Supplement - Dealer/Technician Configuration Program: User Instructions

CATERPILLAR® Reach Service Manual Appendix
Supplement - Dealer/Technician Configuration Program: User Instructions
7:
Supplement - Dealer/Technician
Configuration Program: User Instructions
Overview This supplement explains how to use the Dealer/Technician
Configuration Program. The Configuration Program is used to
configure and set specific vehicle parameters. This program runs on a
IBM or IBM compatible personal computer (PC), portable or desktop.
System The PC must meet the following requirements:

Requirements • MS-DOS 3.0 or higher
• 512KB memory (minimum RAM)
• 1 floppy disk drive (3 1/2 in. diskette); Hard Drive is optional
• 1 serial port (The serial port designation is COM1 - The serial
port connector must be a DB-9 or DB-25 pin female connector)
• Graphics card (CGA, EGA, or VGA)
Items Included in the The Configuration Package includes the following items:
Configuration Package
• 3 1/2 in. diskette
• 9-pin connector assembly (P/N 1069051)
• 25-pin connector assembly (P/N 1069052)
• Communication Adapter Module (P/N NA012780) (See Figure
7-1.)
• PC Com. Port Protector (P/N NA014936)
Figure 7-1: Communication Adapter Module (P/N NA012780)
PDMM-0057 7-3
Appendix CATERPILLAR® Reach Service Manual
Software Provided The Configuration Program is provided on a 3 1/2 in. floppy diskette.
This diskette contains the following file:
DCAT2P7.EXE - The executable Configuration Program.
Control Program The Configuration Program has two basic functions:

Function
• Change truck options
• Initialize MICRO COMMANDNA default parameters on new or
current VFC
Change Truck Option(s) To add or delete an truck option in the field, the Dealer/Technician
must contact Material Handling Associates for an authorization
number called a Pass-Key. Once the hardware of the option has been
installed, the Configuration Program must be executed and the new
Pass-Key number installed.
NOTE: The new Pass-Key is required in order to run the new option on
the truck.
Initialize MICRO The Configuration Program is capable of:

COMMANDNA Default
• Resetting the Vehicle Manager to factory default parameters
Parameters
When a new VFC is installed and initialized, the default run
parameters are stored into MICRO COMMANDNA memory. The default
parameters vary from model to model. Refer to Table 7-1 on page 6-14
and Table 7-2 on page 6-14 for specific default parameters by Model
or the Maintenance Instruction Manual for complete information.
Connecting PC Before the Configuration Program is run, install the communication

adapter (P/N NA012780) into connector JS5 on the Vehicle Manager
(For Orderpickers above S/N 2000).
1. Connect one end of the cable into the Communication Adapter
Module.
2. Plug the other end of the cable into the serial port of the PC which
has one of the connectors (provided) installed on the serial port of
the computer.
• 9-pin connector is P/N 1069051
• 25-pin connector is P/N 1069052
3. Turn the truck power ON.
7-4 PDMM-0057
Start-Up The user starts the Configuration Program by turning the PC power
ON or by entering “DCAT” directly at the DOS prompt of the PC.
If the PC has a black and white (monochrome) monitor, start the
Configuration Program using the following command:
dcat2p7 /b <Enter>
If a color monitor is used, the Configuration Program will
automatically determine the highest resolution available and adjust
the colors accordingly. The command to start the program with a color
monitor is:
dcat2p7 <Enter>
When started, the Configuration Program displays the Caterpillar Logo
and instructs the user to press the <Enter> key.
Figure 7-2: Opening Display

Pressing the Enter key causes the following events:
• Initialize MICRO COMMANDNA communications
• Start-up communications error
• MICRO COMMANDNA communications time-out
Initialize Once the Configuration Program is started, the program attempts to

MICRO COMMANDNA establish a communication link with the truck’s Vehicle Manager. If
Communications the link is successful, the PC Contactor will be de-energized (this
prevents truck movement) and the main screen will appear.
Start-up If the communication link is not successful, the following error

Communications Error message will appear and the program will stop.
PDMM-0057 7-5
Figure 7-3: Communication Error Screen

If this situation occurs:
1. Turn the truck power OFF.
2. Check all connections to ensure they are correct.
3. Reboot the PC and start the Configuration Program again.
4. If the problem can not be resolved, contact MHA.
Communications Time- The Vehicle Manager expects communications of some sort from the
out Configuration Program. Within 2 minutes, communication link
messages are continually sent to the Vehicle Manager from the PC.
These types of messages are sent automatically as long as the PC is
connected to the Vehicle Manager. This ensures that proper
communications are maintained during the configuration process.
This is necessary due to the Security Status of the truck during
communications.
If the Vehicle Manager does not receive a valid Configuration Program
command within the 2 minutes, the Vehicle Manager will terminate
communications and bring Truck Security back to normal operating
mode.
The communications error message is displayed if communications is
attempted with no response from the truck. Follow the procedure
listed for Start-up Communication Error and retry.
Configuration Status When communications is established between the Vehicle Manager

and the PC, the Configuration Program will ask the Vehicle Manager
for current status. See the following sections for status information.
Main Menu When communications is established and the current configuration is

received the following menu appears with CONFIGURATION
information.
7-6 PDMM-0057
Figure 7-4: Main Menu
Option List If you want to look at how the vehicle is currently configured, press
the F1 key. The Options screen appears as shown below.
Active options will have a check mark (Ö) to the left. Press any key to
continue.
Figure 7-5: Checking Current Selected Options using F1 Key
PDMM-0057 7-7
Choice Selection Two processes can be executed. One or both selections can be chosen.
Select one or both lines by using the UP/DOWN arrow keys. Press the
Enter key to select the highlighted line. When a function is selected, a
check mark (Ö) will appear to the right of that function. In the figure
below, “Change Truck Option(s)” has been selected.
Once the choices have been made, press the Esc key to start the
configuration process.
Figure 7-6: Selecting Function in Main Menu
7-8 PDMM-0057
MC2
Configuration
Information
Date of Manufacture This parameter holds the actual date that the vehicle was initialized in
Final Assembly at the factory. The date could also be the actual ship
date, depending on customer requirements.
Model Type Vehicles which currently use the Configuration Program are:
• Orderpickers and...
• Reach Trucks
The Model Types are represented as follows:
• Orderpickers are represented as “OPR”
• Reach Trucks are represented as “REA”
Drawbar-Drag/Speed This line will only appear for reach trucks. This is the maximum
calculated speed for a specific truck. This information is included in
the Pass-Key received from Material Handling Associates (MHA).
Serial Number The serial number is represented by the last 5 numbers of the actual
truck serial number. For example: L 12345 is a valid Orderpicker
serial number.
Truck Options This line displays currently installed options for this particular truck.
To view the current active options for the vehicle, press the F1 key.
MC2 Version Number This parameter holds the current MICRO COMMANDNA software
version number.
Deadman Hour Meter The Deadman Hour parameter accumulates time, in whole hours,
whenever the truck is ON and an operator is on the Deadman.
Change Truck To add or delete an option to a truck, the technician must have
Options contacted Material Handling Associates and requested a new Pass-
Key. Material Handling Associates (MHA) is responsible for generating
the new Pass-Key. Every truck produced will require a unique code.
To add or delete an option, a proper Field Installed Option Kit (FIOK)
inquiry must be processed by MHA. The new Pass-Key may be part of
the FIOK inquiry when the paper work is returned to the Dealer; if
not, the Pass-Key must be obtained by phone, fax, or mail.
Additional hardware for the option, if any, must be installed before
this procedure is followed.
To change an option, move the cursor until “Change Truck Option(s)”
is highlighted, then press the Enter key. If another line from the menu
is desired, use the UP/DOWN arrow keys to step through the list.
PDMM-0057 7-9
When all the desired items have been selected, press the Esc key. The
main menu will disappear and a line for the Pass-Key received from
the MHA appears. The Pass-Key should be entered exactly as received
from the Parts Division. There are exactly 28 characters to be entered.
Figure 7-7: Entering Vehicle Pass-Key

Characters 0-9 and A-F are valid; No other characters are allowed.
If the Pass-Key is incorrectly entered, you are allowed to correct the
mistake. Use the left/right arrow keys to position the cursor then
make the correction. Once the correct Pass-key is entered, press the
Enter key.
Pressing the Esc key at any point will exit the entry process and the
program will abort.
The following is an example of adding the sidegate power disconnect
option to an orderpicker. Battery state-of-charge with lift interrupt,
wire guidance, lift/lower limit switch with bypass, and lift/lower
without deadman are current active options. The Pass-Key numbers
received from MHA (either on the Sales Pricing Inquiry, phone call,
fax, or mail) appear as follows:
4BA0-221-630395A-02-082E0-000-4B80
Enter the Pass-Key into the PC exactly as received. When all 28
characters have been correctly entered, press the Enter key. The
Configuration Program makes the following checks:
• Valid Truck
• Valid Truck Information
• Valid Entry
Valid Truck A check is made to verify that the truck being reconfigured is in fact
the correct truck that is supposed to receive the update. This prevents
7-10 PDMM-0057
changes being made to the wrong truck. Part of the information of the
new Pass-Key is unique, even when a new Pass-Key is entered.
The old Pass-Key must match the current truck Pass-Key that is
stored in the Vehicle Manager. If the Pass-Keys do not match, an error
message is displayed.
Valid Truck Information The Truck Type, Date of Manufacture, and Serial Number are
embedded in the New Pass-Key. These can not be changed and must
be the same as the truck’s current information.
This is a redundant check to ensure this is the correct truck. If any of
these parameters do not match, an error message is displayed.
Valid Entry The final check verifies that the new Pass-Key calculates properly with
the information entered.
If the Pass-Key was entered incorrectly, an error message will be
displayed.
At this point any error is probably due to an entry error. Verify the
Pass-Key received from MHA. If the numbers have been entered
correctly and an error still occurs, contact MHA for help.
When the Configuration Program determines that the information
entered is correct, it begins to send commands to the Vehicle
Manager.
The following figures show the screens which appear when the
complete Pass-Key is entered and the result after pressing Enter.
Figure 7-8: Configuration Menu after Last Character is Entered But Before
Enter Key is Pressed.
PDMM-0057 7-11
Figure 7-9: Configuration Menu after Enter Key is Pressed
Verification You can verify that the option has been added. Press the F1 key to
display the Option List. A checkmark next to an option indicates that
the option has been successfully added to this vehicle.
Figure 7-10: Reviewing Option List after Adding Option
Invalid/Incorrect Pass- If the Pass-Key is entered incorrectly or is not the correct one for that
Key vehicle, a message will appear.
7-12 PDMM-0057
Figure 7-11: Display After an Incorrect Pass-Key is Entered
Initialize Default Selection of this function sends a command to the Vehicle Manager to
Parameters initialize the Vehicle Function Controller (VFC) to its factory default
values.
These parameters will NOT be reset as a result of initializing the
truck.
NOTE: The hour meters are NOT reset as a result of initializing the
truck.
Figure 7-12: Selecting Initialize
Orderpicker The factory default parameters for specific models are listed in
Table 7-1 on page 7-14 and Table 7-2 on page 7-14.
PDMM-0057 7-13
Parameter Factory Default Value

Drive NORMAL
Lift NORMAL
Speed MAXIMUM
Cutout 20%
BSOC 85%
User Password CAT1
SuperUser Password CAT2
Table 7-1: Factory Default Parameters: Performance Orderpicker
Reach Truck
Parameter Factory Default Value
User Password CAT1
SuperUser Password CAT2
Electronic Key 3
Table 7-2: Factory Default Parameters: Reach Truck
The following figure shows the screen after the Configuration Program
has completed initializing the Vehicle Manager to the factory default
values.
Figure 7-13: Vehicle Manager Initialized to Factory Default Values
Lost If communication is successful, the Configuration Program is exited in

Communications a normal manner and control is passed to DOS. If any error
communicating to the Vehicle Manager is detected, an error message
will be displayed.
7-14 PDMM-0057
Figure 7-14: Communication Error Screen

NOTE: Any error communicating to the Vehicle Manager will cause the
Configuration Program to stop. The truck power must be
recycled and the Configuration Program restarted.
Connector Wiring The diagram below Figure 7-15: shows the proper assembly of both
the 9-pin and 25-pin connectors. Both connectors MUST be female in
order to mate with the COM port on your PC. No other style connector
will work!
PDMM-0057 7-15
Figure 7-15: Connector Wiring
7-16 PDMM-0057
DCAT Problem Report Figure 7-16: Below is a sample Dealer/Technician Configurative

(DCAT) Problem Report form.
Dealer/Technician Configurative (DCAT)

Problem Report
SPR No.: _______
Customer Name: _______________________________

Location: _______________________________
Contact: _______________________________
Phone: _______________________________
Dealer Name: _______________________________

Submitted By: _______________________________
Date: _______________________________
Phone: _______________________________
DCAT Software Version No.: _______________________________
Truck Information:
Model: ________________________________
Serial Number: ________________________________
Date of Manufacture: ________________________________
Options (DCAT List): ________________________________
Problem Description:
Description
_________________________________________________________________________________
_________________________________________________________________________________
__________________________________________________________________________________
Disposition:
Authorization: _____________________ Date: __________
Return to Material Handling Associates
Figure 7-16: Problem Report
PDMM-0057 7-17
Lubrication Equivalency Chart
7:
Lubrication Equivalency Chart

LUBRICATION EQUIVALENCY CHART
Lube P/N TEXACO CITGO EXXON PHILLIPS GULF SHELL CHEVRON SOHIO MOBIL
*LUBE ’A’ Hyd. Univis J13
Reservoir Oil for Aircraft Hyd Aeroshell Aviation Hydrau-
Cold Storage similar to
Oil 15 Mil-H- Fluid 4 Mil- lic Fluid A Mil-H-
Mil-H-
(+40o -20o F) 5606B H-5606A 5606A
applicaions. 5606A.
**LUBE
’A’(1056009)
Hyd. Reservoir
Oil for Cold HD AZ 32 Tellus T Oil
Storage In & 1627 Rando 32
Out (20o to 70o
) applicaion.
LUBE ’B’ Hyd.
Reservoir Oil for
extreme heat- AW-MV 423 or 424
ing conditions
See Note 3.
LUBE ’B’
(8T9578) Hyd. Pacemaker
Reservoir Oil for Rando Oil HD
XD-20
46 Hydraulic Harmony Tellus T Oil-
Standard (+50o Hydraulic Nuto H46 Magnus A, 315 DTE-15
Oil Mil-H- 46-AW 46
- 120o F) appli- 17672B
Oil Mil-H-
cations. See 460001B.
note 1.
LUBE ’C’ Drive
Unit gear Case
for below 30o F. Shell Rotella
C-6 10W-30 Exxon Extra Trop-Artic All Gulflube Multron Delvac Spe-
Pump Motors T Oil 15W- Delcco 400 Motor
URSATEX Motor Oil Motor Oil Season Motor Oil Motor Oil 10W-30 Mil- cial 10W-30
w/oil cup, foot 40 API Ser- Oil 15W-40 API
pedal, lift 10W-30 2166 Mil-H- 10W-30 API 10W-40 Mil-L- X.H.D. L-46152 API API Service
vice SE CC Service SE
chains, etc. for 46152. Service SE 46152 10W-30 Service SE SE
and CD
above and below
30oF.
LUBE ’D’ Drive Multi-
Unit Gear case Multigear Premium Philube SMP purpose
Gear Oil GX Spirax HD- Universal Gear
for above 30oF Lubricant EP Gear Oil Gear Oil SAE Gear Mobilube
80W-90 Mil- 85W-90 Mil- Lubricant 80W- Gear EP 90
85W-90 Mil-L- MP90 Mil-L- 80W-90 Mil-L- Lubri- HD 80W-90.
L-2105B L-2105B 90 Mil-L-2105B
2105B 2105B 2105C cant
80W-90
LUBE ’E’ Drive
Unit and Caster
swivel, caster
spring rod piv-
ots, steer gear Regal AFB 2
box, load HEP2 (above RONEX MP Philube 1B and Gulfcrow Alvania Avi-Motive Bearing Mobil
wheels, Grease Mil-G- or UNIREX n Grease
30oF only) N2 RB Grease Grease EP2 Grease Guard "LT" Grease 77
uprights, reach 18709A No. 2
arms, caster
wheel bearings,
etc., (above and
below 30o F).
FLUID ’G’ (990-
625) Brake
Fluid SAE. (SAE
J-17-03F type
Dow Corning Silicone or Equivalent
70R-3 or
exceed). Do not
use anything
less than DOT5.
LUBE ’H’ AGMA Honor Cyl. Oil Cylesstic Senet Valvata J- Super Cyl.
#8 See Note 2. 680 Hector 630S Cyl. Oil 680X
TK-680 186 680 600W
LUBE ’J’ Cold
Temperature SHC626
Synthetic Oil
30oF to 85oF
NOTE 1: Agway UF Hyd. Fluid is also UPDATED
approved. *CLASS I ** CLASS II NOTE 2: Fisk Brother’s Lubriplate CP-8 gear oil is also approved.
1/30/95
NOTE 3: NOCO Torque TDH is also approved.
Table 7-3: Lubrication Equivalency Chart
PDMM-0057 7-19
Standard Torque Data For Bolts

Grade Identification
None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts

Tightening Torque Tightening Torque Tightening Torque
Size
Dry Oiled* Dry Oiled* Dry Oiled*
in. lbs. in. lbs. in. lbs. in. lbs. in. lbs. in. lbs.
4-40 5 4 8 6 12 9
4-48 6 5 9 7 13 10
6-32 10 8 16 12 23 17
8-32 19 14 30 22 41 31
8-36 20 15 31 23 43 32
10-24 27 21 43 32 60 45
10-32 31 23 49 38 68 51
1/4-20 66 49 96 75 144 108
1/4-28 76 56 120 86 168 120
ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs.
5/16-18 11 8 17 13 25 18
5/16-24 12 9 19 14 25 20
3/8-16 20 15 30 23 45 35
3/8-24 23 17 35 25 50 35
7/16-14 30 24 50 35 70 55
7/16-20 35 25 55 40 80 60
1/2-13 50 35 75 55 110 80
1/2-20 55 40 90 65 120 90
9/16-12 70 55 110 80 150 110
9/16-18 80 60 120 90 170 130
5/8-11 100 75 150 110 220 170
5/8-18 110 85 170 130 240 180
3/4-10 175 130 260 200 380 280
3/4-16 195 145 300 220 420 320
7/8-9 165 125 430 320 600 460
7/8-14 185 140 470 350 660 500
1-8 250 190 640 480 900 680
1-12 270 200 700 530 1000 740
1 1/8-7 350 270 800 600 1280 960
1 1/8-12 400 300 880 660 1440 1080
1 1/4-7 500 380 1120 840 1820 1360
1 1/4-12 550 420 1240 920 2000 1500
1 3/8-6 660 490 1460 1100 2380 1780
1 3/8-12 740 560 1680 1260 2720 2040
1 1/2-6 870 650 1940 1460 3160 2360
1 1/2-12 980 730 2200 1640 3560 2660
Table 7-4: Standard (Ferrous) Torque Data for Bolts

*NOTE: Use “oiled” values for bolts with thread-locking compound
7-20 PDMM-0057
Ferrous Metric Bolts, Coarse Thread

(The grade rating is stamped on the head of the bolt.)
Grade 8.8 Grade 10.9
Diameter
Torque (with bolts oiled*) Torque (with bolts oiled*)
(in millimeters)
Newton-meters Foot-pounds Newton-meters Foot-pounds
6 8.6 6 12 9
8 21 15 29 21
10 42 30 68 43
12 72 55 101 75
16 174 130 245 181
20 340 255 475 350
24 580 435 820 605
Table 7-5: Torque Data for Ferrous Metric Bolts

Brass MS63 Metric Bolts, Coarse Thread
Diameter Torque (with bolts oiled*)

(in millimeters) Newton-meters Inch-pounds
3 0.5 4.4
3.5 0.79 7
4 1.2 10.6
5 2.2 19.4
6 3.9 34.5
8 9 79.6
10 17 150
Table 7-6: Torque Data for Brass Metric Bolts

PDMM-0057 7-21
Conversion Table
Conversion
Table To Convert... Multiply by...
Inches to Millimeters 25.4
Inches to Centimeters 2.54
Feet to Meters 0.305
Yards to meters 0.914
Miles to Kilometers 1.609
Millimeters to Inches 0.039

Centimeters to Inches 0.394
Meters to Feet 3.281
Meters to Yards 1.094
Kilometers to Miles 0.621
Square inches to Square Centimeters 6.452
Square Feet to Square Meters 0.093
Square Yards to Square Meters 0.836
Square Centimeters to Square Inches 0.155

Square Meters to Square Feet 10.155
Square Meters to Square Yards 1.196
Fahrenheit to Celsius
(oF - 32)
1.8
Celcius to Fahrenheit
(oC X 1.8) +32
Gallons to Liters 3.785

PSI to KPa 6.894
Table 7-7: Conversion Table
7-22 PDMM-0057
Decimal Equivalent Chart

MM
4ths 8ths 16ths 32nds 64ths To 3 Places To 2 Places
Equivalent
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
Table 7-8: Decimal Equivalent Chart
PDMM-0057 7-23
(Continuation)
4ths 8ths 16ths 32nds 64ths To 3 Places To 2 Places MM Equiv.
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
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
Table 7-9: Decimal Equivalent Chart (cont.)
7-24 PDMM-0057
Electrical & Hydraulic Schematics

7: Appendix
Electrical & Hydraulic Schematics
PDMM-0057 7-25
A B C D
JPI- JPS8-
1 5
4 CONTROL LATCH
2
2 PC FU5 OPERATOR
3
4
3
2
MEMORY ENABLE
DATA LATCH
DATA IN
DISPLAY 6 9
DISPLAY
350A TP2 SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
FU8 10 SHIELD
150A 1 L1 2
TP7
JPD1- JPH1- JPH2- JPS2-

FW-B+
H-BRIDGE CONTROL
10 1 5 5
FIELD T1 REVERSE
11 2 4 4
1 WIRING FW-B- FIELD CURRENT
(FW) 12 3 2 2
S1 T3 FIELD CURRENT LIMIT
P FW-2 4 4 H-BRIDGE 1 1
A2 FW-B+ FORWARD
9 5 CONTROL 8 8
2 T2 FIELD PWM
MODULE
7 6 MODULE 7 7
FU6 MD CR1 5 7
FW-2 (HCM) 6 6
PGND
3 450A
TP3 A1 S2 FW-1
T5
3
1
8
9
+12
T4
9
+12V
PGND
FW-1
6 10
FW-B- LOOP
2 11
T1 I-LIMIT
T2 T3 T4
JP
B+
S
JPS12-
5
B1 B2 B1 B2 4 B-
S B+
3
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4 7
PGND
8
PGND
JP 2
B-
RESISTOR ASSEMBLY
JPT1-
4 B+KEY
4 CHOPPER
CONTROL
MODULE
JPT2-
4
JPS1-
4
ARM CURRENT
CHOPPER CONTROL
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT LIMIT
TP6 SENSOR 1 1
TP5 CHOPPER ENABLE
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMPERATURE
8 8
B CHOPPER PWM
MODULE
e 8 7 7
C1 B-DRIVE PGND
6 6
+12V
5
E 2 PGND
TP4 HT E-DRIVE
T˚
JPF4- 3
HEATSINK
E
B+KEY
JPF3- JPS10-
JPF2- 8 8
14 PC-CONTACTOR
B-PC 7 7
B-CONTACTOR
6 6
5 13
11
B-
B+PC
B-PC
FU1
B-PCF
5
4
5
4
P-CONTACTOR
1S-CONTACTOR
+12V
3 3
B+KEY
2 2
POWER PANEL
FU2 B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
DRIVER
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
X Y
1
P P CNTR
6 B+ B+
B+ F1
FILT FILT 4
F2 F1 PC
2
2
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
Figure 7-17: Electrical Schematic 24V, Single Filter (Sheet 1 of 8)
7-26 PDMM-0057
E F G H
JPS4- JPC1-
9 9
+12V 14 14
THROTTLE VR1
AGND
11 11
CONTROL HANDLE
2
15 15 S20
LIFT
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
GND
VEHICLE 2 2
MANAGER HORN S3
DIRB SOL
9
DIRB
CONTROL HANDLE
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
3 3 7
SSHIFT RIGHT S9 EQ SOL EQ
10 10
AGND 1 2
SHIELD
B+KEY
3
3
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
DRIVER
ASSEMBLY
(HDA)
4
JPN10- JPM-
3 1 T˚
JPS9- JPN14- REACH PGND
ON
DT
13 13 2 2 MD
+12V TRAC TEMP
12 12
PGND JPN11-
11 11
DEADMAN
10 10 S/S 3
2ND EN
9 9
EQ EN 2
8 8
HORN EN
DIRB EN
7
6
7
6
TILT
S/S EN JPN9-
5 5
UNNESTED 3
4 4
REMOTE 2
MASTSW2
3 3 DIRB 1
2 2
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25 1 2
PRESSURE DIRA 1
24 24 B+KEY
TRAC TEMP 2
23 23 B+F
LIFT TEMP 4
22 22 REMOTE
SPARE 1
DIRA EN
21
20
21
20 EQ 5
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
REACH EN
17
16
17
16
2ND TS21- RED
REMOTE EPO
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
SOL 8
B+ FILTERED
2 GREEN 2 GREEN 2 SIDE 1

SIDESHIFT SOL
SHIFT
AGND
+5.3V
+12V
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
1 2 3 4 5 6 4 ORANGE 4
JPP1- REMOTE EPO
6 BLUE 6 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
E F G H
PDMM-0057 7-27
A B C D
STANDARD MAST SPEED LIMIT SWITCH LIFT INHIBIT WITH BYPASS

2 JPN7- JPN13- S12 *
S10
1 COM NC 1
MASTSW1 INHBTBYP
HYDRAULIC HYDRAULIC
DRIVER 2 2
+12V DRIVER B-PCF
ASSEMBLY ASSEMBLY
3 JPN12-
(HDA) B-PCF (HDA) S13
1 COM NC
LIFT INHBT
*MAST IN FULLY LOWERED POSITION 2
+12V
3
B-PCF
3 OTHER THAN STANDARD MAST SPEED LIMIT SWITCH

*REMOVE S12 TO ELIMINATE BYPASS CAPABILITY
JPN8-
S11
1 COM NC
MASTSW2
HYDRAULIC
DRIVER 2
+12V
ASSEMBLY
(HDA) 3
B-PCF
*MAST IN FULLY LOWERED POSITION

4
STROBE OR WARNING LIGHT
JPN2- WL
1 FU9
+ -
B+PCF
HYDRAULIC JP201-1
DRIVER SPL-2
BLACK
ASSEMBLY
2
(HDA) B-PCF
JP201-2
WHITE
5
WORKING LIGHTS AND OR FAN LIGHT
JP204B-2
WHITE
HYDRAULIC LIGHT
DRIVER JPN3-
ASSEMBLY
1
(HDA) B+KEY JP204A-2
6 JP204B-1 JP204A-1 WHITE
BLACK BLACK FAN
2 FU11
B+PCF
SPL-3 JP203-1 JP206-1 JP206-2
BLACK BLACK WHITE
3
B-PCF
JP203-2
WHITE
7 NOTE:
SPECIAL WIRING REQUIRED WHEN USED WITH KEYED AUX. POWER
A B C D
Figure 7-17: Electrical Schematic 24V, Single Filter (Sheet 3 of 8
7-28 PDMM-0057
E F G H
ACCESSORY ACCESSORY
POWER FUSED POWER FUSED
10 AMPS 10 AMPS
2
B-
TS8 B+ B-
TS8 B+
2 1 2 1
SPL-12
SPL-12
FU12
FU12
3
JPN3-1 JPN3-3 TP4 PC-1
WITH KEY ON WITH BATTERY
NOTE:
KEYED AUX POWER REQUIRES SPECIAL WIRING
WHEN USED WITH WORKING LIGHTS AND OR FAN
AUX. POWER FUNCTIONS
NESTED SWITCH 4
TS19- S19
HYDRAULIC TS21-4
DRIVER 4 WHITE COM NC
ASSEMBLY REMOTE EPO
(HDA) 6 TS21-6
BLACK
B-PCF
*REACH CARRIAGE IN RETRACTED (NESTED) POSITION

REMOVE WIRE FROM JPN5-1 TO JPF1-1 5
TRAVEL ALARM AND OR LIGHT
LIGHT
DA1
+ -
JP202-1 JP202-2
JPS3- 5 4 BLACK WHITE
6 A SPL-1
OUTPUT#1 6
VEHICLE K1
MANAGER 7 *
OUTPUT#2 R5 ALARM
(VM) B 1 2
TZ1
4 7
TS19- +
5 FU10 NO COM
B+PCF -
HYDRAULIC
DRIVER 6
B-PCF
ASSEMBLY
(HDA)
7
*USE JPS3-7 TO K1- FOR FORWARD TRAVEL. USE JPS3-8 TO K1- FOR REVERSE TRAVEL. CONNECT BOTH JPS3-6 & JPS3-7 FOR ALL TRAVEL.
E F G H
PDMM-0057 7-29
A B C D
REMOTE LIFT/LOWER
2
JPN4-
S1
1 2 2
1
B+KEY
2 4 NORMAL
B+F 1 2 POSITION
4
REMOTE 1 1 2
HYDRAULIC 3
DRIVER REMOTE*
1 2
ASSEMBLY POSITION
(HDA)
S16 S17
3 TS19- TS21-2
GREEN R3 LIFT
2 2 1 2 1
SIDESHIFT SOL
S14 S15
TS21-3
BLACK R2
3 2 1 2 1 LOWER
REACH SOL
TS21-4
RED S18
4 2 1
REMOTE EPO
5
B+KEY
6 TS21-6
B-PCF
4 WHITE
JPN5-1
PPDA
REMOTE EPO K2-4
TP1
K2-7
JPF1-1
5
*REMOVE TP1 ON PPDA
1
DA2
SOL1
2 1 6
S3 VFC
9
6 OUTPUT #3
DA2
NO NC B
3
4 1 K3
7 7
A
COM
A B C D
7-30 PDMM-0057
E F G H
REMOTE LIFT/LOWER WITH UNNESTED SWITCH

2
JPN4-
S1
1 2 2
1
B+KEY
2 4 NORMAL
B+F 1 2 POSITION
4
REMOTE 1 1 2
HYDRAULIC 3
DRIVER REMOTE*
1 2
ASSEMBLY POSITION
(HDA)
S16 S17
TS19- TS21-2 3
GREEN R3 LIFT
2 2 1 2 1
SIDESHIFT SOL
S14 S15
TS21-3
BLACK R2
3 2 1 2 1 LOWER
REACH SOL
TS21-4 S19
S18
4 RED COM NO 2 1
REMOTE EPO
REMOTE EPO
5 EPO
B+KEY
6 TS21-6
B-PCF
WHITE 4
4
JPN5-1 DA2
NO NC B
PPDA
REMOTE EPO
5
TP1
4 1 K2
7
JPF1-1 A
COM
5
*REMOVE TP1 ON PPDA
1
DA2
SOL1
2 1 6
S3 VFC
9
OUTPUT #3
6
DA2
NO NC B
3
4 1 K3
7
A 7
COM
E F G H
PDMM-0057 7-31
A B C D
LEGEND
IDENT. SHEET DESCRIPTION
2 CCM 1 CHOPPER CONTROL MODULE

C1 1 CAPACITOR FOR SNUBBER CIRCUIT
CR1 1 DIODE ON FIELD WIRING ASSEMBLY
DA1 2 DIODE ASSY FOR BACKUP ALARM
D2 1 DIODE FOR SNUBBER CIRCUIT

DE 1 DRIVE MOTOR ENCODER
DIRA 1 SOLENOID FOR AUX OIL DIRECTION CONTROL
DIRB 1 SOLENOID FOR AUX OIL DIRECTION CONTROL
DT 1 DRIVE MOTOR TEMPERATURE SENSOR
EQ 1 SOLENOID FOR AUX PRESSURE EQUALIZING CONTROL
FU1 1 CONTROL FUSE FOR B- TO HDA 15A

FU2 1 CONTROL FUSE FOR B- TO PPDA 15A
FU3 1 CONTROL FUSE FOR B+ TO HDA 15A
FU4 1 CONTROL FUSE FOR B+ TO PPDA 15A
FU5 1 POWER FUSE FOR TRAVEL, 350A
3 FU6 1 POWER FUSE FOR LIFT, 450A
FU8 1 POWER FUSE FOR FIELD & AUX MOTOR 150A

FU9 1 CONTROL FUSE FOR STROBE OR WARNING LIGHT 10A (OPTION)
FU10 1 CONTROL FUSE FOR TRAVEL LIGHT AND OR ALARM 10A (OPTION)
FU11 1 CONTROL FUSE FOR WORKING LIGHTS AND OR FAN 10A (OPTION)
FU12 1 CONTROL FUSE FOR AUX POWER (INLINE) 10A (OPTION)
FW 1 FIELD WIRING CARD
H 1 HORN
HCM 1 H-BRIDGE CONTROL MODULE
HT 1 HEATSINK TEMPERATURE SENSOR
JPB+ 1 CONNECTOR TO BATTERY POS.

JPB- 1 CONNECTOR TO BATTERY NEG.
JPC1 1 CONNECTOR ON CONTROL HANDLE
JPD1 1 CONNECTOR ON FIELD WIRING CARD FOR H-BRIDGE MODULE
JPF1 1 CONNECTOR ON POWER PANEL DRIVER CARD FOR HYDRAULIC DRIVER ASSEMBLY
4 JPF2
JPF3
1
1
CONNECTOR ON POWER PANEL DRIVER CARD FOR CONTACTOR PANEL
CONNECTOR ON POWER PANEL DRIVER CARD FOR VEHICLE MANAGER CONTROL AND POWER
JPF4 1 CONNECTOR ON POWER PANEL DRIVER CARD FOR TEMP SENSOR IN HEATSINK
JPH1 1 CONNECTOR ON H-BRIDGE CARD FOR H-BRIDGE MODULE

JPH2 1 CONNECTOR ON H-BRIDGE MODULE FOR VEHICLE MANAGER
JPI 1 CONNECTOR ON OPERATOR DISPLAY
JPN1 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR SOLENOIDS

JPN2 2 CONNECTOR ON HYDRAULIC DRIVER CARD FOR WARNING LIGHT
JPN3 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR OPTIONAL POWER
JPN4 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR KEYSWITCH
JPN5 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR POWER PANEL DRIVER CARD
JPN6 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR DEADMAN AND HORN
JPN7 2 CONNECTOR ON HYDRAULIC DRIVER CARD FOR STANDARD MAST SWITCH
JPN8 2 CONNECTOR ON HYDRAULIC DRIVER CARD FOR OTHER THAN STANDARD MAST SWITCH
JPN9 1 CONNECTOR ON HYDRAULIC DRIVER CARD
5 JPN10
JPN11
1
1
CONNECTOR ON HYDRAULIC DRIVER CARD FOR TEMP. SENSOR TRACTION MOTOR
CONNECTOR ON HYDRAULIC DRIVER CARD
JPN12 2 CONNECTOR ON HYDRAULIC DRIVER CARD FOR LIFT INHIBIT SWITCH
JPN13 2 CONNECTOR ON HYDRAULIC DRIVER CARD FOR LIFT INHIBIT BYPASS
JPN14 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR VEHICLE MANAGER
JPS1 1 VEHICLE MANAGER CONNECTOR FOR CHOPPER CONTROL MODULE

JPS2 1 VEHICLE MANAGER CONNECTOR FOR H-BRIDGE MODULE
JPS3 1 VEHICLE MANAGER CONNECTOR FOR EXPANSION (OPTIONAL)
JPS4 1 VEHICLE MANAGER CONNECTOR FOR CONTROL HANDLE
JPS6 1 VEHICLE MANAGER CONNECTOR FOR DIAGNOSTICS
JPS8 1 VEHICLE MANAGER CONNECTOR FOR OPERATOR DISPLAY
JPS9 1 VEHICLE MANAGER CONNECTOR FOR HYDRAULIC DRIVER
JPS10 1 VEHICLE MANAGER CONNECTOR FOR POWER PANEL DRIVER
JPS11 1 VEHICLE MANAGER CONNECTOR FOR POWER SUPPLY (INSIDE BOX)
JPS12 1 VEHICLE MANAGER CONNECTOR FOR DRIVE MOTOR ENCODER
JP201 2 CONNECTOR ON MAST FOR WARNING/ STROBE LIGHT
6 JP202
JP203
2
2
CONNECTOR ON MAST FOR TRAVEL LIGHT
CONNECTOR ON MAST FOR WORKING LIGHT
JP204 2 CONNECTOR ON OHG FOR WORKING LIGHTS
JP205 2 CONNECTOR ON OHG FOR OPERATOR FAN
JPP1 1 CONNECTOR ON POWER SUPPLY
JPM 1 CONNECTOR ON DRIVE MOTOR TEMP SENSOR
JPT1 1 CHOPPER CONTROL MODULE (C.C.M.) CONNECTOR TO TRANSISTOR & PPDA

JPT2 1 CHOPPER CONTROL MODULE (C.C.M.) CONNECTOR TO VEHICLE MANAGER
JPZ 1 CONNECTOR ON LIFT MOTOR TEMPERATURE SENSOR (OPTIONAL)
K1 2 RELAY FOR BACKUP ALARM OPTION
K2 2 RELAY FOR REMOTE LIFT/LOWER WITH UNNESTED SWITCH OPTION
K3 2 RELAY FOR REMOTE LIFT/LOWER

7
A B C D
7-32 PDMM-0057
E F G H

L/H
LF
1
1
SOLENOID FOR LOAD HOLDING
CARD ASSY. LINE FILTER
2
MD 1 DRIVE MOTOR
MP 1 LIFT PUMP MOTOR
MX 1 AUX PUMP MOTOR
P 1 LIFT PUMP CONTACTOR

PC 1 POWER DISCONNECT CONTACTOR
Q1 1 CHOPPER TRANSISTOR
REACH,SOL 6 1 SOLENOID FOR REACH

REC1 1 FREE WHEELING RECTIFIER
R2 2 RESISTOR FOR REMOTE LIFT/LOWER

3
R4 1 RESISTOR FOR SNUBBER CIRCUIT
R5 2 RESISTOR FOR TRAVEL ALARM (OPTION)
S1 1 KEY SWITCH
S2 1 DEADMAN SWITCH
S3 1 HORN SWITCH
S4 1 REACH SWITCH
S5 1 RETRACT SWITCH
S6 1 TILT UP SWITCH
S7 1 TILT DOWN SWITCH
S8 1 SIDE SHIFT LEFT SWITCH
S9 1 SIDE SHIFT RIGHT SWITCH
S10 2 SPEED LIMIT SWITCH
S12 2 LIFT INHIBIT BYPASS SWITCH
S13 2 LIFT INHIBIT SWITCH
S14
S15
2
2
REMOTE LIFT/LOWER
REMOTE LIFT/LOWER
4
S16 2 REMOTE LIFT/LOWER
S18 2 REMOTE EPO
S19 2 UNNESTED CARRIAGE SWITCH
S20 1 LIFT SWITCH
S21 1 LOWER SWITCH
SIDESHIFT,SOL 8 1 SOLENOID FOR SIDE SHIFT
SOL 1 2 REMOTE LOWER SOLENOID (OPTION)
SPL1 2 SPLICE FOR TRAVEL LIGHT (OPTION)
SPL2 2 SPLICE FOR WARNING OR STROBE LIGHT (OPTION)
SPL3 2 SPLICE FOR WORKING LIGHTS AND OR FAN (OPTION)
SPL12 2 SPLICE FOR AUX POWER (OPTION)
T1 1 TERMINAL FOR BASE DRIVE TO TM1-B1

T2
T3
1
1
TERMINAL FOR BASE DRIVE TO TM1-B2
5
T5 1 TERMINAL FOR CATHODE FOR CR1
TILT,SOL 7 1 SOLENOID FOR TILT

TM1 1 DUAL TRANSISTOR MODULE FOR FIELD WIRING ASSEMBLY
TS19 1 TERMINAL STRIP FOR MAST CABLE ON HYDRAULIC DRIVER CARD

TS21 1 TERMINAL STRIP FOR MAST CABLE ON CARRIAGE
TP2 1 TIE POINT ON TRAVEL FUSE

TP3 1 TIE POINT ON LIFT FUSE
TP4 1 TIE POINT FOR B-
TP5 1 TIE POINT ON HEAT SINK (BOTTOM SIDE)
TP6 1 TIE POINT ON HEAT SINK (TOP SIDE)
TP7 1 TIE POINT ON FIELD FUSE 6
TZ1 2 TRANSZORB ACROSS TRAVEL ALARM (OPTION)
VR1 1 VARIABLE RESISTOR FOR THROTTLE
WL 2 WARNING LIGHT
2ND 1 SOLENOID FOR 2ND STAGE PUMP (LIFT)
7
1. SCHEMATIC SHOWS TRUCK SWITCHED OFF, DEADMAN SWITCH OFF AND
CARRIAGE FULLY LOWERED.
E F G H
PDMM-0057 7-33
A B C D
2 JPI-
1
JPS8-
5
CONTROL LATCH
2 4
MEMORY ENABLE
3 3
DATA LATCH
PC FU5 OPERATOR 4 2
DATA IN
DISPLAY 6 9
DISPLAY
350A TP2 SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
FU8 10 SHIELD
150A 1 L1 2
TP7
JPD1- JPH1- JPH2- JPS2-

FW-B+
H-BRIDGE CONTROL
10 1 5 5
FIELD T1 REVERSE
11 2 4 4
1 WIRING FW-B- FIELD CURRENT
(FW) 12 3 2 2
S1 T3 FIELD CURRENT LIMIT
P FW-2 4 4 H-BRIDGE 1 1
A2
3 2
9 5
FW-B+
T2
CONTROL 8 8
FORWARD
FIELD PWM
MODULE
7 6 MODULE 7 7
FU6
1
MD CR1 5 7
FW-2 (HCM) 6 6
PGND
450A +12 +12V
FW-1 3 8 9
TP3 R1 A1 S2 T4 PGND
2 T5 1 9
FW-1
6 10
2 FW-B- LOOP
1S 2 11
T1 I-LIMIT
T2 T3 T4
JP 1
B+
S
JPS12-
5
B1 B2 B1 B2 4 B-
S B+
3
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4 7
PGND
8
PGND
JP 2
B-
RESISTOR ASSEMBLY
4 JPT1-
4 B+KEY
CHOPPER JPT2- JPS1-
CONTROL 4 4
MODULE ARM CURRENT
CHOPPER CONTROL
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT LIMIT
TP6 SENSOR 1 1
TP5 CHOPPER ENABLE
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMPERATURE
8 8
B CHOPPER PWM
MODULE
e 8 7 7
C1 B-DRIVE PGND
6 6
+12V
5
TP4 E 2 PGND
HT E-DRIVE
T˚
JPF4- 3
HEATSINK
E
B+KEY
JPF3- JPS10-
5 JPF2-
14 B-PC
8
7
8
7
PC-CONTACTOR
B-CONTACTOR
13 6 6
B- FU1 P-CONTACTOR
5 5
11 B-PC B-PCF 1S-CONTACTOR
B+PC 4 4
+12V
3 3
B+KEY
2 2
POWER PANEL
FU2 B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
DRIVER
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
6 X
P
Y
1 P CNTR
B+ F1 1S
B+ B+ X Y
FILT 4
FILT 1S 1S CNTR
PC
F2 F1
2 B CNTR
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
7-34 PDMM-0057
E F G H
+12V
JPS4-
9
14
JPC1-
9
14
2
THROTTLE VR1
11 11
AGND
15 15
CONTROL HANDLE
LIFT S20
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
GND
VEHICLE 2 2
MANAGER HORN S3 9
DIRB
CONTROL HANDLE
DIRB SOL
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
7
SSHIFT RIGHT
AGND
3
10
3
10
S9 EQ SOL
1
EQ
2
3
SHIELD
3
B+KEY
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
4
DRIVER
ASSEMBLY
(HDA)
JPN10- JPM-
3 1 T˚
JPS9- JPN14- REACH PGND
ON
DT
13 13 2 2 MD
+12V TRAC TEMP
12 12
PGND JPN11- JPZ-
11 11
DEADMAN
10 10 S/S PGND
3 1 T˚
2ND EN ON
9 9 PT
EQ EN
8 8 2 2 MP
HORN EN LIFT TEMP
DIRB EN
7
6
7
6
TILT
S/S EN JPN9-
5 5
UNNESTED 3
4 4 PGND
REMOTE 2 0
MASTSW2
3 3 DIRB PRESSURE
1 +
PRESS
2 2 +12V
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25
5
1 1 2
PRESSURE
TRAC TEMP
24 24 DIRA B+KEY
2
23 23 B+F
LIFT TEMP 4
22 22 REMOTE
SPARE 1
21 21
DIRA EN
20 20 EQ
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
REACH EN
17
16
17
16
2ND TS21- RED
REMOTE EPO
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
SOL 8
B+ FILTERED
2 GREEN 2 GREEN 2 SIDE 1

SIDESHIFT SOL
SHIFT
AGND
+5.3V
+12V
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
JPP1-
1 2 3 4 5 6
REMOTE EPO
4 ORANGE 4 6
6 BLUE 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
E F G H
PDMM-0057 7-35
A B C D
STANDARD MAST SPEED LIMIT SWITCH LIFT INHIBIT WITH BYPASS
2 JPN7-
S10 JPN13- S12 *
1 COM NC 1
MASTSW1 INHBTBYP
HYDRAULIC HYDRAULIC
DRIVER 2 2
+12V DRIVER B-PCF
ASSEMBLY ASSEMBLY
3 JPN12-
(HDA) B-PCF (HDA) S13
1 COM NC
LIFT INHBT
*MAST IN FULLY LOWERED POSITION 2
+12V
3
B-PCF
3 OTHER THAN STANDARD MAST SPEED LIMIT SWITCH

*REMOVE S12 TO ELIMINATE BYPASS CAPABILITY
JPN8-
S11
1 COM NC
MASTSW2
HYDRAULIC
DRIVER 2
+12V
ASSEMBLY
(HDA) 3
B-PCF
*MAST IN FULLY LOWERED POSITION
4
STROBE OR WARNING LIGHT
JPN2- WL
1 FU9
+ -
B+PCF
HYDRAULIC JP201-1 JP201-2
DRIVER BLACK WHITE
ASSEMBLY SPL-2
2
(HDA) B-PCF
WORKING LIGHTS AND/OR FAN LIGHT
JP204B-2
WHITE
HYDRAULIC LIGHT
DRIVER JPN3-
ASSEMBLY
1
(HDA) B+KEY JP204B-1 JP204A-1 JP204A-2
6 BLACK BLACK WHITE
FAN
2 FU11
B+PCF
JP203-1 JP206-1 JP206-2
BLACK BLACK WHITE
3 SPL-3
B-PCF
JP203-2
WHITE
7 NOTE:
SPECIAL WIRING REQUIRED WHEN USED WITH KEYED AUX. POWER
A B C D
7-36 PDMM-0057
E F G H
ACCESSORY ACCESSORY
POWER FUSED POWER FUSED
10 AMPS 10 AMPS
2
B-
TS8 B+ B-
TS8 B+
2 1 2 1
SPL-12
SPL-12
FU12
FU12
3
JPN3-1 JPN3-3 TP4 PC-1
WITH KEY ON WITH BATTERY
NOTE:
KEYED AUX POWER REQUIRES SPECIAL WIRING
WHEN USED WITH WORKING LIGHTS AND OR FAN
AUX. POWER FUNCTIONS
NESTED SWITCH
4
TS19-
HYDRAULIC TS21-4 S19
DRIVER 4 WHITE COM NC
ASSEMBLY REMOTE EPO
(HDA)
TS21-6
6 BLACK
B-PCF
*REACH CARRIAGE IN RETRACTED (NESTED) POSITION

5
REMOVE WIRE FROM JPN5-1 TO JPF1-1
TRAVEL ALARM AND OR LIGHT
LIGHT
DA1
+ -
JP202-1 JP202-2
JPS3- 5 4 BLACK WHITE
6 A SPL-1 6
OUTPUT#1
VEHICLE K1
MANAGER 7 *
OUTPUT#2 R5 ALARM
(VM) B 1 2
TZ1
4 7
TS19- +
5 FU10 NO COM
B+PCF -
HYDRAULIC
DRIVER 6
B-PCF
ASSEMBLY
(HDA) 7
*USE JPS3-7 TO K1- FOR FORWARD TRAVEL. USE JPS3-8 TO K1- FOR REVERSE TRAVEL. CONNECT BOTH JPS3-6 & JPS3-7 FOR ALL TRAVEL.
E F G H
PDMM-0057 7-37
A B C D
REMOTE LIFT/LOWER
2 JPN4-
S1
1 2 2
1
B+KEY
2 4 NORMAL
B+F 1 2 POSITION
4
REMOTE 1 1 2
HYDRAULIC 3
DRIVER REMOTE*
1 2
ASSEMBLY POSITION
(HDA)
S16 S17
TS19- TS21-2
3 2 GREEN R3 LIFT
2 1 2 1
SIDESHIFT SOL
S14 S15
TS21-3
BLACK R2
3 2 1 2 1 LOWER
REACH SOL
TS21-4
RED S18
4 2 1
REMOTE EPO
5
B+KEY
6 TS21-6
B-PCF
4 WHITE
JPN5-1
PPDA
REMOTE EPO K2-4
TP1
K2-7
JPF1-1
5 *REMOVE TP1 ON PPDA

1
DA2
SOL1
2 1 6
S3 VFC
9
6 OUTPUT #3
DA2
NO NC B
3
4 1 K3
7
7 COM
A
A B C D
7-38 PDMM-0057
E F G H
REMOTE LIFT/LOWER WITH UNNESTED SWITCH

JPN4- 2
S1
1 2 2
1
B+KEY
2 4 NORMAL
B+F 1 2 POSITION
4
REMOTE 1 1 2
HYDRAULIC 3
DRIVER REMOTE*
1 2
ASSEMBLY POSITION
(HDA)
S16 S17
TS19- TS21-2
2 GREEN R3 LIFT 3
2 1 2 1
SIDESHIFT SOL
S14 S15
TS21-3
BLACK R2
3 2 1 2 1 LOWER
REACH SOL
TS21-4 S19
S18
4 RED COM NO 2 1
REMOTE EPO
REMOTE EPO
5 EPO
B+KEY
6 TS21-6
B-PCF
WHITE 4
4
JPN5-1 DA2
NO NC B
PPDA
REMOTE EPO
5
TP1
4 1 K2
7
JPF1-1 A
COM
*REMOVE TP1 ON PPDA

5
1
DA2
SOL1
2 1 6
S3 VFC
9
OUTPUT #3
6
DA2
NO NC B
3
4 1 K3
7
COM
A 7
E F G H
PDMM-0057 7-39
A B C D
LEGEND
2 BL
CCM
2
1
BACKUP LIGHT
CHOPPER CONTROL MODULE
C1 1 CAPACITOR FOR SNUBBER CIRCUIT
CR1 1 DIODE ON FIELD WIRING ASSEMBLY
DA1 2 DIODE ASSY FOR BACKUP ALARM
D2 1 DIODE FOR SNUBBER CIRCUIT

DE 1 DRIVE MOTOR ENCODER
DIRA 1 SOLENOID FOR AUX OIL DIRECTION CONTROL
DIRB 1 SOLENOID FOR AUX OIL DIRECTION CONTROL
DT 1 DRIVE MOTOR TEMPERATURE SENSOR
EQ 1 SOLENOID FOR AUX PRESSURE EQUALIZING CONTROL
FU1 1 CONTROL FUSE FOR B- TO HDA 15A

FU2 1 CONTROL FUSE FOR B- TO PPDA 15A
FU3 1 CONTROL FUSE FOR B+ TO HDA 15A
FU4 1 CONTROL FUSE FOR B+ TO PPDA 15A
FU5 1 POWER FUSE FOR TRAVEL, 350A
3 FU6 1 POWER FUSE FOR LIFT, 450A
FU8 1 POWER FUSE FOR FIELD & AUX MOTOR 150A

FU9 2 CONTROL FUSE FOR STROBE OR WARNING LIGHT 10A (OPTION)
FU10 2 CONTROL FUSE FOR BACKUP ALARM AND OR LIGHT 10A (OPTION)
FU11 2 CONTROL FUSE FOR WORKING LIGHTS AND/OR FAN 10A (OPTION)
FU12 2 CONTROL FUSE AUX POWER FUNCTIONS (INLINE) 10A (OPTION)
FW 1 FIELD WIRING CARD
H 1 HORN
HCM 1 H-BRIDGE CONTROL MODULE
HT 1 HEATSINK TEMPERATURE SENSOR
JPB+ 1 CONNECTOR TO BATTERY POS.

JPB- 1 CONNECTOR TO BATTERY NEG.
JPC1 1 CONNECTOR ON CONTROL HANDLE
JPD1 1 CONNECTOR ON FIELD WIRING CARD FOR H-BRIDGE MODULE
JPF1 1 CONNECTOR ON POWER PANEL DRIVER CARD FOR HYDRAULIC DRIVER ASSEMBLY
4 JPF2
JPF3
1
1
CONNECTOR ON POWER PANEL DRIVER CARD FOR CONTACTOR PANEL
CONNECTOR ON POWER PANEL DRIVER CARD FOR VEHICLE MANAGER CONTROL AND POWER
JPF4 1 CONNECTOR ON POWER PANEL DRIVER CARD FOR TEMP SENSOR IN HEATSINK
JPH1 1 CONNECTOR ON H-BRIDGE CARD FOR H-BRIDGE MODULE

JPH2 1 CONNECTOR ON H-BRIDGE MODULE FOR VEHICLE MANAGER
JPI 1 CONNECTOR ON OPERATOR DISPLAY
JPN1 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR SOLENOIDS

JPN2 2 CONNECTOR ON HYDRAULIC DRIVER CARD FOR WARNING LIGHT
JPN3 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR OPTIONAL POWER
JPN4 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR KEYSWITCH
JPN5 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR POWER PANEL DRIVER CARD
JPN6 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR DEADMAN AND HORN
JPN7 2 CONNECTOR ON HYDRAULIC DRIVER CARD FOR STANDARD MAST SWITCH
JPN8 2 CONNECTOR ON HYDRAULIC DRIVER CARD FOR OTHER THAN STANDARD MAST SWITCH
JPN9 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR PRESSURE SENSOR
5 JPN10
JPN11
1
1
CONNECTOR ON HYDRAULIC DRIVER CARD FOR TEMP. SENSOR TRACTION MOTOR
CONNECTOR ON HYDRAULIC DRIVER CARD FOR TEMP. SENSOR LIFT MOTOR
JPN12 2 CONNECTOR ON HYDRAULIC DRIVER CARD FOR LIFT INHIBIT SWITCH
JPN13 2 CONNECTOR ON HYDRAULIC DRIVER CARD FOR LIFT INHIBIT BYPASS
JPN14 1 CONNECTOR ON HYDRAULIC DRIVER CARD FOR VEHICLE MANAGER
JPS1 1 VEHICLE MANAGER CONNECTOR FOR CHOPPER CONTROL MODULE

JPS2 1 VEHICLE MANAGER CONNECTOR FOR H-BRIDGE MODULE
JPS3 1 VEHICLE MANAGER CONNECTOR FOR EXPANSION (OPTIONAL)
JPS4 1 VEHICLE MANAGER CONNECTOR FOR CONTROL HANDLE
JPS6 1 VEHICLE MANAGER CONNECTOR FOR DIAGNOSTICS
JPS8 1 VEHICLE MANAGER CONNECTOR FOR OPERATOR DISPLAY
JPS9 1 VEHICLE MANAGER CONNECTOR FOR HYDRAULIC DRIVER
JPS10 1 VEHICLE MANAGER CONNECTOR FOR POWER PANEL DRIVER
JPS11 1 VEHICLE MANAGER CONNECTOR FOR POWER SUPPLY (INSIDE BOX)
JPS12 1 VEHICLE MANAGER CONNECTOR FOR DRIVE MOTOR ENCODER
JP201 2 CONNECTOR ON MAST FOR WARNING/ STROBE LIGHT
6 JP202
JP203
2
2
CONNECTOR ON MAST FOR TRAVEL LIGHT
CONNECTOR ON MAST FOR WORKING LIGHT
JP204 2 CONNECTOR ON OHG FOR WORKING LIGHTS
JP206 2 CONNECTOR ON OHG FOR OPERATOR FAN
JPP1 1 CONNECTOR ON POWER SUPPLY
JPM 1 CONNECTOR ON DRIVE MOTOR TEMP SENSOR
JPT1 1 CHOPPER CONTROL MODULE (C.C.M.) CONNECTOR TO TRANSISTOR & PPDA

JPT2 1 CHOPPER CONTROL MODULE (C.C.M.) CONNECTOR TO VEHICLE MANAGER
JPZ 1 CONNECTOR ON LIFT MOTOR TEMPERATURE SENSOR (OPTIONAL)
K1 2 RELAY FOR BACKUP ALARM OPTION
K2 2 RELAY FOR REMOTE LIFT/LOWER WITH UNNESTED SWITCH OPTION
K3 2 RELAY FOR REMOTE LIFT/LOWER

7
A B C D
7-40 PDMM-0057
E F G H

L/H 1 SOLENOID FOR LOAD HOLDING
LF 1 CARD ASSY, LINE FILTER
2
MD 1 DRIVE MOTOR
MP 1 LIFT PUMP MOTOR
MX 1 AUX PUMP MOTOR
P 1 LIFT PUMP CONTACTOR

PC 1 POWER DISCONNECT CONTACTOR
PRESS 1 PRESSURE SENSOR
PT 1 LIFT PUMP/MOTOR TEMPERATURE SENSOR
Q1 1 CHOPPER TRANSISTOR
REACH,SOL 6 1 SOLENOID FOR REACH

REC1 1 FREE WHEELING RECTIFIER
R1 1 RESISTOR FOR FIELD WIRING CARD

R3
R4
2
1
RESISTOR FOR REMOTE LIFT/LOWER
RESISTOR FOR SNUBBER CIRCUIT
3
R5 2 RESISTOR FOR TRAVEL ALARM (OPTION)
1S 1 SHORTING CONTACTOR
S1 1 KEY SWITCH
S2 1 DEADMAN SWITCH
S3 1 HORN SWITCH
S4 1 REACH SWITCH
S5 1 RETRACT SWITCH
S6 1 TILT UP SWITCH
S7 1 TILT DOWN SWITCH
S8 1 SIDE SHIFT LEFT SWITCH
S9 1 SIDE SHIFT RIGHT SWITCH
S12 2 LIFT INHIBIT BYPASS SWITCH
S13 2 LIFT INHIBIT SWITCH
S15
S16
2
2
REMOTE LIFT/LOWER
REMOTE LIFT/LOWER
4
S18 2 REMOTE EPO
S19 2 UNNESTED CARRIAGE SWITCH
S20 1 LIFT SWITCH
S21 1 LOWER SWITCH
SIDESHIFT,SOL 8 1 SOLENOID FOR SIDE SHIFT
SOL 1 2 REMOTE LOWER SOLENOID (OPTION)
SPL-1 2 SPLICE FOR BACKUP LIGHT (OPTION)
SPL-2 2 SPLICE FOR STROBE OR WARNING LIGHT (OPTION)
SPL-3 2 SPLICE FOR WORKING LIGHTS AND/OR FAN (OPTION)
SPL-12 2 SPLICE FOR AUX. POWER FUNCTIONS (OPTION)

T4
T5
1
1
TERMINAL FOR CATHODE FOR CR1
5
TILT,SOL 7 1 SOLENOID FOR TILT
TS8 2 TERMINAL STRIP FOR AUX. POWER FUCNTIONS (OPTION)

TS19 1 TERMINAL STRIP FOR MAST CABLE ON HYDRAULIC DRIVER CARD
TS21 1 TERMINAL STRIP FOR MAST CABLE ON CARRIAGE
TP2 1 TIE POINT ON TRAVEL FUSE

TP3 1 TIE POINT ON LIFT FUSE
TP4 1 TIE POINT FOR B-
TP5 1 TIE POINT ON HEAT SINK (BOTTOM SIDE)
TP6 1 TIE POINT ON HEAT SINK (TOP SIDE)
TP7 1 TIE POINT ON FIELD FUSE
6
TZ1 2 TRANSZORB ACROSS TRAVEL ALARM (OPTION)
VR1 1 VARIABLE RESISTOR FOR THROTTLE
WL 2 WARNING LIGHT
2ND 1 SOLENOID FOR 2ND STAGE PUMP (LIFT)
7
1. SCHEMATIC SHOWS TRUCK SWITCHED OFF, DEADMAN SWITCH OFF AND
CARRIAGE FULLY LOWERED.
E F G H
PDMM-0057 7-41
+
Low Performance
Remote Lift / Lower
2nd
A Sol. B
Pump Man.
Spool Val.
NOT ON ALL MODELS C
L/H Sol.
Cyl.
R L/L
P
P1 A B P1 CV 1 Cyl.
C Sol 1
D
Remote
Lower
Tank
Lift
P2 P2 CV 2 Rel.
2nd
Sol.
Sol 1
Option
D
Reach
Sol.
Dir A
Sol.
Dir B S/S
A1 Sol.
Sol.
Aux.
P3 Press. EQ
Sol.
A2
Tilt
Steer
Sol.
Ret.
Tank
LEGEND
Pressure Lines
Return Lines
Suction Lines
Figure 7-19: Hydraulic Schematic (Sheet 1 of 1)
PDMM-0057 7-42
Decal Replacement
Decal
2
6
Replacement Figure 7-20: Decal Replacement (Sheet 1 of 3)
PDMM-0057 7-43
Decal Replacement
10
3
5
11
9
15
2 13
4 1
7 17
8
8
Figure 7-21: Decal Replacement (Sheet 2 of 3)
7-44 PDMM-0057
Decal Replacement
FIGURE 7-10
QTY. DESCRIPTION
ITEM NO.
1 1 Caterpillar Decal (16.25 in. Battery Comp.)
2 1 Lubrication Decal
4 1 Cold Storage Decal
5 1 Basic Plate
6 1 Handle Instruction Decal
7 1 Traction Motor Decal
8 1 General Warning Decal
9 AR Auxiliary Plate
10 1 UL Type E Plate
11 2 Battery Warning Decal
12 1 Operator Display Decal
14 1 General Warning Decal (14.5 in. Battery Comp., Not Illustrated)
Figure 7-22: Decal Replacement (Sheet 3 of 3)
PDMM-0057 7-45
Brush Replacement
Brush If any of the brushes require replacement, the complete brush set
should be replaced. Do not replace just one or two brushes. Refer to
Replacement Figure 7-23 for minimum brush lengths.
24-Volt Trucks
Minimum Commuta- Minimum
Motor Manufacturer Part Number
tor Diameter Length*
2.625 in. 0.75 in.
Drive Advanced 1201792
(66.67 mm) (19.05 mm)
Advanced 2.80 in. 0.62 in.
Lift 1011425
(71.1 mm) (15.8 mm)
2.75 in. 0.62 in.
Auxiliary Advanced 1201793
(69.85 mm) (15.8 mm)
* Measurement of brush length refers to the "short" side dimension.
When ordering replacements refer to the motor part number on the

motor nameplate.
36-Volt Trucks
Minimum Commuta- Minimum
Motor Manufacturer Part Number
tor Diameter Length*
3.11 in. 0.60 in.
Drive Advanced 1011419
(78.99 mm) (15.24 mm)
Advanced 2.80 in. 0.62 in.
Lift 1011413
(71.1 mm) (15.8 mm)
2.938 in. 0.575 in.
Prestolite 1011412
(75 mm) (14.61 mm)
General Elec- 3.1 in. 0.77 in.
1011426
tric (78.7 mm) (19.6 mm)
2.75 in. 0.62 in.
Auxiliary Advanced 1011418
(69.85 mm) (15.8 mm)
* Measurement of brush length refers to the "short" side dimension.
Figure 7-23: Minimum Brush Lengths
7-46 PDMM-0057
Brush Replacement
Brush When ordering replacements, refer to the motor serial number on the
Replacement motor nameplate.
(cont.) Do not substitute brushes. The brushes are matched to the motor
type and application to provide the best service. Substituting brushes
of the wrong grade can cause commutator damage or excessive brush
wear.
Where accessible, new brushes should be seated to the commutator
curvature. This can be accomplished by wrapping a piece of 00
sandpaper around the commutator, seating the brush in the brush
holder, and turning the armature. On smaller motors where space is
limited, a brush seating stone may be used. DO NOT use emery cloth
to seat brushes.
After the brushes are seated, the dust should be blown out of the
motor with dry compressed air [30 psi (206.8 kPa)].
PDMM-0057 7-47

Supplement - Dealer/Technician Configuration Program: User Instructions

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Supplement - Dealer/Technician Configuration Program: User Instructions

Încărcat de

Drepturi de autor:

Formate disponibile

CATERPILLAR® Reach Service Manual Appendix