Removal (EZ/ES/ET/EF)p. 311

Figure 7-39: Control Handle, Right Halfp. 311

Figure 7-40: Control Handle Cable Routing (EZ,ES,ET,EF)p. 312

Assemblyp. 312

Figure 7-41: Tilt/Sideshift Button (EZ/ES/ET/EF)p. 312

Figure 7-42: Control Handle Assembly (EZ/ES/ET/EF)p. 312

Figure 7-43: Control Handle Installation (EZ/ES/ET/EF)p. 313

Installationp. 313

Figure 7-44: Control Handle Cable Loop (EZ/ES/ET/EF)p. 313

Throttle Potentiometer (VR1)p. 314

Removalp. 314

Figure 7-45: Throttle Potentiometer VR1 (EZ/ES/ET/EF)p. 314

Installationp. 315

Lift/Lower Potentiometer (VR2)p. 316

Figure 7-46: Lift Lower Potentiometer VR2 (EZ/ES/ET/EF)p. 316

Return Spring Replacementp. 316

Lift Knob Replacement, solid state pots onlyp. 317

Potentiometer Removalp. 317

Potentiometer Installationp. 318

Figure 7-47: Lift/Lower Knob and Potentiometer (EZ/ES/ET/EF)p. 318

Tilt/Sideshift Switch Card (S6-S9)p. 319

Figure 7-48: Tilt/Sideshift Switch Card (EZ/ES/ET/EF cold storage)p. 320

Removal (Cold Storage)p. 320

Installationp. 320

Horn Switch (S3)p. 321

Reach/Retract Switches (S4/S5)p. 321

Figure 7-49: Horn and Reach/Retract Switches (EZ/ES/ET/EF)p. 321

Removalp. 321

Installationp. 321

Figure 7-50: Connector JPS4 at System Cardp. 323

Control Handle, Series DS/DT/DZp. 323

Control Handle Shellp. 323

Removalp. 323

Disassemblyp. 323

Figure 7-51: Control Handle, Right Half (DS/DT/DZ)p. 324

Figure 7-52: Control Handle Cable Routing (DS/DT/DZ)p. 324

Assemblyp. 324

Figure 7-53: Tilt/Sideshift Button (DZ/DS/DT)p. 324

Figure 7-54: Control Handle Assembly (DS/DT/DZ)p. 325

Figure 7-55: Lift/Lower Knob and Potentiometer (DS/DT/DZ)p. 325

Figure 7-56: Control Handle Installation (DS/DT/DZ)p. 325

Installationp. 325

Figure 7-57: Control Handle Cable Loop (DS/DT/DZ)p. 326

Figure 7-58: Throttle Potentiometer VR1 (DS/DT/DZ)p. 326

Throttle Potentiometer (VR1)p. 326

Removalp. 326

Installationp. 327

Figure 7-59: Control Handle Shaft Installation (DS/DT/DZ)p. 328

Lift/Lower Potentiometer (VR2)p. 329

Return Spring Replacementp. 329

Figure 7-60: Lift Power Potentiometer VR2 (DS/DT/DZ)p. 329

Lift Knob Replacement, solid state pots onlyp. 329

Potentiometer Removalp. 330

Potentiometer Installationp. 330

Tilt/Sideshift Switch Card (S6-S9)p. 331

Figure 7-61: Tilt/Sideshift Switch Card (DS/DT/DZ cold storage)p. 332

Removal (Cold Storage)p. 332

Installationp. 332

Figure 7-62: Horn and Reach/Retract Switches (DS/DT/DZ)p. 333

Horn Switch (S3)p. 333

Reach/Retract Switches (S4/S5)p. 333

Removalp. 333

Installationp. 333

Key Switchp. 335

Electrostatic Dischargep. 335

Figure 7-63: Key Switch (Series EZ/ES/ET/EF)p. 335

Removalp. 335

Figure 7-64: Key Switch (Series DS/DT/DZ)p. 335

Installationp. 335

Operator Display (OD)p. 336

Pre-programmed vs. blank ODp. 336

Electrostatic Dischargep. 336

Figure 7-65: Operator Display Interface Cardp. 337

Removalp. 337

Figure 7-66: Operator Display Interface Cardp. 337

Installationp. 337

4-D® Control Panel and Displayp. 339

Figure 7-67: 4-D Control Panelp. 339

Removalp. 339

Installationp. 339

Drive and Brakep. 341

Drive Unitp. 342

Figure 7-68: Drive Unit Removal/Installation Toolp. 342

Removalp. 342

Figure 7-69: Drive Motor, Series EZ-Bp. 343

Installationp. 344

Repair Proceduresp. 345

Figure 7-70: Drive Motor Power Cablesp. 346

Drive Motorp. 346

Removalp. 346

Figure 7-71: Drive Motor, Series EZ-Bp. 346

Figure 7-72: Securing Hoist to Drive Motorp. 347

Installationp. 347

Drive Encoderp. 350

Figure 7-73: Drive Encoderp. 350

Removalp. 350

Figure 7-74: Drive Encoder Connection at System Card JPS15p. 350

Installationp. 350

Brake Adjustmentp. 352

Figure 7-75: Brake Assembly, Snap Ring Stylep. 352

Snap Ring Style Brakep. 352

Figure 7-76: Brake Assembly, Nut-Retained Stylep. 355

Nut-Retained Style Brakep. 355

Without Adjusting Boltsp. 355

With Adjusting Boltsp. 356

Figure 7-77: Brake Adjusting Bolt detailp. 356

Brake Pad Inspectionp. 358

Bleeding Brakep. 358

Brake Assemblyp. 359

Snap Ring Style Brakep. 359

Removalp. 359

Disassemblyp. 360

Assemblyp. 360

Installationp. 360

Brake O-ring Seal Replacementp. 362

Deadman (Brake) Pedalp. 365

Inspectionp. 365

Adjustmentp. 365

Figure 7-78: Deadman Switch (Series EZ/ES/ET/EF)p. 367

Deadman Switch (S2)p. 367

Removalp. 367

Figure 7-79: Deadman Switch (Series EZ/ES/ET/EF)p. 367

Installation and Adjustmentp. 367

Figure 7-80: Deadman Switch and Bracketp. 368

Figure 7-81: Deadman Switch (Series DS/DT/DZ)p. 368

Figure 7-82: Deadman Pedal, Switch, and Master Cylinder Assembly (DS/DT/DZ)p. 369

Brake Master Cylinderp. 369

Removalp. 369

Figure 7-83: Deadman Switch (DS/DT/DZ)p. 369

Figure 7-84: Brake Master Cylinder and Deadman Pedalp. 370

Installation and Bleedingp. 370

Inertial Dampenerp. 372

Figure 7-85: Inertial Dampener (unrelated parts removed for clarity)p. 372

Removalp. 372

Figure 7-86: Inertial Dampener (nuts, retainer, springs, friction plate removed)p. 372

Figure 7-87: Inertial Dampener (A-frame springs, slide plate removed)p. 373

Figure 7-88: Inertial Dampener (jacked up for shoulder bolt removal)p. 373

Installation and Adjustmentp. 373

Figure 7-89: Inertial Dampener partsp. 374

Figure 7-90: Inertial Dampener adjustmentp. 374

Electrical Componentsp. 375

Figure 7-91: Battery Disconnect Blockp. 376

Battery Proceduresp. 376

Battery Connector/Cablesp. 376

Locationp. 376

Inspectionp. 376

Figure 7-92: Battery Cable Removal from Connectorp. 377

Removal, Repair, and Installationp. 377

Figure 7-93: Battery Cable and Connectorp. 377

Battery Gatesp. 377

Inspectionp. 377

Battery Rollersp. 378

Inspectionp. 378

Figure 7-94: Battery Cable and Filler Plugp. 378

Battery Exterior Cleaningp. 378

Testing, Charging, and Maintenancep. 379

Battery State-of-Chargep. 379

Figure 7-95: Chip Extraction tool P/N 950-032p. 382

Firmware Replacementp. 382

General Instructionsp. 382

Figure 7-96: Firmware Socket and Chipp. 382

Removalp. 382

Figure 7-97: Firmware Chip Removalp. 382

Figure 7-98: Firmware Chip Inspection (chips upside down to reveal pins)p. 383

Chip Installationp. 383

Figure 7-99: Firmware Chip improperly seated in socketp. 383

Figure 7-100: Firmware Chip fully seated in socketp. 383

Pin Extractionp. 384

Figure 7-101: Molex Connector, end viewp. 384

Removalp. 384

Insertionp. 384

Figure 7-102: Pin Extractionp. 384

Wiring, Generalp. 385

Inspectionp. 385

Repairp. 385

Soldering Proceduresp. 386

Motorsp. 387

Figure 7-103: Motor Brush, Typical Locationp. 387

Motor Brushesp. 387

Inspectionp. 387

Replacementp. 388

Motor Brush Spring Tensionp. 389

Figure 7-104: Motor Brush Spring Tension Inspectionp. 389

Inspectionp. 389

Commutatorp. 392

Figure 7-105: Mica Undercuttingp. 392

Inspectionp. 392

Servicingp. 392

Figure 7-106: Motor Terminal Nutsp. 393

Terminal Nutsp. 393

Electric Motor Testsp. 394

Figure 7-107: Motor Circuitsp. 394

Motor Typesp. 394

Open Circuit Motor Testp. 394

Grounded Motor Testp. 395

Short Circuited Armature or Field Windingp. 396

Drive Motorp. 398

Electric Steering Motorp. 398

Lift Motorp. 399

Figure 7-108: Lift Motor, Series DZ-Ap. 399

Lift Motor – Series EZ-A/ES/ET/EF/DZ-A/DS/DTp. 399

Testingp. 399

Removalp. 399

Figure 7-109: Lift Motor Fan, Series EZ-Ap. 400

Installationp. 400

Lift Motor – Series EZ-B/DZ-Bp. 402

Figure 7-110: Control Handle Removalp. 402

Testingp. 402

Figure 7-111: Terminal Strip TS8 Location, Series EZ-Bp. 402

Removalp. 402

Figure 7-112: Hydraulic Filler Bracket, Attached Componentsp. 403

Figure 7-113: Lift Motor/Pump and Steering Motor/Pumpp. 403

Figure 7-114: Lift Pump, Accessing Lower Mounting Boltp. 403

Figure 7-115: Lift Motor Temperature Sensor and Connectorp. 404

Figure 7-116: Hydraulic Filler Bracket, Attached Componentsp. 404

Installationp. 404

Auxiliary Motorp. 407

Figure 7-117: Aux Motor, Series DZ-Ap. 407

Auxiliary Motor, Series ES/ET/EZ-A/DS/DT/DZ-Ap. 407

Testingp. 407

Removalp. 407

Figure 7-118: Aux Motor, Series EZ-Ap. 407

Installationp. 408

Figure 7-119: Auxiliary Pump and Motor Couplingp. 408

Auxiliary Motor, Series EZ-B/DZ-Bp. 409

Figure 7-120: Auxiliary Motor, Series EZ-Bp. 409

Testingp. 409

Removalp. 409

Figure 7-121: Auxiliary Pump and Motor Couplingp. 410

Installationp. 410

Contactorsp. 411

Figure 7-122: Contactor location, 3-motor, non-cold storagep. 411

Contactor Removalp. 411

Contactor Installationp. 411

Figure 7-123: Contactor location, 4-motor, cold storagep. 411

Figure 7-124: Contactor / Fuse Panel Layout, 4-motor, Non-Cold Storagep. 412

Figure 7-125: Contactor / Fuse Panel Layout, 4-motor, Cold Storagep. 412

Figure 7-126: Contactor / Fuse Panel Layout, 3-motor, Non-Cold Storagep. 413

Figure 7-127: Contactor / Fuse Panel Layout, 3-motor, Cold-Storagep. 413

Contactor Tip Replacementp. 414

Inspectionp. 414

Figure 7-128: Severely Pitted Contactor Tipsp. 414

Figure 7-129: Contactorp. 414

Contactor Tip Kitp. 414

Removalp. 415

Figure 7-130: Contactorp. 415

Figure 7-131: Contactorp. 415

Replacementp. 415

Figure 7-132: Contactorp. 416

Figure 7-133: Power Panel Temperature Sensorp. 417

Temperature Sensorp. 417

Removalp. 417

Figure 7-134: Drive Motor Temperature Sensorp. 417

Figure 7-135: Lift Motor Temperature Sensor, EZ-B/DZ-Bp. 417

Installationp. 417

Figure 7-136: Lift Motor Temperature Sensor, DZ-Ap. 418

Fusesp. 419

Test/Inspectionp. 419

Fuse Locator Chartp. 419

Figure 7-137: Mechanical Horn and Suppressor, Series ETp. 421

Horn Componentsp. 421

Horn and Suppressor Removalp. 421

Figure 7-138: Mechanical Horn and Suppressor, Series DZp. 421

Horn and Suppressor Installationp. 421

Figure 7-139: Electronic Horn and Suppressor, Series EZp. 422

Horn Suppressor Module Retrofitp. 422

Horn Relay (K2) Removalp. 423

Figure 7-140: Horn Relay location on system cardp. 423

Horn Relay (K2) Installationp. 423

Static Strapp. 424

Figure 7-141: Static Strap location on undersidep. 424

Inspection, Removal, Installationp. 424

Cold Storage Componentsp. 425

Figure 7-142: Control Panel Cover Heaters and Thermostatsp. 425

Control Panel & Control Panel Cover Heaters and Thermostatsp. 425

Removalp. 425

Figure 7-143: Control Panel Heater and Thermostatsp. 425

Installationp. 425

Control Handle Heaterp. 426

Figure 7-144: Cold Storage Heater Fuse locationsp. 426

Power Panel (Traction) Heatsinkp. 427

Removalp. 427

Figure 7-145: Power Panel (Traction) Heatsink locationp. 427

Installationp. 428

Figure 7-146: Power Panel (Traction) Heatsink componentsp. 428

Power Transistor (Q1)p. 429

Figure 7-147: Main Power Transistor Q1 on Power Panelp. 429

Removalp. 429

Installationp. 429

Testingp. 430

Figure 7-148: Q1 Power Transistor Connectionsp. 430

Figure 7-149: Regen Assembly locationp. 432

Regen Assemblyp. 432

Removalp. 432

Installationp. 432

Rectifiersp. 434

REC1, REC2, REC3p. 434

Figure 7-150: REC1, REC2, and REC3p. 434

Removalp. 434

Installationp. 434

Testingp. 435

Snubber Resistor R2p. 437

Figure 7-151: Snubber Resistor R2 location on Power Panelp. 437

Testingp. 437

Figure 7-152: System Card Componentsp. 438

System Cardp. 438

Removalp. 438

Installationp. 439

VFC Cardp. 441

Removalp. 441

Figure 7-153: VFC Card Location on System Cardp. 441

Figure 7-154: VFC Card, Removedp. 442

Installationp. 442

Figure 7-155: Power Card Locationp. 443

Power Cardp. 443

Removalp. 443

Figure 7-156: Power Card Connectionsp. 443

Installationp. 444

Coil Driver Cardsp. 445

Removalp. 445

Figure 7-157: Coil Driver Boardsp. 445

Installationp. 445

Figure 7-158: 4-D Circuit Cardp. 446

4-D® Circuit Cardp. 446

Removalp. 446

Figure 7-159: 4-D Circuit Card Connectorsp. 446

Installationp. 446

Field Transistors TM1/TM2p. 448

Removalp. 448

Installationp. 448

Testing TM1/TM2p. 449

Figure 7-160: TM1/TM2 Field Transistor Connectionsp. 449

SMARTi® Modulep. 450

Removalp. 450

Installationp. 450

Operationp. 450

Line Filterp. 451

Figure 7-161: Line Filter, Series EZ-Bp. 451

Removalp. 451

Figure 7-162: Line Filter, Series DZ-Bp. 451

Installationp. 451

Figure 7-163: 4-D Caster Switch detailp. 452

Switch S61/S62 (4-D®Caster Wheel)p. 452

Removalp. 452

Figure 7-164: 4-D Caster Switches and Bracketp. 452

Replacementp. 452

4-D® Proximity Sensorp. 454

Figure 7-165: 4-D Proximity Sensor relative to Drive Motorp. 454

Removalp. 454

Figure 7-166: PS63 connection on 4-D Circuit Cardp. 454

Installation and Adjustmentp. 455

Figure 7-167: 4-D Proximity Sensor alignmentp. 456

Figure 7-168: 4-D Proximity Sensor and Harnessp. 456

4-D® Proximity Sensor Sensing Ringp. 457

Figure 7-169: 4-D Proximity Sensor Sensing Ring at Drive Motorp. 457

Removalp. 457

Figure 7-170: 4-D Proximity Sensor Sensing Ringp. 457

Replacementp. 457

Hydraulic Componentsp. 459

Hydraulic Fluid Replacementp. 460

Series EZ-Bp. 460

Draining the Systemp. 460

Figure 7-171: Auxiliary Motor Pressure Line at Manifoldp. 460

Refilling the Systemp. 461

Bleeding the Systemp. 462

Procedurep. 462

Figure 7-172: Bleed Screw, Side Lift Cylinderp. 462

Lift Pumpp. 464

Lift Pump – Series EZ-B/DZ-Bp. 464

Figure 7-173: Lift Pump Location, Series EZ-Bp. 464

Removalp. 464

Figure 7-174: Lift Pump, Series EZ-Bp. 464

Installationp. 465

Figure 7-175: Lift Pump, Accessing Lower Mounting Boltp. 465

Lift Pressure Adjustmentp. 466

Figure 7-176: Lift Pressure Test Port, Series EZ-B/DZ-Bp. 466

Figure 7-177: Lift Pressure Test Port, Series EZ-A/ES/ET/EF/DZ-A/DS/DTp. 466

Figure 7-178: Lift Pressure Relief Valve & Adjusting Screw, Series EZ-B/DZ-Bp. 467

Figure 7-179: Lift Pressure Relief Valve & Adjusting Screw, Series EZ-A/ES/ET/EF/DZ-A/DS/DTp. 467

Auxiliary Pumpp. 468

Aux Pump – Series EZ-B/DZ-Bp. 468

Figure 7-180: Auxiliary Pump, Series EZ-Bp. 468

Removalp. 468

Figure 7-181: Auxiliary Pump with Couplingp. 469

Installationp. 469

Figure 7-182: Auxiliary Pressure Adjustment Port, Series EZ-B/DZ-Bp. 470

Auxiliary System Pressure Adjustmentp. 470

Figure 7-183: Auxiliary Pressure Adjustment Port, Series DZ-A shownp. 470

Figure 7-184: Aux Pressure Adjustment Screw, Series EZ-Bp. 471

Steering Pumpp. 472

Figure 7-185: Control Handle Removalp. 472

Steering Pump – Series EZ-B/DZ-B Onlyp. 472

Removalp. 472

Figure 7-186: Steering Pumpp. 472

Figure 7-187: Steering Pump with Couplingp. 473

Installationp. 473

Steering Pressure Adjustmentp. 474

Figure 7-188: Steering Pressure Adjustment Portp. 474

Series EZ-B/DZ-B Onlyp. 474

Figure 7-189: Steering Pressure Test Port, Series EZ-Bp. 474

Manifold, Mainp. 476

Figure 7-190: Manifold Layout, Series EZ-A/ES/ET/EF/DS/DT, Top View (Dual Lift Pump shown)p. 476

Figure 7-191: Manifold Layout, Series EZ-A/ES/ET/EF/DS/DT, Side View (Dual Lift Pump shown)p. 476

Figure 7-192: Main Manifold, Single Pumpp. 477

Main Manifold – Series EZ-A/ES/ET/DS/DTp. 477

Removalp. 477

Figure 7-193: Main Manifold, Dual Pumpp. 477

Installationp. 478

Main Manifold – Series EZ-B/DZ-Bp. 480

Figure 7-194: Manifold Layout, Series EZ-B/DZ-B, Top Viewp. 480

Figure 7-195: Manifold Layout, Series EZ-B/DZ-B, Side Viewp. 480

Figure 7-196: Hydraulic Manifold, Series EZ-Bp. 481

Removalp. 481

Figure 7-197: Lift Pump and Pressure Hosesp. 482

Figure 7-198: Solenoid, Typical, Coil Removedp. 482

Installationp. 482

Manifold, Reachp. 484

Figure 7-199: Reach Manifoldp. 484

Removalp. 484

Installationp. 484

Manifold, Tilt/Sideshiftp. 485

Figure 7-200: Tilt/Sideshift Manifold Tractor Side (Tilt Manifold Shown)p. 485

Removalp. 485

Figure 7-201: Tilt/Sideshift Manifold Forks Sidep. 485

Installationp. 485

Solenoids (General)p. 486

Figure 7-202: Solenoid Removal, Typicalp. 486

Removalp. 486

Installationp. 486

Figure 7-203: Solenoid Valve and Coil, Typicalp. 486

Hydraulic Solenoidp. 487

Solenoid – Series EZ-Bp. 487

Figure 7-204: Solenoid, Typical, Coil Removedp. 487

Removalp. 487

Installationp. 488

Hydraulic Componentsp. 489

Adjustment (Proportional Valve)p. 489

Hydraulic Componentsp. 491

Solenoid, 4-D Caster Wheel Positionerp. 491

Figure 7-205: 4-D Wheel Positioner Solenoidp. 491

Removalp. 491

Figure 7-206: 4-D Caster Wheel Positioner Solenoid Locationp. 491

Replacementp. 492

Pressure Transducerp. 493

Diagnosing Failuresp. 493

Figure 7-207: Connector PS-6 at System Cardp. 494

Figure 7-208: Pressure Transducer, Series EZ-Bp. 494

Removalp. 494

Figure 7-209: Pressure Transducer, Series EZ-Ap. 495

Installationp. 495

Pressure Switch, HTIp. 496

Hydraulic Componentsp. 497

Lift Cylindersp. 497

Figure 7-210: Lift Cylinder, Back Cylinder, exploded viewp. 498

Figure 7-211: Lift Cylinder, Front Cluster, exploded view (Part 1 of 2)p. 499

Figure 7-212: Lift Cylinder, Front Cluster, exploded view (Part 2 of 2)p. 500

Lift Cylinder, Front Clusterp. 501

Removalp. 501

Installationp. 502

Lift Cylinder, Back Cylinder, Threaded Anchor Retentionp. 504

Figure 7-213: Reach carriage removedp. 504

Removalp. 504

Installationp. 505

Figure 7-214: Anchoring lift cylinderp. 505

Figure 7-215: Blocking telescopicsp. 506

Adjustmentp. 506

Figure 7-216: Checking pivot support platep. 506

Figure 7-217: Blocking inner telescopicp. 507

Lift Cylinder, Back Cylinder, Spiral Ring Retentionp. 508

Spiral Ring Inspectionp. 508

Hydraulic Componentsp. 509

Lift Cylinder, Back Cylinder, Spiral Ring Retentionp. 509

Figure 7-218: Spiral Ring, Windingp. 509

Figure 7-219: Spiral Ring, Seatedp. 509

Cylinder Removalp. 512

Lift Cylinder, Back Cylinder, Spiral Ring Retentionp. 513

Cylinder Installationp. 513

Lift Cylinder, Side Cylinder Seal Repackingp. 516

Removalp. 516

Repacking and Assemblyp. 517

Figure 7-220: Cylinder Seal Installation Guide & Driverp. 517

Lift Cylinder Front and Back Cylinder Seal Repackingp. 519

Removalp. 519

Repacking and Assemblyp. 520

Figure 7-221: Cylinder Seal Installation Guide & Driverp. 520

Lift Cylinder Lowering Cushionp. 521

Removalp. 521

Installationp. 522

Flow Controlp. 523

Removalp. 523

Figure 7-222: Flow Control, Blockingp. 523

Installationp. 524

Reach Cylinderp. 525

Adjustmentp. 525

Figure 7-223: Blocking Carriagep. 525

Removalp. 525

Figure 7-224: Reach Cylinder Hydraulic Hosesp. 525

Figure 7-225: Reach Cylinder Yoke Attachmentp. 526

Figure 7-226: Reach Cylinder Housing Attachmentp. 526

Disassemblyp. 526

Figure 7-227: Removing External Lock Ringp. 526

Figure 7-228: Reach Cylinder Disassemblyp. 527

Reassemblyp. 527

Figure 7-229: Deep-Reach® Cylinder Disassemblyp. 528

Installationp. 529

Figure 7-230: Blocking the Reach Carriagep. 530

Tilt Cylinderp. 530

Removalp. 530

Figure 7-231: Tilt Cylinder Hoses and Yokesp. 530

Figure 7-232: Tilt Cylinder Snap Ringp. 530

Figure 7-233: Tilt Cylinder Piston and Connecting Pinp. 531

Installationp. 531

Figure 7-234: Tilt Cylinder, Disassemblyp. 532

Disassemblyp. 532

Reassemblyp. 532

Sideshift Cylinderp. 534

Cascade Sideshift Cylinderp. 534

Removalp. 534

Figure 7-235: Cascade Sideshift Cylinderp. 534

Installationp. 534

Figure 7-236: Sideshift Cylinder, Clampedp. 535

Disassemblyp. 535

Figure 7-237: Sideshift Cylinder Retaining Ring Removalp. 535

Figure 7-238: Sideshift Cylinder, Piston Removalp. 536

Figure 7-239: Sideshift Cylinder, Seal Removalp. 536

Figure 7-240: Sideshift Cylinder, Cross Sectionp. 537

Reassemblyp. 537

Bolzoni Sideshift Cylinderp. 538

Removalp. 538

Installationp. 538

Disassembly/Reassemblyp. 539

Figure 7-241: Bolzoni Sideshift Assemblyp. 540

4-D® Caster Wheel Positioner Cylinderp. 541

Figure 7-242: 4-D Caster Positioner Cylinderp. 541

Removalp. 541

Replacementp. 542

Mast, Chain, Hose and Cablep. 543

Mast Typesp. 544

Figure 7-243: Blocking Inner and Outer Telescopicsp. 545

Over-the-Mast Hose/Cablep. 545

Removalp. 545

Figure 7-244: Blocking Reach Carriagep. 545

Figure 7-245: Over-the-Mast Hose/Cable Retaining Screwsp. 545

Figure 7-246: Over-the-Mast Hose connections (reach)p. 546

Installationp. 546

Adjustmentp. 547

Figure 7-247: Hose and Cable Tension Adjustmentp. 547

Mast Bearing Shimmingp. 549

Generalp. 549

Figure 7-248: Blocking Mastp. 549

Main Mast Upper Bearing Shimmingp. 549

Figure 7-249: Upper Mast Bearing, Outer Telescopicp. 550

Figure 7-250: Upper Mast Bearing, Main Mastp. 551

Complete Mast Shimmingp. 551

Objective of Mast Shimmingp. 551

This section describes procedures for:p. 552

Mast Disassemblyp. 552

Figure 7-251: Mast Disassembly, securing hoses/cablep. 552

Shimming Main Frame to Outer Telescopicp. 553

Figure 7-252: Shimming Outer Telescopic Bearingp. 553

Shimming Outer Telescopic to Inner Telescopicp. 555

Figure 7-253: Shimming Inner Telescopic Bearingp. 555

Shimming Inner Telescopic to Carriagep. 557

Bearings, Reach Carriagep. 560

Figure 7-254: Reach Carriage Roller Bearingsp. 560

Removalp. 560

Installationp. 560

Bearings, Reach Half Shaftp. 561

Figure 7-255: Half Shaft Locationp. 561

Removalp. 561

Figure 7-256: Half Shaft Assemblyp. 561

Installationp. 561

Reach Carriage Assemblyp. 563

Figure 7-257: Blocking Reach Mechanism and Forksp. 563

Removalp. 563

Figure 7-258: Carriage Removal, Hoses, Cable, and Chainsp. 563

Figure 7-259: Carriage Removedp. 564

Installationp. 565

Reach Carriage Bumpersp. 567

Removalp. 567

Figure 7-260: Blocking Reach Mechanismp. 567

Figure 7-261: Reach Wear Stripp. 567

Installationp. 567

Reach Carriage Wear Stripsp. 568

Removalp. 568

Figure 7-262: Blocking Reach Mechanismp. 568

Figure 7-263: Reach Wear Stripp. 568

Installationp. 568

Forksp. 569

Figure 7-264: Fork Latchp. 569

Fork Position Adjustmentp. 569

Figure 7-265: Fork Wear Calipersp. 569

Fork Tip Height Adjustmentp. 569

Fork Inspectionp. 569

Figure 7-266: Fork Wear Inspectionp. 570

Figure 7-267: Fork Latch and Safety Boltp. 570

Removal (with Tilt and Sideshift)p. 570

Figure 7-268: Fork Removal (with Tilt and Sideshift)p. 570

Installation (with Tilt and Sideshift)p. 570

Figure 7-269: Fork Removal (with Tilt and no Sideshift)p. 571

Removal (with Tilt and no Sideshift)p. 571

Installation (with Tilt and no Sideshift)p. 571

Lift Chains, Mainp. 572

Generalp. 572

Adjustmentp. 572

Lubricationp. 573

Figure 7-270: Chain Anchor Nut lubricationp. 573

Defect-Cause Chartp. 574

Removalp. 575

Figure 7-271: Blocking Carriagep. 575

Installationp. 576

Reach Carriage Lift Chain Anchorsp. 578

Upper (Adjustable) Chain Anchorp. 578

Removalp. 578

Installationp. 578

Lower Chain Anchorsp. 579

Removalp. 579

Installationp. 579

Equalization Chainsp. 581

Adjustmentp. 581

Figure 7-272: Equalization Chain Adjustmentp. 581

Lubricationp. 582

Removalp. 583

Figure 7-273: Blocking Inner and Outer Telescopicsp. 583

Figure 7-274: Equalization Chain Adjuster Locknutp. 583

Figure 7-275: Equalization Chain Anchor Cap Screwsp. 584

Installationp. 584

Figure 7-276: Equalization Chain Sheave Access Plate (7/8 Inch or 18/20 cm mast)p. 585

Equalization Chain Sheavep. 585

7- or 8-Inch (18- or 20-cm) Deep Mast Uprightsp. 585

Removalp. 585

Figure 7-277: Equalization Chain Anchor Locknutp. 585

Figure 7-278: Equalization Chain Anchor Cap Screwsp. 586

Installationp. 586

9-Inch (23-cm) Deep Mast Uprightsp. 586

Removalp. 586

Installationp. 586

Carriage Bumpersp. 587

Removalp. 587

Installationp. 587

Mechanical Stops Adjustmentp. 588

Figure 7-279: Mast Bumper Adjustmentp. 588

Figure 7-280: Mast Stop Adjustmentp. 588

Fork Carriage Tilt Pinsp. 589

Removalp. 589

Figure 7-281: Fork Carriage Tilt Pinp. 589

Figure 7-282: Removing Tilt Pivot Pinp. 589

Installationp. 589

Figure 7-283: Baseleg undersidep. 590

4-D Caster: Wheels, Wheel Bearings, Thrust Bearing, Swivel Bearingp. 590

Figure 7-284: 4-D Caster and Cylinderp. 590

Disassemblyp. 590

Figure 7-285: 4-D Caster Wheel and Bearingsp. 592

Figure 7-286: 4-D Caster disassembledp. 592

Reassemblyp. 593

Mast Backlash Adjustmentp. 595

Adjustmentp. 595

Figure 7-287: Mast Backlash Bolt locationp. 595

Optionsp. 597

Cold Storage Requirementsp. 598

Componentsp. 598

Requiredp. 598

Not Permittedp. 598

Lubricantsp. 598

Sealing Treatmentp. 598

Corrosion Inhibitor Coatingp. 599

Fork Height-Tilt Indicator (HTI)p. 600

Fork Height Indicatorp. 600

Fork Tilt Indicatorp. 600

HTI Codes and Troubleshootingp. 601

Code E1p. 601

Code E2p. 602

HTI Active Maintenance Modep. 603

Figure 7-288: HTI Displayp. 603

Figure 7-289: HTI Active Maintenance Mode segmentsp. 604

Component Proceduresp. 605

Mast Locationsp. 605

Figure 7-290: Typical left side mast location (drawing shows view from forks toward mast)p. 606

Figure 7-291: Typical right side mast location (drawing shows view from forks toward mast)p. 607

Fork Height Indicatorp. 608

Cable Replacementp. 608

Figure 7-292: HTI Cable attachment (top)p. 608

Removalp. 608

Figure 7-293: HTI Cable attachment (bottom)p. 608

Installationp. 608

Figure 7-294: HTI Encoder Cable Pathp. 609

HTI Encoder Assemblyp. 610

Figure 7-295: HTI Encoder Assembly Installationp. 610

Removalp. 610

Installationp. 610

Figure 7-296: HTI Encoder Assemblyp. 610

HTI Display Cardp. 611

Figure 7-297: HTI Display Cardp. 611

Removalp. 611

Figure 7-298: HTI Display locationp. 612

Installationp. 612

Figure 7-299: HTI Display Cardp. 612

Calibrating and Setting the Height Indicatorp. 612

Figure 7-300: HTI Displayp. 613

Fork Tilt Indicatorp. 614

Fork Carriage Shimmingp. 614

Figure 7-301: Tilt Plates and Shims (one side visible)p. 614

HTI Pressure Switch (S31)p. 615

Figure 7-302: Pressure Switch location, 4-motor lift trucksp. 615

Removalp. 615

Figure 7-303: Pressure Switch location, 3-motor lift trucksp. 615

Installationp. 615

Adjustmentp. 616

Figure 7-304: Tilt Pressure Switchp. 616

HTI Theory of Operationp. 616

Fork Height Indicatorp. 616

Fork Tilt Indicatorp. 617

Electrical Schematicp. 618

Figure 7-305: HTI Electrical Schematicp. 618

Theory of Operationp. 619

Traction System Functional Operationp. 620

Overviewp. 620

Power Transistor Descriptionp. 620

Figure 8-1: Power Transistor Operationp. 620

Operation of the Travel Systemp. 621

Connecting Battery, Three-Motor Configurationp. 621

Figure 8-2: Connecting the Battery – Three-Motor (Sheet 1 of 2)p. 622

Figure 8-3: Connecting the Battery – Three-Motor (Sheet 2 of 2)p. 623

Connecting Battery, Four-Motor Configurationp. 624

Figure 8-4: Connecting the Battery – Four-Motor (Sheet 1 of 2)p. 625

Figure 8-5: Connecting the Battery – Four-Motor (Sheet 2 of 2)p. 626

Turning Key Switch (S1) ON, Three-Motor Configurationp. 627

Three-Motor Configurationp. 627

Figure 8-6: Turning the Key Switch (S1) ON – Three-Motor (Sheet 1 of 2)p. 628

Figure 8-7: Turning the Key Switch (S1) ON – Three-Motor (Sheet 2 of 2)p. 629

Turning Key Switch (S1) ON, Four-Motor Configurationp. 630

Four-Motor Configurationp. 630

Figure 8-8: Turning the Key Switch (S1) ON – Four-Motor (Sheet 1 of 2)p. 631

Figure 8-9: Turning the Key Switch (S1) ON – Four-Motor (Sheet 2 of 2)p. 632

Startup Sequencep. 633

SelfTest Checksp. 633

Closing Deadman Switch (S2)p. 634

Figure 8-10: Closing Deadman Switch (S2) – Three-Motor (Sheet 1 of 2)p. 635

Figure 8-11: Closing Deadman Switch (S2) – Three Motor (Sheet 2 of 2)p. 636

Requesting Travelp. 637

Figure 8-12: Drive Motor Encoder Phasesp. 638

Figure 8-13: Requesting Forward Travel – Three-Motor (Sheet 1 of 2)p. 639

Figure 8-14: Requesting Forward Travel – Three-Motor (Sheet 2 of 2)p. 640

Contactor Coilsp. 641

Figure 8-15: 24 Volt Contactor Coil Voltage Readingsp. 641

Closed Loop Speed Controlp. 642

Figure 8-16: Closed Loop Speed Control Functional Block Diagramp. 642

Torque On Demandp. 643

Figure 8-17: Torque On Demandp. 643

Thermal Cut-Backp. 644

Elevated Height Limitsp. 644

Current Limitingp. 645

Figure 8-18: Duty Cycle Comparison for Current Limitingp. 645

Requesting Travel: B Speedp. 646

Figure 8-19: “B” Speed (Bypass) Operation – Three-Motor (Sheet 1 of 2)p. 647

Figure 8-20: “B” Speed (Bypass) Operation – Three-Motor (Sheet 2 of 2)p. 648

Proportional Pluggingp. 650

Figure 8-21: Recirculation and Proportional Pluggingp. 651

Regenerative Brakingp. 652

Regenp. 652

Figure 8-22: Regenerative Braking – Q1 turned OFFp. 653

Figure 8-23: Regenerative Braking – Q2 turned ONp. 655

Drive Modep. 656

Figure 8-24: Regenerative Braking – Drive Modep. 657

Brake Systemp. 658

Braking Processp. 658

Steering Systemp. 660

Three-Motor Configurationp. 660

Figure 8-25: Hydraulic Schematic – Steering Theory, 3-motorp. 661

Four-Motor Configurationp. 662

Figure 8-26: Hydraulic Schematic – Steering Theory, 4-motorp. 663

Lift/Lower System Functional Operationp. 664

Liftp. 664

Variable Liftp. 664

Figure 8-27: Pulse Width Modulation duty cyclep. 664

Figure 8-28: Variable Lift – Hydraulicp. 665

Figure 8-29: Lift – System Card (Sheet 1 of 2)p. 666

Figure 8-30: Lift – System Card (Sheet 2 of 2)p. 667

High-Speed Lift (lift trucks with dual lift pump)p. 668

Figure 8-31: High Speed Lift – Hydraulicp. 669

Lowerp. 670

Figure 8-32: Pulse Width Modulation duty cyclep. 670

Figure 8-33: Variable Lower – Hydraulicp. 671

Figure 8-34: Lower – Three-Motor (Sheet 1 of 2)p. 672

Figure 8-35: Lower – Three-Motor (Sheet 2 of 2)p. 673

Remote Lift/Lower (Optional)p. 674

Figure 8-36: Electrical Schematic – Remote Lift/Lower (Optional)p. 675

Figure 8-37: Electrical Schematic – Remote Lift/Lower with Nested Switch (Optional)p. 675

Auxiliary Systemp. 677

Auxiliary Control Pin Numbersp. 677

Reachp. 678

Slow Speed Reachp. 678

High Speed Reachp. 678

Figure 8-38: Electrical Schematic – Reach (Sheet 1 of 2)p. 679

Figure 8-39: Electrical Schematic – Reach (Sheet 2 of 2)p. 680

Figure 8-40: Hydraulic Schematic – Reach, Three-Motor, slow speedp. 681

Figure 8-41: Hydraulic Schematic – High Speed Reach, Three-Motor, high speedp. 682

Sideshiftp. 683

Figure 8-42: Hydraulic Schematic – Sideshift, Three-Motorp. 684

Figure 8-43: Electrical Schematic – Sideshift (Sheet 1 of 2)p. 685

Figure 8-44: Electrical Schematic – Sideshift (Sheet 2 of 2)p. 686

Fork Tiltp. 687

Figure 8-45: Hydraulic Schematic – Fork Tilt, Three-Motorp. 688

Figure 8-46: Electrical Schematic – Fork Tilt (Sheet 1 of 2)p. 689

Figure 8-47: Electrical Schematic – Fork Tilt (Sheet 2 of 2)p. 690

4-D® Controlp. 691

Software Controlp. 691

4-D Caster Wheel Positionp. 691

Drive Wheel Positionp. 691

Caster Wheel Position at Vehicle Power-Upp. 691

Fore-Aft Travelp. 691

Sideways Travelp. 692

Considerations for Sideways Travelp. 692

Automatic Caster Wheel Positioningp. 692

Throttle Boostp. 693

No Regen for Sideways Travelp. 693

4-D® Speed Limitsp. 693

Hard Acceleration Settingp. 693

Travel Alarm Optionsp. 693

Auxiliary Systemp. 693

Sideshiftp. 693

4-D® Steeringp. 694

Figure 8-48: Electrical Schematic – 4-D Steering (Sheet 1 of 2)p. 695

Figure 8-49: Electrical Schematic – 4-D Steering (Sheet 2 of 2)p. 696

Figure 8-50: Schematic, Hydraulic, 4-D Steeringp. 697

Appendixp. 699

Lubrication Specification Chartp. 700

Figure A-1: Lubrication Specification Chartp. 700

Thread Adhesives, Sealants, and Lubricantsp. 701

Figure A-2: Thread Adhesives, Sealants, Lubricantsp. 701

Torque Chart – Standard (Ferrous)p. 703

Figure A-3: Torque Chart – Standardp. 703

Torque Chart – Metric (Ferrous)p. 704

Figure A-4: Torque Chart – Ferrous Metricp. 704

Figure A-5: Torque Chart – Brass Metricp. 704

Torque Chart – Standard (Brass)p. 705

Figure A-6: Torque Chart – Standard Brassp. 705

Decimal Equivalent Chartp. 706

Figure A-7: Decimal Equivalent Chartp. 706

Standard/Metric Conversionsp. 708

Figure A-8: Standard/Metric Conversion Chartp. 708

Electrical Schematicsp. 711

Figure A-9: Series ES/ET/EZ-A/DS/DT/DZ-A (Elec. Schematic, Sheet 1, Part 1 of 2)p. 712

Figure A-10: Series ES/ET/EZ-A/DS/DT/DZ-A (Elec. Schematic, Sheet 1, Part 2 of 2)p. 713

Figure A-11: Series EF (Elec. Schematic, Sheet 2, Part 1 of 2)p. 714

Figure A-12: Series EF (Elec. Schematic, Sheet 2, Part 2 of 2) Scale H=8.66 W=9.85p. 715

Figure A-13: Series EZ-B/DZ-B (Elec. Schematic, Sheet 1, Part 1 of 2) Scale =90%p. 716

Figure A-14: Series EZ-B/DZ-B (Elec. Schematic, Sheet 3, Part 2 of 2)Scale =90%p. 717

Figure A-15: Options (Elec. Schematic, Sheet 4, Part 1 of 3) Scale 125%p. 718

Figure A-16: Options (Elec. Schematic, Sheet 4, Part 2 of 3) Scale 95%p. 719

Figure A-17: Options (Elec. Schematic, Sheet 4, Part 3 of 3) Scale 95×95%p. 720

Figure A-18: Options (Elec. Schematic, Sheet 5, Part 1 of 3)W=6.75 H=8.25p. 721

Figure A-19: Options (Elec. Schematic, Sheet 5, Part 2 of 3) Scale W=6.75 H=8.25p. 722

Figure A-20: Options (Elec. Schematic, Sheet 5, Part 3 of 3) Scale W=6.75” H=8.25”p. 723

Figure A-21: Heater Options (Elec. Schematic, Sheet 6, Part 1 of 3)W=6.75 H=8.25p. 724

Figure A-22: Heater Options (Elec. Schematic, Sheet 6, Part 2 of 3) Scale W=6.75 H=8.25p. 725

Figure A-23: Heater Options (Elec. Schematic, Sheet 6, Part 3 of 3) Scale W=6.75” H=8.25”p. 726

Figure A-24: HTI Option (Elec. Schematic, Sheet 7, Part 1 of 2) Scale W=6.75” H=8.25”p. 727

Figure A-25: 4-D (Elec. Schematic, Sheet 7, Part 2 of 2) Scale W=6.75” H=8.25”p. 728

Figure A-26: Legend (Elec. Schematic, Sheet 8, Part 1 of 3) Scale W=6.75” H=8.25”p. 729

Figure A-27: Legend (Elec. Schematic, Sheet 5, Part 2 of 3) Scale W=6.75” H=8.25”p. 730

Figure A-28: Legend (Elec. Schematic, Sheet 5, Part 3 of 3) cale W=6.75” H=8.25”p. 731

Hydraulic Schematicsp. 733

Figure A-29: Hydraulic Schematic, Series ES/ET/EZ-A/DS/DT/DZ-BScale W=6.75” H=8.25”p. 734

Figure A-30: Hydraulic Schematic, Series EZ-B/DZ-BScale W=6.75” H=8.25”p. 735

Figure A-31: Hydraulic Schematic, Series EFle W=6.75” H=8.25”p. 736

Indexp. 737

Numericsp. 737

Ap. 737

Bp. 737

Cp. 737

Dp. 738

Ep. 738

Fp. 738

Gp. 739

Hp. 739

Ip. 739

Kp. 739

Lp. 739

Mp. 740

Op. 740

Pp. 740

Qp. 741

Rp. 741

Sp. 741

Tp. 742

Vp. 742

Wp. 743

Delivery

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Raymond EASi Reach-Fork Lift Truck Maintenance Manual PDMM-0080 – EZ ET ES DS DT EF DZ Series

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Raymond EASi Reach-Fork Lift Truck Maintenance Manual – PDMM-0080

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