Maintenance Manual

Model 102XM Pallet Truck

Models: Serial Numbers:

102XM 102-03-00500 and Up

Publication: 1010183C Revised: 20 Mar 2014

Replaces
Publication: 1010183B Revised: 17 February 2005
This publication applies to Model 102XM pallet trucks S/N 102-03-00500 and Up, and to all subsequent
releases of this product until otherwise indicated in new editions or bulletins. Changes occur periodically to the
information in this publication.

For a list of changes, see “Page Revision Record” on page xi.

Technical changes or additions to the text and illustrations are indicated by a vertical line to the left of the
change.

If you need assistance with your pallet truck, contact your local authorized Raymond Sales and Service Center.
To locate a Sales and Service Center, go to www.raymondcorp.com.

©2003, 2005, 2014 The Raymond Corporation.

The following terms are trademarks of The Raymond Corporation: Raymond, Above. And beyond., and Safety
On The Move. All other brand and product names are trademarks or registered trademarks of their respective
companies.
Model 102XM Maintenance Manual

Table of Contents
Page Revision Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Document Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
List of Revised Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Service Bulletins and Service Information Documents Included . . . . . . . . xii
Product Improvement Notices Included . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . ............... 1-1
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . ................ . 1-2
Interactive Electronic Technical Manuals . . . . . . . . ................ . 1-3
Abbreviations & Symbols . . . . . . . . . . . . . . . . . . . . ................ . 1-4
Safety . . . . . . . . . . . . . . . . . . . ................ . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . ................. . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . ................. . . . . . . . . . . . . . . . . . 2-6
Jacking Safety . . . . . . . . . . . ................. . . . . . . . . . . . . . . . . . 2-9
Fork Section . . . . . . . . . . ................. . . . . . . . . . . . . . . . . 2-9
Tractor Section . . . . . . . . ................. . . . . . . . . . . . . . . . . 2-9
Towing . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . . . . 2-10
Static Safety . . . . . . . . . . . . ................. . . . . . . . . . . . . . . . . 2-11
Welding Safety . . . . . . . . . . . ................. . . . . . . . . . . . . . . . . 2-12
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Truck Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Operator Display and Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Special Truck Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Hour Meter (H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Error Codes (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Error Code History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Changing Truck Parameters (P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Programming Truck Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Programming Service Parameters . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Parameter Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Setting Individual PIN-key Codes . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Parameter Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Parameter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Parameter 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Parameter 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Parameter 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Parameter 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Parameter 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Parameter 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Parameter 15
(starting with software version 3.6) . . . . . . . . . . . . . . . . . . . . . . 3-12
Parameter 16
(starting with software version 3.6) . . . . . . . . . . . . . . . . . . . . . . 3-12

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 Model 102XM Maintenance Manual

Parameter 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-12
Parameter 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-13
Parameter 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-13
Parameter 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-14
Display Part Numbers (Pn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-14
Service Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3-15
Digital Inputs/Outputs from Power Amplifier . . . . . . . . . . . . . . . .. 3-16
Power Amplifier Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-16
Power Amplifier Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-16
Digital Input from Vehicle Manager Control Sensors . . . . . . .. 3-17
Typical Power Amplifier Status . . . . . . . . . . . . . . . . . . . . . . . .. 3-17
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3-18
Programmable Maintenance Tool . . . . . . . . . . . . . . . . . . . . . . . . .. 3-19
Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-20
Faults Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-20
Information Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-21
Programmer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-21
Service Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-22
TruckCom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3-23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-23
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-23
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-24
Main Program Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-24
Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-24
Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-25
Tool Buttons and Menu Bar . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-25
Information Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-25
Status Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-26
Connect Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-26
Disconnect Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-26
Downloading Program Function . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-27
Normal Downloading
(trucks with key) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Normal Downloading
(trucks with keypad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Emergency Downloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Emergency Downloading (trucks with key) . . . . . . . . . . . . . . . . 3-28
Emergency Downloading
(trucks with keypad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Truck Report Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Parameters Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
PIN Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Hour Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Diagnostics Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Representation of Signal Colors . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Tiller Arm Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Drive Controller Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Other Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Save to File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Download from File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Reset CAN Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Delete Error Code Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

iv Publication:1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual

Reset Hour Meter . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . .. .. . 3-34

Read Error Code Log . . . . . . . . . . . . . . .. .. . .. .. . .. . .. .. . 3-34
Help - About the TruckCom Application .. .. . .. .. . .. . .. .. . 3-34
Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . .. .. . 3-34
FlashWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . .. .. . . 3-35
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . .. .. . 3-35
Requirements . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . .. .. . 3-35
Installing FlashWare on PC . . . . . . . . . . . . . .. .. . .. .. . .. . .. .. . 3-35
Connecting PC to Truck . . . . . . . . . . . . . . . .. .. . .. .. . .. . .. .. . 3-35
Starting FlashWare . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . .. .. . 3-36
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Initial 90 Day/250 Deadman Hours (HD) Maintenance . . . . . . . . . . . . . . 4-3
Every 180 Days or 500 Deadman Hours . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Every 360 Days or 2000 Deadman Hours (HD) . . . . . . . . . . . . . . . . . . . . 4-6
Contactor Tip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
List of Troubleshooting Charts and Tables . . . . . . . . . . . . . . . . . . . . . . . . 5-2
How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Shorts to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Shorts to Frame Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
DC Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
DC Motor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Open Circuit Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Grounded Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Short-Circuited Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Short-Circuited Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
List of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Symptom Table: Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
BDI does not Reset to 100% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Horn Does Not Sound When Horn Button Pushed. No Fault Codes. 5-13
Green/Red LED on Keypad Not Illuminated When Key Pressed. . . . 5-14
Symptom Tables: Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
No Lift, Lift Motor Does Not
Run, Travel is OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
No Lift or Slow Lift, Lift Motor Does Run . . . . . . . . . . . . . . . . . . . . . 5-16
No Lower, Lift and Travel OK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Unable to Pick Up a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Slow Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Load Drifting/Settling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
No Lift or Lower. No Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Symptom Tables: Travel (Forward/Reverse) System . . . . . . . . . . . . . . . . 5-19
Slow Travel, Lift/Lower OK. No Fault Codes . . . . . . . . . . . . . . . . . . 5-19
Truck Does Not Accelerate Correctly . . . . . . . . . . . . . . . . . . . . . . . . 5-19

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 Model 102XM Maintenance Manual

No Travel Mode. No Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Messages and Codes . . . . . . . . . . . ................ . . . . . . . . . . . . 6-1
List of Messages and Codes . . . . ................. . . . . . . . . . . . . . . 6-2
Messages and Caution Codes . . ................. . . . . . . . . . . . . . . 6-3
Code ‘TEST’ . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-3
Code ‘SLO’ . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-3
Code ‘Sro’ (C14) . . . . . . . . . . ................. . . . . . . . . . . . . . 6-3
Code C19 . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-4
Code HPd (C20) . . . . . . . . . . ................. . . . . . . . . . . . . . 6-4
Code C28 . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-5
Code C29 . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-6
Code C35 . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-6
Code Lo (C41) . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-6
Code Hi (C42) . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-7
Code C43 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-7
Code Hot1 (C44) . . . . . . . . . . ................. . . . . . . . . . . . . . 6-8
Code C46 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-8
Error Codes . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . . 6-9
Code E101 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-9
Code E104 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-9
Code E106 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-10
Code E107 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-10
Code E108 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-11
Code E110 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-11
Code E112 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-11
Code E114 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-12
Code E115 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-12
Code E118 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-13
Code E140 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-13
Code E141 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-13
Code E142 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-14
Code E150 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-14
Code E151 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-15
Code E157 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-15
Code E159 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-15
Code E160 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-16
Code E161 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-16
Code E200 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-17
Code E201 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-17
Code E202 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-17
Code E214 . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-18
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . ............ 7-1
List of Component Procedures by Component System . ............. . 7-2
Component Locator Photos . . . . . . . . . . . . . . . . . . . . ............ 7-5
Finish and Accessories . . . . . . . . . . . . . . . . . . . . . . . . ............ 7-7
Tractor Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............. . 7-8
Tractor Cover Removal . . . . . . . . . . . . . . . . . . . . . . ............. 7-8
Tractor Cover Installation . . . . . . . . . . . . . . . . . . . . ............. 7-8
Tractor Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............. . 7-9
Bumper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . ............. 7-9
Bumper Installation . . . . . . . . . . . . . . . . . . . . . . . . ............. 7-9

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Model 102XM Maintenance Manual

Steering and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Control Handle Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Control Handle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Horn Button/Switch Replacement . . . . . . . . . . . . . . . . . . . . . . 7-13
Lift/Lower Button Replacement . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Push Button Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Emergency Reverser Replacement . . . . . . . . . . . . . . . . . . . . . . 7-14
Control Handle Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Control Handle Stem Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Control Handle Stem Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Drive Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Electromagnetic Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Brake Disc Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Friction Disc Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Mechanically Releasing the Brake . . . . . . . . . . . . . . . . . . . . . . 7-21
Electric Brake Release Kit Installation . . . . . . . . . . . . . . . . . . . 7-22
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Drive Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Drive Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Drive Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Drive Unit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Drive Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Drive Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Drive Unit Housing Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Gear Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Changing Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Swing-out Battery Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Removal (single battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Installation (single battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Removal (entire battery pack) . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Installation (entire battery pack) . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Maintenance-Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Battery Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Battery Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Charging a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Adding Water to a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Battery Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Battery Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Power Cable Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Wiring Harness Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Wiring Harness Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Wiring Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

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 Model 102XM Maintenance Manual

Wiring Harness Soldering Procedures . . . . . . . . . . . . . .. .. . .. . .. 7-40

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 7-41
Fuse Test/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-41
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 7-42
Circuit Breaker Test/Inspection . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-42
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 7-43
Horn Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-43
Horn Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-43
Traction Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 7-44
Cleaning the Traction Power Amplifier . . . . . . . . . . . . .. .. . .. . .. 7-44
Traction Power Amplifier Removal. . . . . . . . . . . . . . . . .. .. . .. . .. 7-44
Traction Power Amplifier Installation . . . . . . . . . . . . . .. .. . .. . .. 7-44
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 7-45
Main Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-45
Main Contactor Removal . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-45
Main Contactor Installation . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-45
Main Contactor, Sealed . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-45
Sealed Main Contactor Removal . . . . . . . . . . . . . . .. .. . .. . .. 7-45
Sealed Main Contactor Installation . . . . . . . . . . . .. .. . .. . .. 7-46
Lift Motor Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-46
Master Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 7-47
Master Control Relay Inspection/Test . . . . . . . . . . . . . .. .. . .. . .. 7-47
Switches (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 7-48
Testing/Inspecting Switches . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-48
Main ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-48
Main ON/OFF Switch Inspection . . . . . . . . . . . . . .. .. . .. . .. 7-48
Main ON/OFF Switch Removal . . . . . . . . . . . . . . .. .. . .. . .. 7-48
Main ON/OFF Switch Installation . . . . . . . . . . . . .. .. . .. . .. 7-48
Arm Angle Switches . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-49
Arm Angle Switches Adjustment . . . . . . . . . . . . . .. .. . .. . .. 7-49
Arm Angle Switches Removal . . . . . . . . . . . . . . . . .. .. . .. . .. 7-50
Arm Angle Switches Installation . . . . . . . . . . . . . . .. .. . .. . .. 7-50
Arm Angle Switches (Plastic Switch Bridge) . . . . . .. .. . .. . .. 7-50
Lift-Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-53
Lift-Limit Switch Adjustment . . . . . . . . . . . . . . . . .. .. . .. . .. 7-53
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-53
Key Switch Inspection . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-53
Motors, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 7-54
Motor Brush Inspection . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-54
Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-54
Motor Brush Spring Tension. . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-55
Brush Spring Tension Inspection . . . . . . . . . . . . . .. .. . .. . .. 7-55
Terminal Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-56
Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 7-57
Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-57
Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-57
Traction Motor Installation . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-57
Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 7-59
Lift Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-59
Lift Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-59
Lift Motor Brush Replacement . . . . . . . . . . . . . . . . . . .. .. . .. . .. 7-59

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Model 102XM Maintenance Manual

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Hydraulic Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Changing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
Hydraulic Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
Hydraulic Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Reservoir Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Reservoir Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Filter Screen and Inlet Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Filter Screen and Inlet Tube Removal . . . . . . . . . . . . . . . . . . . . 7-66
Filter Screen and Inlet Tube Installation . . . . . . . . . . . . . . . . . . 7-66
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Hydraulic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Hydraulic Pump Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . 7-68
Relief Valve Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Relief Valve Setting Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Relief Valve Setting Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Hydraulic Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Solenoid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Pallet Forks and Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Load Wheel Pull Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Carrier Frame Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Downstops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
Lower Link and Pivot Block Inspection . . . . . . . . . . . . . . . . . . . 7-76
Downstop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
Skid Shoe Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
Skid Shoe Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Cold Storage Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Theory of Operation . . . . . . . . ................ ............... 8-1
Definitions . . . . . . . . . . . . . . ................. ................ . 8-2
Acceleration . . . . . . . . . . ................. ................ 8-2
Arm Angle Switches . . . . ................. ................ 8-2
Click-to-Creep. . . . . . . . . ................. ................ 8-2

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 Model 102XM Maintenance Manual

Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-2
Controller Area Network (CAN) . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-2
Creep Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-2
Current Limiting. . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-2
Deceleration (Neutral Braking) . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-3
Emergency Reverse. . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-3
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-3
High Pedal Disable (HPD) . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-3
Open Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-3
Overvoltage Cutoff . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-3
PIN-Key Code . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-3
Pulse Width Modulation . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-3
Regenerative Braking . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-3
Short Circuit or “Short” . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-3
Speed Limiting . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-4
Static Return to Off (SRO). . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-4
Thermal Cutback (Traction Power Amplifier) . . . .. .. . .. .. . .. . . . . 8-4
Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-4
Truck Off Delay (Keypad only). . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-4
Undervoltage Cutoff . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-4
Vehicle Manager . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-4
Truck Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . . 8-5
Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . . 8-6
Vehicle Manager . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-6
Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-6
Direction/Speed Control. . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-6
Control Handle Positioning . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-6
Travel Request . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-6
Emergency Reverse . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-7
Electric Brake Release Switch . . . . . . . . . . .. .. . .. .. . .. . . . . 8-7
Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . . 8-8
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-8
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. . . . . 8-8
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . . . . A-3
Component Specific Service/Torque Chart . . . . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Torque Chart - Metric (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Torque Chart - Thread-Forming Screws . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Torque Chart - Straight Thread Face Seal O-Rings . . . . . . . . . . . . . . . . A-11
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

x Publication:1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual

Page Revision Record

Page Revision Record

This page is a record of the revision of all pages List of Revised Pages
in this manual. Whenever a page is revised, this
section is updated and included in the revision. Revision C standardized placement of content
into eight chapters instead of six. Chapters
Pages are revised due to technical and were added for Messages and Codes and Theory
non-technical changes identified as follows: of Operation, removing this content from the
• Technical changes – These changes are Troubleshooting chapter. Operator Display and
identified by a vertical line (change bar) in Programming content was moved from the
the left margin next to the change. Pages Troubleshooting chapter to the Systems
affected by technical changes are Overview chapter. These changes align content
identified with “Revised: Month Year” in of this manual with other Raymond manuals to
the footer. These pages may also be aid users in locating information from one
available on the Raymond iNet. model or class truck to another.
• Non-technical changes – These changes
consist of typographical and grammatical
corrections, paragraph renumbering,
repagination, and so on. Non-technical
changes are not identified with a change
bar, however, affected pages are identified
with “Revised: Month Year” in the footer.

Document Revision History

• 1010183A, Original Issue Date,
Issued: 24 November 2003
• 1010183B, Revision B,
Revised: 17 Feb 2005
• 1010183C, Revision C,
Revised: 20 Mar 2014

Publication: 1010183, Issued: 20 Mar 2014 xi

 Model 102XM Maintenance Manual

Service Bulletins and Service Information Documents Included

Service Bulletins and Service Information

Documents Included
The following Service Bulletins and Service Information documents were incorporated into this
manual.

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

Document Number Subject Date

RSB PLT-05-001 Installation of Stainless Steel Brake Plate March 3, 2005

RSB PLT-05-002 Drive Wheel Studs March 17, 2005

RSB PLT-05-004 Battery/Charger Pack Retention Bracket July 21, 2005

RSB PLT-08-010 Damaged Lift-Limit Switch September 30, 2008

RSB PLT-09-005 New Bumper for Trucks with Caster Assembly September 28, 2009

RSB PLT-09-006 Sealed Main Contactor Kit July 29, 2009

RSB PLT-10-001 Drive Motor Cable Routing July 29, 2010

RSI PLT-11-003 New Switch Bridge August 24, 2011

RSI PLT-13-002 Tiller Switch Arm Failures March 21, 2013

xii Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual

Product Improvement Notices Included

Product Improvement Notices Included

The following Product Improvement Notices were incorporated into this manual.

Use the blank rows below to log Product Improvement Notices when they are added to this manual.

Document Number Subject Date

RPIN PLT-05-R001 Parameter Default Setting 21 September 26, 2005

RPIN PLT-06-R015 Harness Routing Shown in Raymond Maintenance July 25, 2006
Manual 1010183B

RPIN PLT-07-R003 Retaining Strap for Lift Cylinder May 18, 2007

RPIN PLT-07-R005 Electric Brake Release July 20, 2007

RPIN PLT-07-R008A Handle Stem and Arm Angle Switch Bracket December 6, 2007

RPIN PLT-07-R009A Troubleshooting when the BDI does not reset to 100% December 13, 2007

RPIN PLT-07-R010 TruckCom - Truck Communications Program July 30, 2007

RPIN PLT-07-R011 New Cold Storage Hydraulic Fluid November 13, 2007

RPIN PLT-07-R016 New Software Release December 13. 2007

RPIN PLT-08-R005 Applying thread-locking compound to the mounting June 6, 2008

hardware for the bumper, skid bars, optional casters,
and brackets

RPIN PLT-08_R013 Electronic Tiller Arm Card (ETAC) Ordering (TruckCom November 12, 2008
Programming portion)

RPIN PLT-10-R001 New Rocker Switch and PMT Procedures April 9, 2010

Publication: 1010183, Issued: 20 Mar 2014 xiii

 Model 102XM Maintenance Manual

Product Improvement Notices Included

xiv Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 1. How To Use This Manual

Section 1. How To Use This Manual

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Section 1. How To Use This Manual Model 102XM Maintenance Manual

Manual Design

Manual Design • Section 6. Messages and Codes lists the

electrical fault codes.
• Section 7. Component Procedures gives
The Model 102XM Maintenance Manual is
information for testing, removal,
designed with the following objectives in mind:
installation, and adjustment of individual
• Provide technical coverage for expected lift truck components. To find a
levels of user expertise component procedure, you can use one of
• Anticipate your needs and reduce your three methods:
decisions regarding maintenance • Look up the component name in the list
• Reduce page flipping through a “one-stop of Component Procedures.
shopping” approach • Find the component in the Component
Locator Photographs.
The two-line running page header at the top of
• Look up the component name in the
each page tells you the following:
Index.
• Name of the manual
• Section 8. Theory of Operations explains
(Model 102XM Maintenance Manual)
flow within hydraulic and electrical
• Current chapter title systems for various conditions of lift truck
(example: this page How to Use This operation.
Manual)
• Appendix contains information such as
• Current topic torque values, lubricants, and
(example: this page Manual Design) standard/metric conversions.
• Index lists subjects alphabetically.
This manual contains the following sections:
• Section 1. How to Use This Manual
contains descriptive information about the
manual in Manual Design and a reference
table of Abbreviations & Symbols you may
find throughout this manual.
• Section 2. Safety contains definitions of
warning and caution notes, explains
general safety rules and safety rules for
battery safety, jacking safety, towing
safety, static safety, and welding safety.
• Section 3. Systems Overview contains
general information on truck
specifications, operation, programming,
and details for modes of operation.
• Section 4. Scheduled Maintenance
outlines the recommended schedule of
preventive services to keep your truck
working most efficiently.
• Section 5. Troubleshooting is a set of
general troubleshooting guidelines and a
set of troubleshooting tables for symptoms
not accompanied by a fault code. Once you
are familiar with the symptoms listed, you
may instead simply find the symptom in
the “List of Troubleshooting
Charts/Tables”.

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Model 102XM Maintenance Manual Section 1. How To Use This Manual

Interactive Electronic Technical Manuals

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

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

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

Green colored text in the Maintenance Manual

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

Blue colored text in the Maintenance Manual is

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

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Section 1. How To Use This Manual Model 102XM Maintenance Manual

Abbreviations & Symbols

Abbreviations & Term/Symbol Definition

Symbols E
E UL Electric Truck Type
Certification Rating with
These abbreviations, acronyms, and symbols safeguards against inherent fire
are used in this manual. and electrical shock hazards
EE UL Electric Truck Type
Term/Symbol Definition Certification Rating where
electrical equipment is
A
completely enclosed
A Ampere
ESD Electrostatic Discharge
AC Alternating Current
ESDS Electrostatic Discharge Sensitive
amp Ampere or amplifier
ETAC Electronic Tiller Arm Card
ANSI American National Standards (See Vehicle Manager)
Institute
API American Petroleum Institute F

approx approximately F Fahrenheit

aux auxiliary ft. foot or feet

AWG American Wire Gauge ft. lb. foot pound(s)

FU Fuse
B
BSOC Battery State-of-Charge G
GA gauge
C
gal. gallon or gallons
C Celsius or Centigrade
gm grams
CAN Controller Area Network
Gnd ground
CCW counterclockwise
cm centimeter H

COP Computer Operating Program HD hours on deadman

CS Cold Storage
I
CV check valve
IETM Interactive Electronic Technical
CW clockwise Manual
in. inch or inches
D
in. lb. inch pound(s)
DC Direct Current
DGND digital ground J
diam. diameter JP jack and pin connector
DMM Digital Multi-Meter
K
DOT US Department of
Transportation K thousand
DVM Digital Volt-Meter kg kilogram(s)

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Model 102XM Maintenance Manual Section 1. How To Use This Manual

Abbreviations & Symbols

Term/Symbol Definition Term/Symbol Definition

km/cm2 kilometers per square centimeter RCFP Relay Control Fuse Panel
km/h kilometers per hour ROM Read Only Memory
kPa kilo Pascal rpm revolutions per minute
R/R Remove and Replace
L
l liter(s) S
lb. pound or pounds S or SW Switch
LED Light Emitting Diode SAE Society of Automotive Engineers
L/H Load Holding S/N Serial Number
L/L Lift/Lower SOL Solenoid
spec specification
M
SPI Service Port Interface
m meter(s)
SPL Splice
mA milliampere
Std Standard
mm millimeter
SWM Supplier Wireless Module
mph miles per hour
ms millisecond(s) T
TA Traction Power Amplifier
N
temp Temperature
N/A Not Applicable or Not Available
TM Traction Motor
Nm newton meter
TP Tie Point
NVM Non-Volatile Memory
TS Terminal Strip

O T/S Troubleshoot

OD Operator’s Display
U
OSHA Occupational Safety and Health
Administration UL Underwriters Laboratories, Inc.

oz. ounce UNC Unified Coarse thread

UNF Unified Fine thread
P
P pump or lift contactor V

pot potentiometer V Volt or Volts

psi pounds per square inch VAC Volts Alternating Current

PWM Pulse Width Modulation VDC Volts Direct Current

P/N Part Number VM Vehicle Manager (ETAC)

R W

RAM Random Access Memory wrt with respect to

Publication: 1010183, Issued: 20 Mar 2014 1-5

Section 1. How To Use This Manual Model 102XM Maintenance Manual

Abbreviations & Symbols

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

1-6 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 2. Safety

Section 2. Safety

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Section 2. Safety Model 102XM Maintenance Manual

Definitions

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

A warning specifies a potentially

hazardous situation that, if not
prevented, could result in death or
serious injury.

A caution specifies a potentially

hazardous situation that, if not avoided,
could result in minor or moderate injury
or in damage to the lift truck or nearby
objects. A caution can also alert against
unsafe practices.

2-2 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 2. Safety

General Safety

General Safety Operate this truck only from the operator’s

position.
6299-002.tif

Do not operate or work on this truck unless

you are trained, qualified, authorized, and have
read the Owner and Operator Manuals.
8B15004D.tif

Know the truck’s controls and what they do.

6299-008.tif
Before working on this truck, always press the
red OFF key ( O ) on the keypad and disconnect
the truck’s battery connector (unless this
manual tells you otherwise).
6299-003.tif

Report any malfunction or unsafe condition to

your supervisor immediately. Do not operate
this truck if it needs repair or if it is in any way
unsafe.
6299-001.tif
Do not wear watches, rings, or jewelry when
working on this truck.
1864_067.tif

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Section 2. Safety Model 102XM Maintenance Manual

General Safety

Obey the scheduled lubrication, maintenance, Clean up any hydraulic fluid, oil, or grease that
and inspection steps. has leaked or spilled on the floor.
schedmnt.tif spills.tif

Obey exactly the safety and repair instructions Always park this truck indoors.
in this manual. Do not take “shortcuts.” 6299-004.tif

6299-014.tif

Do not park this truck in a cold storage area

Do not use an open flame near the truck. overnight.
23L6S012.tif 6299-015.tif

Do not use gasoline or other flammable liquids Do not wash this truck with a hose.
for cleaning parts. 6299-010.tif

6299-009.tif

2-4 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 2. Safety

General Safety

Do not add to or modify this truck until you

contact your local authorized Raymond Sales
and Service Center to receive written
manufacturer approval.
6299-011.tif

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Section 2. Safety Model 102XM Maintenance Manual

Battery Safety

Battery Safety Make sure a shower and eyewash station are

nearby in case there is an accident.
04G6S059.tif

As a battery is being charged, an

explosive gas mixture forms within and
around each cell. If the area is not
correctly ventilated, this explosive gas
can remain in or around the battery for
several hours after charging. Make sure
there are no open flames or sparks in A battery gives off explosive gases. Never
the charging area. An open flame or smoke, use an open flame, or use anything that
spark can ignite this gas, resulting in gives off sparks near a battery.
serious damage or injury. 23L6S012.tif

Battery electrolyte is a solution of

sulfuric acid and water. Battery
electrolyte causes burns. If any
electrolyte comes in contact with your
clothing or skin, flush the area
immediately with cold water. If the
solution gets on your face or in your Keep the charging area well-ventilated to avoid
eyes, flush the area with cold water and hydrogen gas concentration.
get medical help immediately. 04G6S058.tif

Wear personal protective equipment to protect

eyes, face, and skin when checking, handling,
or filling batteries. This equipment includes
goggles or face shield, rubber gloves (with or
without arm shields), and a rubber apron.
25L6SO16.tif

2-6 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 2. Safety

Battery Safety

Press the red OFF key ( O ) on the keypad before Keep plugs, terminals, cables, and receptacles
disconnecting the battery from the truck at the in good condition to avoid shorts and sparks.
battery connector. Do not break live circuits at 27Y7S013.tif

the battery terminals. A spark often occurs at

the point where a live circuit is broken.
6299-003.tif

Do not lay tools or metal objects on top of the

battery. A short circuit or explosion could Keep filler plugs firmly in position at all times
result. when not checking the electrolyte level, adding
04G6S057.tif
to the cells, or checking the specific gravity.
09G6S047.tif

Vent Hole

Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.
6299-013.tif

Make sure the vent holes in the filler plugs are

open to permit the gas to escape from the cells.

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Section 2. Safety Model 102XM Maintenance Manual

Battery Safety

Do not permit cleaning solution, dirt, or any Obey the charging procedures in the Battery
foreign matter to enter the cells. Instruction Manual and in the Battery Charger
6299-007.tif
Instruction Manual.
25L6S014.tif

Make sure you install the correct size and

voltage battery. A smaller or lighter weight
battery could seriously affect truck stability.
An incorrect voltage battery could damage the
truck’s electrical system. See the truck’s
specification plate for more information.
6299-012.tif

Never plug a battery charger into the truck’s

battery connector. Plug the battery charger only
into the battery connector from the battery.
6299-005.tif

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Model 102XM Maintenance Manual Section 2. Safety

Jacking Safety

Jacking Safety Tractor Section

1. Lower the forks completely. Remove any
When it is necessary to jack the truck off the load.
floor to perform maintenance procedures, 2. Position all controls in neutral.
observe the following safety precautions:
3. Block the wheels to prevent movement of
the vehicle.
4. Press the red OFF key ( O ) on the keypad
Use extreme care whenever the truck is and disconnect the battery connector.
jacked up. Keep hands and feet clear 5. Position the jack in the designated jacking
from the vehicle while jacking the truck. position.
After the truck is jacked, put solid blocks Figure 2-2. Tractor Jacking Points
beneath it to support it. DO NOT rely on 6270-003.tif

the jack alone to hold the truck.

Fork Section
1. Using the lift button, raise the forks to
maximum height.
2. Block the fork section by placing a block
behind the load wheels as shown in
Figure 2-1. The tractor section remains on
the floor.
Figure 2-1. Blocking the Fork Section 6. Jack one side of the truck so that the drive
27Y7S068.tif tire is no more than 1 in. (25.4 mm) off the
floor.
7. Block that side of the truck in position.
8. Jack the other side of the truck level with
the first side.
9. Block that side of the truck in position.
NOTE: After working on a vehicle, test all
controls and functions to make sure
operation is correct.

3. Lower the forks on the blocks.

4. Press the red OFF key ( O ) on the keypad
and disconnect the battery connector.

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Section 2. Safety Model 102XM Maintenance Manual

Towing

Towing
To safely tow this truck:
1. Lower the forks and remove any load.
2. Press the red OFF key ( O ) on the keypad
and disconnect the battery connector.
3. Using a suitable towing vehicle, lift the
tractor end of the truck until the drive tire
is no more than 1 in. (25.4 mm) off the
floor.
4. Tow the truck slowly in the tractor-first
direction.
NOTE: If a suitable towing vehicle is not
available, the electromagnetic brake
must be disabled to move this truck. See
“Mechanically Releasing the Brake” on
page 7-21.

2-10 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 2. Safety

Static Safety

Static Safety Figure 2-3. Anti-Static Kit (P/N 1-187-059) With Wrist
Strap and Mat
mat2.tif

Electronic circuit boards can contain Wrist Strap Static-Dissipative

Electrostatic Discharge Sensitive (ESDS) Work Surface
devices.

Static charges can accumulate from normal

operation of the truck as well as movement or
contact between non-conductive materials
(plastic bags, synthetic clothing, synthetic soles
on shoes, styrofoam coffee cups, and so forth).

Accumulated static can be discharged through

human skin to a circuit board or component by
touching the parts. Electrostatic Discharge
(ESD) is also possible through the air when a
charged object is put close to another surface at
a different electrical potential. Static discharge
can occur without you seeing or feeling it. Ground Cord

Whenever working on or near static-sensitive

electronics, always use static discharge Wrist straps (P/N 1-187-058/001) are available
precautions. in quantities of 25, as part number
1-187-058/005.
1. Put a static discharge wrist strap around
your wrist. Connect the ground cord to the A wrist strap tester is available as part number
wrist strap connector. 1-187-060.
2. Connect the ground cord to an unpainted,
grounded surface on the truck frame. Contact your authorized Raymond Sales and
3. If you are removing or installing Service Center for information.
static-sensitive components, put them on
a correctly grounded static mat.
4. To transport static-sensitive components,
including failed components being
returned, put the components in an
anti-static bag or box (available from your
Raymond Sales and Service Center).

The wrist strap and associated accessories

should be tested monthly to verify they are
working correctly. The wrist strap contains a
one megohm resistor in the strap cord that acts
as a fuse for personal protection. If this resistor
is open, the strap becomes ineffective.

Figure 2-3 shows the components of the

Raymond anti-static field service kit, part
number 1-187-059. The kit includes a wrist
strap, ground cord, and static-dissipative work
surface (mat). Follow the instructions packaged
with this kit.

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Section 2. Safety Model 102XM Maintenance Manual

Welding Safety

Welding Safety • You always press the red OFF key ( O ) on

the keypad and disconnect the battery
before you attempt to inspect, service, or
repair the lift truck. Discharge residual
charge in the power amplifier by
connecting a load across the power
Flame cutting or welding on painted amplifier’s B+ and B– (such as a contactor
surfaces may produce potentially coil).
harmful fumes, smoke, and vapors. 6299-003.tif

Remove any coating in the vicinity

where the operation(s) will be
performed prior to performing flame
cutting or welding operations.

Coating removal may be by mechanical

methods, chemical methods, or a • Check for shorts to frame as identified on
combination of methods. Perform flame page 5-4. If any shorts are found, remove
cutting and/or welding operations only them before you proceed with the welding
in well ventilated areas. Use local operation.
exhaust if necessary.
• Clean the area to be welded.
Before working on this truck, make sure that: • Protect all truck components from heat,
weld spatter, and debris.
• Fire protection equipment is nearby.
• Attach the ground cable to a clean,
• You know where the nearest eyewash
unpainted surface as close to the weld
station is located.
area as possible.
04GSO59.tif

• Do not perform any welding operations

near the electrical components.
• Do not attach the ground cable to
fasteners or other removable components.
• If you must weld near the battery
compartment, remove the battery from the
truck.
• When you are finished welding, perform all
ground tests and electrical inspections
before operating the vehicle.

2-12 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 3. Systems Overview

Section 3. Systems Overview

Publication:1010183, Issued: 20 Mar 2014 3-1

Section 3. Systems Overview Model 102XM Maintenance Manual

Introduction

Introduction
This manual provides information for
maintenance and repair of the Raymond Model
102XM pallet trucks.

This manual contains the most current and

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

For the latest information on your Raymond lift

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

3-2 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 3. Systems Overview

Truck Model Identification

Truck Model
Identification
Figure 3-1. Model 102XM Pallet Truck
6349-002.jpg

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Section 3. Systems Overview Model 102XM Maintenance Manual

Vehicle Specifications

Vehicle Specifications

The total weight of the load must include

the pallet and the container or the
device holding the load.

Category Model 102XM

Maximum Load Capacity 4,500 lb. (2,041 kg)
Upright Height 50.8 in. (129.1 cm)
Overall Length (Handle Raised) up to 81.8 in. (207.8 cm)
Overall Width 28.0 in. (711 mm)
Maximum Lift Height 8.65 in. (219.7 mm)
Regular Speed, Maximum 3.9 mph (6.3 kph)
Stopping Distance 6 ft. (1.83 m)
Battery Compartment Width 7.8 or 9.0 in. (198 or 228 mm)
Battery Voltage 24V
Minimum Battery Weight 200 lb. (91 kg)
Maximum Battery Weight 660 lb. (299 kg)
Truck Weight Without Battery 800 lb. (362 kg)
Wheel: Drive 10 x 5 in. Rubber
Wheel: Load 3.25 x 5 in. Polyurethane (2)

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Model 102XM Maintenance Manual Section 3. Systems Overview

Lift Truck Specifications

Lift Truck Specifications compartment near the hydraulic unit for

detailed truck and load information. See
Figure 3-2.
This lift truck is rated for performance by load
center and load weight with forks elevated. Due to continuous product improvement,
specifications are subject to change without
Review the specification plates located on the notice or obligation.
top right side of the tractor frame and inside the

Figure 3-2. Lift Truck Specification Plate - Model 102XM Pallet Truck
3939-352-256.cgm

Nominal battery
Serial number voltage

Raymond model Maximum battery

weight for this lift
truck
Approximate weight
of lift truck with Power rating of
battery installed, battery
minus load
Hour rating of
battery
Approximate weight Minimum battery
of lift truck minus weight for this lift
battery and load truck
Battery weight must be
Maximum load between the minimum
capacity for this lift and maximum weight
truck

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Section 3. Systems Overview Model 102XM Maintenance Manual

Operator Display and Programming

Operator Display and Hour Meter (H)

Programming To change Hour Meter settings:
1. Enter the Special Truck Mode. See
The Operator Display is installed on the top of “Special Truck Mode” on page 3-6.
the control handle and displays operational and 2. Press and hold the horn button until “H”
servicing information. is displayed. The hour meter indicator
Figure 3-3. Operator Display (hourglass icon) is illuminated. See
P0010517.png

Figure 3-3. If the horn button is released

A at the wrong time, turn the truck OFF and
Explanation of
Symbols:
start over.
3. Choose the desired time to be displayed by
A = Alpha-Numeric pressing the thumb controls:
Field
• A. = key time
B = Hour Meter
Indicator • b. = activity time (drive, lift, lower)
C = Parameter • c. = traction motor time
Indicator
D = Battery • d. = lift time
Indicator • S. = time to service
E = Error Indicator E D C B 4. Press the thumb control to step between
the different functions. The display shows
the number of hours for each function. See
“Parameter 20” on page 3-12.
Special Truck Mode 5. Press the red OFF ( O ) key on the keypad
to end the hour meter display.
NOTE: Installation of a Service Key is required
to make some changes. See
“Programming Service Parameters” on Error Codes (E)
page 3-8.
When an error occurs, a code is displayed. See
To enter a Special Truck Mode: “Messages and Caution Codes” on page 6-3.
1. Press and hold the horn button (S18). At
the same time turn the key switch ON, or Error Code History
enter the operator-specific PIN-key code
on the keypad, then press the green ON To access Error Code History:
button on the keypad. 1. Enter the Special Truck Mode. See
2. Continue to hold the horn button while “Special Truck Mode” on page 3-6.
the display (see Figure 3-3) cycles through 2. Press and hold the horn button until “E” is
the following functions: displayed. The error indicator (wrench
• H = Hour Meter icon) is illuminated. See Figure 3-3. If the
horn button is released at the wrong time,
• E = Error Codes
turn the truck OFF and start over.
• P = Parameters
• Use the thumb control to scroll through
• Pn = Hardware and Software Part the last 50 error codes. The latest fault
Numbers is shown first. The display first shows
3. Release the horn button at the selected the error code and then the hour the
display. If the horn button is released at fault occurred.
the wrong time, turn the truck OFF and
start over.

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Operator Display and Programming

• The error codes are divided into two 2. Press and hold the horn button until “P” is
groups C = caution and E = error. displayed. The parameter indicator (wheel
• The C error codes are not stored. It is icon) is illuminated. If the horn button is
only a caution and is highlighted on the released at the wrong time, turn the truck
display as long as the fault exists. OFF and start over.

• For example, if you only have one fault 3. Use the thumb control to scroll to the
registered in the memory, the second desired truck parameter you want to
empty place is shown like this: Fault: E change or view. See “Truck Driver
- - - and time: - - - -. Parameters” on page 3-7. Release the
thumb control to neutral when the desired
3. End displaying the error code history by parameter number is shown.
pressing the red OFF ( O ) key on the
keypad. 4. Press the horn button once to access the
parameter. The parameter symbol on the
display starts flashing.
Changing Truck Parameters (P) 5. Change the parameter value by pressing
the thumb control up or down. Release the
thumb control to neutral when the desired
parameter number is shown.
Modifying specific truck parameters 6. Press the horn button again to confirm the
changes the driving characteristics of the change. The parameter symbol on the
truck. display stops flashing and remains
illuminated.
Programming Truck Parameters 7. End programming by pressing the red OFF
( O ) key on the keypad.
To program the truck’s operating parameters, • The parameter change is complete. The
follow the directions below (also see “Setting next time the truck is started, the new
Individual PIN-key Codes” on page 3-9): parameter is in effect.
1. Enter Special Truck Mode. See “Special
Truck Mode” on page 3-6.
Table 3-1. Truck Driver Parameters
Range
Parameter Name Unit Step Default Description
(Step)
1 Max Speed, % 10 to 40 2 20 Maximum speed value sent to the
Slow Mode traction power amplifier while in Slow
Mode, except during Turtle Torque
(gives torque boost if high load
encountered)
10: low speed
40: full speed
2 Max Speed, % 10 to 98 2 94 Reduces the maximum speed value
Fast Mode sent to the traction power amplifier
while in Fast Mode (all throttle
positions)
10: low speed
98: full speed

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Operator Display and Programming

Range
Parameter Name Unit Step Default Description
(Step)
3 Acceleration % 30 to 90 5 80 Defines truck acceleration
characteristics. The lower the
number, the less aggressive the
acceleration
30: low acceleration
90: full acceleration
4 Deceleration % 40 to 90 5 65 Defines the automatic plug-braking
characteristic when the throttle is
reduced (including to neutral). A lower
number results in a less aggressive
deceleration.
40: low reduction force
90: full reduction force
5 Truck OFF Min. 0 to 20 1 0 Sets the truck off delay (energy saving
Delay (with feature). If this amount of time passes
optional while the tiller arm is in a brake
Keypad Only) position and the truck is idle (no
outputs requested), the VM powers
the truck OFF. When this parameter
is set to 0, the truck never powers
OFF. If parameter 39 is 1 or 2 (truck
does not have an optional keypad),
the truck never powers OFF.
0: never turns off
20: 20 minutes

Programming Service Parameters 4. Press the horn button once to access this
parameter. The parameter symbol on the
1. Connect the service key to the service key display flashes. Now you can make
connector J41. Make sure the Main changes to the value of the first driver’s
ON/OFF switch (S21) is in the ON PIN code. See Table 3-4.
position. See “Special Tools” on page 3-18.
NOTE: All parameters can be viewed; however,
2. Turn the truck ON while holding the horn
not all parameters can be changed.
button until “P” is displayed. Release the
Driver parameters may or may not be
horn button at “P” to enter parameter
accessed, depending on the value of
mode. The Parameter indicator (wheel
parameter 39.
icon) on the display illuminates when in
parameter mode. See “Special Truck
Mode” on page 3-6. If the horn button is Parameter Displays
released at the wrong time, turn the truck
OFF and start over. When parameters 1 through 5, and 10 are
viewed with the service key, both the parameter
3. Rotate the thumbwheel in the fork
number (left side of display) and the 1st
direction to progress forward through the
operator number (right side of display) are
parameters. While the thumbwheel is held
shown.
and briefly after it is released, both the
parameter number and the driver number
As the parameter number display progresses
are displayed. Stop at parameter 10 (PIN
through parameters 1 through 10, the display
code) for the first driver; the default value
rolls over to the next operator (the operator
of “1” is displayed. See Figure 3-3.
number increases). If a parameter is changed, it
is valid only for the operator shown. After all

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Model 102XM Maintenance Manual Section 3. Systems Overview

Operator Display and Programming

operators and operator parameters are scrolled control in a direction for a time helps
through, Service Parameters 11 through 40 are quickly advance to larger numbers (for
displayed. example, codes greater than 100). The
PIN-key code can be from one to four digits
To quickly display/access a Service Parameter, long. Release the thumb control when the
rotate the thumb control away from the forks desired value is reached.
(sequence backwards through the 7. Press the horn button again to confirm the
parameters/operators). new PIN-key code value. The parameter
symbol on the display stops flashing.
Setting Individual PIN-key Codes 8. To enable additional operators; rotate the
1. Connect the service key at J41. See thumb control in the fork direction to roll
“Special Tools” on page 3-18. Make sure over to the second operator, and stop at
that the Main ON/OFF switch is ON. parameter 10. The default value of “0” is
displayed. Follow the previous steps for
2. Enter Special Truck Mode. See “Special the desired number of different PIN-key
Truck Mode” on page 3-6. codes you want to set up. There are a total
3. Press and hold the horn button until “P” is of ten operators.
displayed. The parameter indicator (wheel
NOTE: Disabling all operators (all PIN-key code
icon) is illuminated. If the horn button is
values = 0) prohibits truck operation
released at the wrong time, turn the truck
without the service key.
OFF and start over.
4. Use the thumb control to scroll through NOTE: Use unique PIN-key codes to avoid
the service parameters. While the thumb confusion. If two operators have the
control is held and briefly after it is same PIN-key code, the higher number
released, both the parameter number (on operator’s parameters are used. For
the left side of the display) and the example if both the first and second
operator number (on the right-this only operator PIN-key code is 1111, and the
occurs if the service key is connected) are first operator’s max speed is 80% and
displayed. Stop (release the thumb control) the second operator’s max speed is 90%,
at parameter 10 (PIN-key code) (See when someone logs in with 1111 the
“Parameter 10” on page 3-12.) for the first max speed used is 90%.
operator; the default value of “1” is
displayed.
5. Press the horn button once to access this
parameter. The parameter symbol on the
display flashes. Now you can make
changes to the value of the first operator’s
PIN-key code.

Changing the 1st operator’s PIN-key

code alters default operation. You will
not be able to press “1” and green ON
( I ) to power the truck unless an
operator’s PIN-key code is set to “1.”

6. Rotate the thumb control in the fork

direction to increase the PIN-key code
value, or in the operator direction to
decrease the value. Holding the thumb

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Operator Display and Programming

Table 3-4. Service Parameters
Parameter Name Unit Range Step Default Description
10 PIN code 0 to 9999 1 1 Can create up to 10 different PIN codes
(keypad (need Service Key to access).
only)
14 Creep Speed –10 to 10 1 –5 Throttle map adjustment. A negative
number allows more featherability at low
speeds. A positive number makes the
truck more responsive at low speeds.
-10: Low speed when reaching first speed
sensor
10: High speed when reaching first speed
sensor
15 Click-to- 0 or 1 1 0 (Set to Enables creep travel with the tiller arm
Creep 1 at the in the fully raised or lowered position.
factory) 0: Disable
1: Enable
NOTE: Activate click-to-creep by quickly
clicking the speed control in
either direction twice with the
tiller in the brake position. “SLO”
blinks on the display when in
click-to-creep mode.
NOTE: Deactivate by clicking the speed
control twice more. Also, the
mode deactivates automatically
after 10 seconds or immediately
if the emergency reverse (belly
button) switch is pushed.
16 Travel 0 to 15 1 0 Sets travel alarm
Alarm 0: OFF
1: Traveling FL
2: Traveling FT
3: Traveling FL or FT
4: Lifting
5: Lifting or Traveling FL
6: Lifting or Traveling FT
7: Lifting or Traveling FL or Traveling FT
8: Lowering
9: Lowering or Traveling FL
10: Lowering or Traveling FT
11: Lowering or Traveling FL or
Traveling FT
12: Lifting or Lowering
13: Lifting or Lowering or Traveling FL
14: Lifting or Lowering or Traveling FT
15: Lifting or Lowering or Traveling FL
or Traveling FT

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Operator Display and Programming

Parameter Name Unit Range Step Default Description

20 Hour Meter 1 to 5 1 2 Select the hour meter you want to
Selection display:
1: (A) key time
2: (b) activity time (drive, lift, or lower)
3: (c) traction motor time
4: (d) coast drive time
5: (S) time to service
21 Battery Size 1 to 20 1 8 Determines the discharge rate for the
battery discharge indicator:
1: Least discharge
20: Greatest discharge
25 Service Hours 0 to 2000 50 0 Sets the service time.
Interval 0: Disable
2000: 2000 hours
39 Access Code 1 to 4 1 3 Defines whether truck has a key switch
or a keypad and what access level service
personnel have to parameters:
1: key switch only (no keypad) and driver
parameters are open,
2: key switch only (no keypad) and driver
parameters are closed,
3: keypad and driver parameters are
open,
4: keypad and driver parameters are
closed.

Parameter Description Parameter 4

Parameter 1 Auto-Plug Braking in Neutral - Defines the

truck’s automatic plug-braking characteristic
when the throttle is reduced (including to
Maximum speed value sent to the power
neutral). A lower number results in a less
amplifier while in Slow mode except during
aggressive deceleration.
Turtle Torque (gives torque boost if high load is
encountered).
Parameter 5
Parameter 2
Automatic Time Off Interval (keypad only) - Sets
truck off delay (energy saving feature). If this
Top Speed - Reduces the maximum speed value
amount of time passes while the tiller arm is in
sent to the traction power amplifier while in fast
a brake position and the truck is idle (no
mode (all throttle positions).
outputs requested), the VM powers the truck
OFF. When this parameter is set to 0, the truck
Parameter 3 never powers OFF. If parameter 39 is 1 or 2
(truck doesn’t have an optional keypad), the
Acceleration - Defines truck’s acceleration truck never powers OFF.
characteristics. A lower number results in a
less aggressive acceleration.

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Operator Display and Programming

Parameter 10 Parameter 16
(starting with software version 3.6)
Can create up to 10 different PIN codes (need
Service Key to access). A Service Key is required The travel alarm can be set as follows.
to assign up to 10 operators their own PIN-key
• 0: OFF
code (one to four digits) for access to the truck.
See “Setting Individual PIN-key Codes” on • 1: Traveling Forks-Leading (FL)
page 3-9. • 2: Traveling Forks-Trailing (FT)
NOTE: Driver is disabled when set to 0 • 3: Traveling FL or FT
(2 through 10 driver’s default Pin is 0), if • 4: Lifting
all drivers are disabled the truck cannot
be driven without the service key. • 5: Lifting or Traveling
• 6: Lifting or Traveling FT
NOTE: If two drivers have the same PIN
number, the driver with the highest • 7: Lifting or Traveling FL or Traveling FT
parameter settings is used for both • 8: Lowering
drivers.
• 9: Lowering or Traveling FL
• 10: Lowering or Traveling FT
Parameter 14
• 11: Lowering or Traveling FL or Traveling
Throttle map adjustment. A negative number FT
allows more featherability at low speeds. A • 12: Lifting or Lowering
positive number makes the truck more
• 13: Lifting or Lowering or Traveling FL
responsive at low speeds. A setting of 0 equals
linear response to the handle commands. • 14: Lifting or Lowering or Traveling FT
• 15: Lifting or Lowering or Traveling FL or
Parameter 15 Traveling FT
(starting with software version 3.6)
Parameter 20
Enables creep travel with the tiller arm in the
fully raised or lowered position: “0” disables the You choose the hour meter you want to display.
option and “1” enables the option. Default • 1 (A) key time
setting is “0”, set to “1” at the factory.
• 2 (b) activity time (drive, lift, or lower)
Activate click-to-creep by quickly clicking the • 3 (c) traction motor time
speed control in either direction twice with the • 4 (d) coast drive time
tiller in the brake position. “SLO” blinks on the
display when in the mode. • 5 (S) time to service
NOTE: If Parameter 25 is set to 0, the power-on
Deactivate by clicking the speed control twice 5 second hour meter display is skipped
more. Also the mode deactivates automatically and 5 (S) is not shown during hour
after 10 seconds or immediately if the meters special truck mode.
emergency reverse switch is pushed.
NOTE: Time to service decrements the value of
Parameter 25 until it reaches 0.
NOTE: As 5 (S) decrements, 2 (b) increments at
the same rate.

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Operator Display and Programming

Parameter 21 Determining Optimum Parameter 21 Setting

- Maintenance Free Batteries
Defines battery capacity (amp-hr. rating) used
to determine a rate for the battery discharge Use the following procedure when working with
indicator. A higher number represents a larger Maintenance Free Batteries.
capacity battery. The higher the number, the 1. Charge the battery. Operate the truck
longer it takes for the battery discharge under normal conditions until you reach
indicator to decrease. the point of lift cutout, 0% on the display,
the battery should be 80% discharged.
Determining Optimum Parameter 21 Setting
2. Let the battery set for at least two hours
- Flooded Lead Acid Batteries
without using it or charging it. After two
hours, measure the voltage of the battery.
Flooded Lead Acid Batteries frequently need
If the discharge voltage meets the
water added. Use the following procedure when
manufacturer’s specifications, the present
using Flooded Lead Acid Batteries.
Parameter 21 setting is good. If the
1. Check the specific gravity of a fully discharge voltage does not match the
charged battery. The specific gravity manufacturer’s specifications, perform the
reading should be between 1.27 and 1.29. remaining steps.
2. Operate the truck under normal NOTE: The discharge voltage can vary between
conditions until you reach the point of lift battery manufacturers. See the battery
cutout, 0% on the display. The battery manufacturer’s information for the exact
should be 80% discharged. discharge specifications.
3. Let the battery set for at least two hours
3. To increase the discharge voltage, you
without using it or charging it. Check the
must decrease the present Parameter 21
specific gravity (SG). If the specific gravity
value. To decrease the discharge voltage,
is near, but not below 1.15, the present
you must increase the present Parameter
Parameter 21 setting is good. If the SG is
21 value. Increase or decrease, as
less than or not near 1.15, perform the
applicable, the present value one digit at a
remaining steps.
time. Do not make big changes.
NOTE: A reading greater than 1.15 reduces the 4. Fully charge the battery and repeat steps 1
risk of damaging the battery. and 2. Adjust per step 3 and repeat as
NOTE: The specific gravity can vary between necessary until the desired results are
battery manufacturers. See the battery obtained.
manufacturer’s information for the exact
discharge specifications. Parameter 25
4. To increase the specific gravity, you must
decrease the present Parameter 21 value. Sets the service time. C29 is displayed when the
To decrease the specific gravity, you must time has expired.
increase the present Parameter 21 value. NOTE: To reset the service timer, access this
Increase or decrease, as applicable, the parameter without changing the value.
present value one digit at a time. Do not
make big changes. NOTE: To disable the service timer, set this
parameter to 0.
5. Fully charge the battery and repeat steps 2
and 3. Adjust per step 4 and repeat as NOTE: This parameter is related to Parameter
necessary until the desired results are 20.
obtained.

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Operator Display and Programming

Parameter 39

Defines whether the truck has a key switch or a

keypad and what access level service personnel
have to parameters.
• 1: key switch only (no keypad) and driver
parameters are open,
• 2: key switch only (no keypad) and driver
parameters are closed,
• 3: keypad and driver parameters are open,
• 4: keypad and driver parameters are
closed.
NOTE: When driver parameters are closed, the
service key is required to access driver
parameters.

Display Part Numbers (Pn)

1. Enter the Special Truck Mode. See
“Special Truck Mode” on page 3-6.
2. Press and hold the horn button until “Pn”
is displayed. If the horn button is released
at the wrong time, turn the truck OFF and
start over.
3. Use the thumb control to scroll and
display the following information:
• HPn = Hardware part number (of VM)
• HSn = Hardware serial number (of VM)
• SPn = Software part number (of VM)
4. End displaying the part number by
pressing the red OFF ( O ) key on the
keypad.

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Service Display

Service Display Table 3-1. Service Display Modes

Flashing
• Connect the service key (see “Special Displayed Data
Symbol
Tools” on page 3-18) in connection point
J41 and press the green ON key ( | ) to B Speed reference value sent to power
amplifier.
start the lift truck.
• The battery status is displayed and the C Digital inputs/outputs from power
symbol “D” is lit continually. amplifier and vehicle manager.
* See explanation following
• Press horn button (S18) to toggle between
display modes. See Table 3-1. BC Battery voltage (V) at vehicle
manager
Figure 3-5. Operator Display
P0010517.png

D Armature current (A)

A
Explanation of BD Field current (A)
Symbols:
CD Armature PWM in %
A = Alpha-Numeric
Field BCD Status of power amplifier. See
“Typical Power Amplifier Status” on
B = Hour Meter page 3-17.
Indicator
C = Parameter E Field resistance (Ohms), used for
Indicator thermal cutback.
D = Battery
Indicator
* Digital inputs/outputs are displayed by
E = Error Indicator E D C B highlighting the figure segments of three of the
numerical field figures (A) in the operator
display. See “Digital Inputs/Outputs from
Power Amplifier”.

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Section 3. Systems Overview Model 102XM Maintenance Manual

Service Display

Digital Inputs/Outputs from Power Amplifier Outputs

Power Amplifier
The second most significant figure active
(marked with arrow).
Power Amplifier Inputs P0012239.png

The first most significant figure active (marked

with arrow).
P0010795.png

P0010785.png

Figure
P0010785.png
Segments

Figure
Segment

Figure
Function
Segment

B
Figure
Function
Segment C Output (J5-2): Lower valve
A D
B Input (J5-14): Arm Angle B E Output (J5-4): Main contactor
interlock
C Input (J5-15): Lift limit
F Output (J5-7): Horn
D Input (J5-12): Arm Angle A
G Output (J5-5): Brake
E Input (J5-2): Lower valve (lit if
valve is present and not powered) DP Output (J5-6): Pump contactor
F

G Input (J5-5): Brake (lit if brake is

present and not released)

DP

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Service Display

Digital Input from Vehicle Manager Typical Power Amplifier Status

Control Sensors

The third most significant figure active (marked

with arrow). Status Comments
P0010806.png

13 No Activity: Main contactor open

because no output requested for
30 seconds or an error occurred.

24 Passive restraint (transitional)

16 Passive restraint

1 Motor drive, plug, or active

neutral braking

17 Active restraint while driving

(overspeed)
P0010785.png

10 Regen

11 Regen taper (transitional)

Figure
Segments 4 Field reversal (transitional)

74 Emergency reverse (regen)

65 Emergency reverse (drive)

6 Disable (major fault, such as

severe overvoltage)

129 Emergency shutdown while in

drive
Figure
Function
Segment 144 Emergency shutdown while in
passive restraint
A

D Vehicle manager input: lift forks

E Vehicle manager input: lower

forks

F (not used)

G (not used)

DP Vehicle manager input: horn

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Section 3. Systems Overview Model 102XM Maintenance Manual

Special Tools

Special Tools
The following tools are available from your local
authorized Raymond Sales and Service Center.

Table 3-2. Special Tools

Tool Part Number Purpose

Anti-static Field Kit 1-187-059 ESD Protection

Anti-static Wrist Straps 1-187-058/001

Anti-static Wrist Strap 1-187-060/100

Tester

Surge Protector 154-010-801 ESD/voltage surge protection for serial type FlashWare
connections

USB/CAN Interface 230489-001 FlashWare connection to truck. See “FlashWare” on

page 3-35 for details.

USB Cable 163793BT USB cable used with FlashWare connection. See
“FlashWare” on page 3-35 for details.

CPC-USB CAN 230489-001 TruckCOM connection to truck (USB port to truck). See
Interface “TruckCom” on page 3-23 for details.

CPC-PP CAN Interface 163792 TruckCOM connection to truck (PC Parallel/printer port to
truck). See “TruckCom” on page 3-23 for details.

USB Cable 163793 USB cable used with TruckCom connection. See
“TruckCom” on page 3-23 for details.

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Special Tools

Programmable Maintenance Figure 3-7. Connecting PMT to Power Amplifier

(P/N 950-185/002 shown)
Tool 6349-010.jpg

NOTE: On trucks with the dual Main ON/OFF

Connector
switch, the wiring harness changed. For
the PMT to connect and display
controller information, the Main
ON/OFF switch must remain in the ON
position.
• Leave the Main ON/OFF switch in the
ON position. Turn OFF the truck by
using the key switch, keypad, or by
disconnecting wire #20 or wire #22
from the “dual” Main ON/OFF rocker
switch (for Raymond trucks
incorporating a “dual” rocker switch).
• When the Programmable Maintenance The Menu Navigation Key moves the screen
Tool is connected to the truck and curser up or down through the Menu list (top or
displaying controller information, bottom arrow), and opens or closes Sub-Menus
restart the truck by using the key (right or left arrows).
switch, keypad, or reconnecting wire Figure 3-8. Programmable Maintenance Tool
#20 or #22 to the dual Main ON/OFF 6957-002.jpg

rocker switch.
Data Inc/Dec
The optional Programmable Maintenance Tool Key
(PMT) (P/N 950-180 or 950-185/002) permits
you to test and diagnose the power amplifier in Bookmark
the truck. See Figure 3-6. Keys
Figure 3-6. Programmable Maintenance Tool
(P/N 950-185 shown)
6957-002.jpg

Menu
Navigation
Key

The Data Inc/Key changes the value of the

parameter indicated by the curser.

The Bookmark Keys allow you to quickly go

back to your favorite selections without having
to navigate back through the Menu.
• To select a position in the menu, hold a
Bookmark Key down for three seconds
until the bookmark set screen is
The PMT is powered by the power amplifier
displayed.
through a four-pin connector at the bottom of
the power amplifier. See Figure 3-7. • To jump to a selected Bookmark position,
press the appropriate Bookmark Key.

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Special Tools

NOTE: The Bookmarks are not permanently parameter value by pressing the Data
stored in the PMT. They are cleared Inc/Dec Key. The new value is set as soon
when the PMT is unplugged. as the Data Inc/Dec Key is released.

The Main Menu is the starting point for the To close a Monitor Menu, sub-menu, or detail
PMT. The main menu displays menu titles: screen, press the left arrow on the Navigation
• Program (not used) Key.

• Monitor
Faults Mode
• Faults
• Functions (not used) In System Faults mode, currently active faults
• Information detected by the controller are displayed.

• Programmer Setup In Faults History mode, the controller’s

diagnostic history file is displayed. This field
If there are no entries within a Menu, then the includes a list of all faults observed and
Menu title is not displayed. recorded by the controller since the history was
last cleared.
Monitor Mode
NOTE: Each fault is listed only once, regardless
of the number of times it occurred.
Real-time status information is displayed in the
Monitor mode for various inputs, outputs, 1. Press the red OFF ( O ) key on the keypad.
temperature, and so forth. This information can 2. Remove the tractor cover.
be helpful in troubleshooting many problems
and is useful for checking out the operation of 3. Connect the PMT to the power amplifier.
the controller during initial installation. Wait for the PMT to “boot up” before
proceeding to the next step.
1. Press the red OFF ( O ) key on the keypad.
4. Enter the PIN key code and press the
2. Remove the tractor cover. green ON ( | ) key on the keypad or turn
3. Connect the PMT to the power amplifier. key switch ON.
Wait for the PMT to “boot up” before 5. To view the present status of the unit, use
proceeding to the next step. the Menu Navigation Key to select
4. Enter the PIN key code and press the Faults -> System Faults
green ON ( | ) key on the keypad or turn 6. To access the log, use the Menu Navigation
key switch ON. Key to select Faults -> Fault History.
5. Use the Menu Navigation Key to select 7. Use the Up and Down arrows on the Menu
Monitor. Navigation Key to scroll through the list of
6. Press the right arrow on the Menu multiple faults.
Navigation Key to enter the sub-menu.
7. Use the Up and Down arrows on the Menu Clear
Navigation Key to scroll through the
sub-menu list of monitor variables. After you have diagnosed and corrected the
problem, clear the diagnostic history file. This
8. Use the right arrow to select and view a permits the power amplifier to accumulate a
single variable. new file of faults. By checking the new history
9. To change the value of the parameter, use file at a later date, you can easily determine
the Data Inc/Dec Key. Alternately, you can whether the problem was completely fixed.
press the right arrow Menu Navigation Key 1. To clear the fault history of the unit, use
once more and enter the detail screen. A the Menu Navigation Key to select
bar graph appears as well as minimum Faults -> Clear Fault History.
and maximum data points. Change the

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Special Tools

2. Press the increment arrow (+) for yes and 1. Press the red OFF ( O ) key on the keypad.
the decrement arrow (-) to cancel and not 2. Remove the tractor cover.
clear the fault history.
3. Connect the PMT to the power amplifier.
“Test Mode Menu” on page 3-21 lists possible Wait for the PMT to “boot up” before
messages you may see displayed when the PMT proceeding to the next step.
is operating in either System Faults or Fault 4. Enter the PIN key code and press the
History mode. green ON ( | ) key on the keypad or turn
the key switch ON.
Information Mode 5. Use the Menu Navigation Key to select
Programmer.
The Information Menu provides access to 6. Press the right arrow on the Menu
product information describing the basic Navigation Key to enter the sub-menu.
revision level of the PMT.
7. Use the Up and Down arrows on the Menu
To view, use the Menu Navigation Key to select Navigation Key to scroll through the
Information in the Main Menu. Remember to sub-menu list of Programmer displays.
press the right arrow to select a Menu. Press 8. Use the right arrow to select and view a
the left arrow to exit. single variable.
9. Change the parameter value by pressing
Programmer Mode the Data Inc/Dec Key. The new value is set
as soon as the Data Inc/Dec Key is
Programmer mode permits you to perform a released.
variety of tasks. Table 3-3. Test Mode Menu

Display Explanation
THROTTLE% Throttle reading, in % of full throttle
ARM CURRENT Motor armature current, in amps
FIELD CURRENT Motor field current, in amps
ARM PWM Armature duty cycle (PWM) - applied as %
FIELD PWM Motor field duty cycle (PWM) - applied as %
BATT VOLTAGE Battery voltage (B+ and B– connection) at key switch input
CAP VOLTAGE Voltage of power amplifier B+ (bus bar)
HEAT SINK TEMP Heatsink temperature - °C
FORWARD INPUT Forward switch: ON/OFF
REVERSE INPUT Reverse switch: ON/OFF
MODE Power Amplifier operating mode: 1 to 4
INTRLCK INPUT Interlock (brake/deadman) switch: ON/OFF
PEDAL INPUT (not used)
EMR REV INPUT Emergency reverse button: ON/OFF
MOTOR RPM (not used)
MAIN CONT Main contactor: ON/OFF
AUX CONT (not used)
REV OUTPUT (not used)

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Special Tools

Display Explanation
BRAKE OUTPUT (not used)
FAULT 1 OUTPUT (not used)
FAULT 2 OUTPUT (not used)
CONTROL STATE (not used)
MODSEL 1 Mode select 1 switch: ON/OFF
MODSEL 2 Mode select 2 switch: ON/OFF

Service Key
Use the optional Service Key (P/N 851-201-500)
directly on the truck to troubleshoot and
program the truck service parameter settings.
See “Programming Service Parameters” on
page 3-8.
Figure 3-9. Service Key
artemis_service_key.jpg

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Model 102XM Maintenance Manual Section 3. Systems Overview

TruckCom

TruckCom (P/N 163793). Connect the interface via the

printer port on a PC. Connect the cable between
the interface and the truck’s CAN terminal.
NOTE: TruckCom is used on trucks with
Vehicle Managers (P/N 1067833-003 The CAN interface is supplied with power from
and below) that are not compatible with the truck and PC electronics and is protected
FlashWare. from any high voltages in the truck if a fault
should occur.
This information is valid for TruckCom version
3.6. When TruckCom is opened, the type of interface
NOTE: Previous versions of TruckCom will not must be selected (under the setting tab
work once TruckCom 3.6 is installed. If dropdown) before attempting to scan for nodes.
you use both TruckCom and
TruckComSE, both versions must be
updated to the new versions.

General
TruckCom is a communication program that
communicates with trucks equipped with CAN
(Controller Area Network) communication.

It enables the following tasks to be performed:

• downloading truck control software
• viewing and adjusting operator/truck
parameters and hour meters. Additionally,
the truck’s parameter set (including hour
meter values) can be saved to file and
reloaded later.
• viewing diagnostic data for various digital
inputs/outputs and analogue data
including voltages, currents, and certain
temperatures.

The program is a Windows program running

under Windows® 95/98, Windows® XP/2000,
and Windows® NT.

Connection
A USB CAN interface of the CPC-USB type
(P/N 230489/001) is needed to connect
TruckCom to the truck, with cable
(P/N 163793). Connect the interface via the
USB port on a PC. Connect the cable between
the interface and the truck’s CAN terminal.

A Parallel port to CAN interface of the CPC-PP

type (P/N 163792) is available to connect
TruckCom to the truck, with cable

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TruckCom

Layout
Main Program Screen

The Main window opens when the program is

started. This shows the menu bar, tool buttons,
workspace, log window, and status window.
Figure 3-10. Main TruckCom Program Screen
TruckCom_001.jpg

Nodes Figure 3-11. Typical Node Window Display

TruckCom_002.jpg

Devices that are connected to and communicate

via the CAN interface are called nodes. The
nodes detected on the bus are shown in the
node window. The current node status and
input component/information is shown with
different icons.

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TruckCom

Icons Icon Definition

The following icons display in the main program Information is shown when a note
screen. has information (for example: error
Table 3-4. Icon Definitions codes).

Truck Report
Icon Definition Refer to “Truck Report Function” on
page 3-28.
Node OK is shown when contact is
made with a node and no errors are
Parameters is shown when a node
reported.
has information on a parameter
Node Not Connected is shown when
there is no contact with a node in the
network. Diagnostics

Node Not OK is shown when an error

is reported by a node. Click on the
Exit
node to obtain more information.

Program Version is shown when

information is available on the
software installed. Click to obtain
more information.

Tool Buttons and Menu Bar

The tool button bar allows direct access to the Explanations of each menu bar item are given
program’s most common functions. The menu in the related section.
bar allows access to all the program functions. Figure 3-12. Tool Button Bar

Information Window

The right section of the main window contains a

status widow where messages are shown. To
see previous messages, use the scroll arrows in
the right margin.

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TruckCom

Status Bar

A status bar at the bottom of the main window

shows variable status when the program is run.

The following items are shown from left to right:

1. Help text “pop-up” via the mouse cursor
2. Connected/not connected to network
3. Truck type connected
4. Initial result of CAN interface
5. Current time
Figure 3-13. Status Bar

Connect Function Disconnect Function

To connect the PC to the network, select the Select the Disconnect function to disconnect
Scan units function. This can be done with the from the network. This can be done with the
menu < Nodes | Scan units > or with the tool menu < Nodes | Set PC off-Line > or with the
button [Scan nodes]. tool button [Set PC off-Line].

This should be done when the truck is supplied The CAN interface is then reset and the CAN
with voltage and in the normal drive mode. The cable can be disconnected if necessary. This
program will run a check and installation of the enables connection to another truck without
CAN interface. A diagnosis will be carried out to having to close the program.
check that units are connected in the system.
The result of this diagnosis is shown in the
Node window.

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TruckCom

Downloading Program Function

Select the Download software function to
download a new program to one of the nodes.
This can be done with the menu < Tools |
Download software... > or with the tool button
[Download].

Figure 3-14.

Normal Downloading Normal Downloading

(trucks with key) (trucks with keypad)

Select Open... to open the file to be downloaded Select Open to open the file to be downloaded
into a node. The file name, file type, and version into a node. The file name, file type, and version
number are shown in the window for file number are shown in the window for file
information. If it is a file for a controller, indicate information. If it is a file for a controller, indicate
the type of controller that is to receive the file. the type of controller is to receive the file. Start
Start downloading by selecting Start... and by downloading by depressing and then releasing
restarting the truck by turning the key OFF and the red key on the truck keypad.
ON.
NOTE: The truck must be restarted within 20
NOTE: The truck must be restarted within 20 seconds from when the Start key is
seconds from when the Start button is activated.
activated.
Restart the truck and close the download
Restart the truck and close the download window when the download is complete, and
window when the download is complete, and then disconnect the PC from the network. A
then disconnect the PC from the network. A new connection can now be made to verify the
new connection can now be made to verify the new program.
new program.

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TruckCom

Emergency Downloading Truck Report Function

E141 is shown in the truck’s display when It is possible to generate a report to a file or disk
starting if, for any reason, there is no program with the truck’s configuration and status.
in the electronics card (interrupted Select menu < Tools | Generate truck report... >
downloading). Communication with the truck or with the tool button Truck report. Save the
via the PC will then be minimized. Use “E141” report in Report.file
to download the program in the card. Figure 3-16. Truck Report Screen

On some trucks, a counter that continuously

counts up is displayed.
NOTE: Once programmed, the logic cards in
some trucks can only be reloaded with
the same basic firmware. In other
words, it is not possible to replace the
basic firmware (other truck type).

Emergency Downloading (trucks with

key)
• Disconnect the battery connector.
Figure 3-17. Example of information generated in the truck
• Select OK in the dialogue box.
report
• Turn the key OFF while reconnecting the
battery connector.
• Turn the key ON to commence
downloading.

Emergency Downloading
(trucks with keypad)
• Disconnect the battery connector.
• Select OK in the dialogue box.
• Keep the red key on the keypad depressed
while reconnecting the battery connector.
• Release the red key to commence
downloading.
Figure 3-15.

The contents of certain rows can vary according

to truck type.

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TruckCom

Parameters Function
To change the truck parameters, select the
Parameter function. This can be done with the Do not attempt to make any
menu < Tools | Change parameters > or with adjustments to the option parameters
the tool button Parameters. unless you have sufficient knowledge of
the truck’s options/ modified functions.
NOTE: The truck must be in Normal mode (not
Specially modified trucks may require
in Parameter mode) when connecting
that you have access to special service
TruckCom. Otherwise TruckCom will
information. Incorrect adjustment of the
report “Unable to determine truck
option service parameters may result in
brand.”
a malfunction.
The parameter numbers follow the description
in the parameter tables. The parameter window PIN Code
shows the information and the current settings
for all parameters. The parameter types are The PIN code values can be set by entering the
divided into tabs. values in the text boxes. Changes can also be
done using the up/down arrows. If a value is
• Driver – Driver parameters and PIN code
entered directly in the text box, then make sure
storing (page 3-7)
to click the Update PIN code button afterwards
• Truck – Service Parameters (page 3-10) to actually change the value.
• Time – time-related service parameters Figure 3-18.

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Section 3. Systems Overview Model 102XM Maintenance Manual

TruckCom

Hour Meters value is entered directly into the text box, make
sure to click the Update __ button afterwards to
Values can be entered directly into the text actually change the value.
boxes for each meter reading. It is also possible Figure 3-19.
to enter values using the up/down arrows. If a

NOTE: The Reset service button resets the

“S. service time” value to 100.

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TruckCom

Diagnostics Function Representation of Signal Colors

To access diagnostics, select the Diagnostic The screen dumps shown in the following
function. This can be done with the menu section have been modified to improve legibility
< Tools | Diagnostic... > or with the tool bar in black and white print.
Diagnostic button. Figure 3-20.
NOTE: If the value “---” is shown in a field, or a
“read status LED” is red, the
communication has been interrupted for
some reason and error data cannot be
shown.
NOTE: The tab information displayed in the
diagnostics mode depends on the type of
truck connected.

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TruckCom

Tiller Arm Tab Figure 3-21. Diagnostic Screen - Tiller Arm Tab

Clicking on the Tiller arm tab will display a

dialogue showing the following:
• Speed lever – The status of the speed
control and travel direction selector. The
status of each individual hall is displayed
• Buttons – The status of the control buttons
is displayed. “Sxx” refers to the switch
designation as given in the electrical
schematics
• Option – Status of options buttons
• Battery – the measured battery voltage
• R14 – not used
• R15 – not used

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TruckCom

Drive Controller Tab Figure 3-22. Diagnostic Screen - Driver Controller Tab

Clicking on the Drive Controller tab displays a • INP pin 11 – The input voltage from the
dialogue box showing the following: man-on platform sensor. “digital O”
• Status of digital inputs and outputs of the indicates the digital status of the input
transistor regulator. pin refers to the motor
controller pin designations as given in the
electrical schematics
• Field PWM – The effective power output
supplied to the field circuit as a
percentage.
• Armature PWM – the effective power output
supplied to the armature circuit as a
percentage.
• Field current – The current flowing in the
field circuit in Amperes.
• Armature current – The current flowing in
the Armature circuit in Amperes
• Raw throttle data – The received speed
control signal as a percentage.
• Temperature – The temperature of the
output stage of the transistor controller in
degrees Celsius.
• INP pin 10 – The input voltage from the
mode/pressure sensor. “digital O”
indicates the digital status of the input.

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TruckCom

Other Menu Functions Help - About the TruckCom

Application
Save to File
To see program information, select < Help |
The truck parameters can be saved in the PC About TruckCom... > or use the tool button
for downloading at a later date. Select < File | [Information]
Save to file | Parameters >. All parameters in
the nodes that are connected to the CAN-bus Exit
will be scanned in and saved in a file. If only the
hour meters are needed, select < File | Save to To exit the program, select < File | Exit > or use
file | Hour meters >. the tool button [Exit].

Download from File

A set of parameters can be downloaded from the

PC to the truck. Select < File | Load from file |
Parameters >. The parameters in the file will be
copied to the nodes connected to the bus. If
only the hour meter settings are needed, select
< File | Load from file | Hour meters >.

Reset CAN Adapter

If problems should occur when resetting the

CAN adapter connected to the PC, this can
normally be done manually by making sure
that the adapter is supplied with voltage, and
then selecting < Nodes | Reset CPC-PP >.

Delete Error Code Log

To delete the truck’s error code log, select

< Tools | Erase error log >.

Reset Hour Meter

To reset the truck’s hour meter to 0, select

< Tools | Reset hour meters >.

Read Error Code Log

To show the truck’s error code log, select

< Tools | Read error log >.

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FlashWare

FlashWare Installing FlashWare on PC

NOTE: FlashWare is used on trucks with If you are a customer service technician, obtain
Vehicle Managers P/N 1067833-004 and FlashWare from your Raymond Sales and
above. Service Center.

If you are a Raymond Sales and Service Center

Overview technician, obtain FlashWare from the iNet
software download site.
FlashWare allows you to interface with the
truck software and update and change settings To install FlashWare on the PC, double-click the
through the following features: installation file and follow the instructions on
• Update Vehicle Manager software the screen. The software package is a
self-extracting executable file. Read the
• Erase Vehicle Manager software
“Read me” file in the software package for the
• Reset Factory Default Settings latest detailed installation instructions.
• Update Power Amplifier Software
• Diagnostics Connecting PC to Truck
• Display Error Log 1. Turn the truck key switch OFF.
2. Remove tractor cover.
For more detailed FlashWare information, click
on Help and select Help Topics from the menu 3. Connect cable (P/N 163793A) to USB/CAN
bar. Interface (dongle P/N 230489-001).
4. Connect the dongle to PC with a standard
Requirements USB cable.
5. Connect cable (P/N 163793A) to the J5
FlashWare can be installed on any
CAN Service Port connector.
IBM-compatible PC with Windows XP, Vista, or
Windows 7 operating system. The PC
communicates with the lift truck software
through a 4-pin serial cable, standard USB
cable, and dongle (USB to CAN translator)
(P/N 230489/001).

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FlashWare

Starting FlashWare 3. From the menu bar, click “Connect to

Truck”, then select “Pallet Trucks”, then
1. Make sure the key switch is ON. click “All Other Pallet Trucks”. See
2. Double-click the FlashWare icon on the Figure 3-23. The Truck Setup screen
main desktop screen or navigate via Start appears on your PC screen.
> Programs > FlashWare. The lift truck 4. For detailed instruction on how to use
opening screen appears. FlashWare, follow the on-screen
instructions in FlashWare Help.

Figure 3-23. Truck Opening Screen with Menu

31-13.jpg

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Model 102XM Maintenance Manual Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance

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Section 4. Scheduled Maintenance Model 102XM Maintenance Manual

Maintenance Guidelines

Maintenance Guidelines Perform all of the scheduled inspections and

maintenance during the suggested intervals.
The time intervals given in this guide are based
Following a regularly scheduled maintenance on Deadman Hours (HD) under normal
program: operating conditions.
• Promotes maximum truck performance
When operating under Severe or Extreme
• Prolongs maximum truck life
conditions, perform these services more often
• Reduces costly down time as indicated in Table 4-1.
• Prevents unnecessary repairs
Refer to the “Lubrication Equivalency Chart” on
Scheduled maintenance includes: page A-2 in the Appendix for lubrication
equivalents. Refer to the manufacturer’s
• Lubrication
supplements for components not identified in
• Cleaning this manual.
• Inspection
• Service

Table 4-1. Maintenance Frequency Table

Operating
Working Environment Service Frequency
Conditions
Light to An eight hour shift of basic material handling 120 days or 250 hours /
Moderate 180 days or 500 hours,
whichever comes first
Severe • Extended heavy duty operation 60 days or 250 hours,
• Freezer operation whichever comes first
• Sudden temperature changes such as going from freezer to
room temperature
Extreme • All UL Type EE rated lift trucks 30 days or 100 hours,
• Dusty or sandy conditions such as in cement plants, lumber whichever comes first
or flour mills, coal dust or stone-crushing areas
• High temperature areas such as in steel mills, foundries,
enclosed (Type EE) applications
• Corrosive chemical atmosphere, such as:
• fish, meat or poultry processing plants, tanneries, or any
other similar applications
• chlorine or salt-sea air environments
• Adverse high humidity, wet, damp, or moist conditions

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Model 102XM Maintenance Manual Section 4. Scheduled Maintenance

Initial 90 Day/250 Deadman Hours (HD) Maintenance

Initial 90 Day/250 Deadman Hours (HD)

Maintenance

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

Component Task

Drive Unit Change fluid. See “Drive Unit Housing Lubrication” on page 7-29.

Hydraulic Reservoir Change hydraulic fluid. Clean screen and magnet. See “Filter Screen and Inlet Tube”
on page 7-66.

Lower Link and Check for wear at the lower link or fork heel. Adjust downstops as necessary. See
Fork Heel “Downstop Adjustment” on page 7-76.

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Section 4. Scheduled Maintenance Model 102XM Maintenance Manual

Every 180 Days or 500 Deadman Hours (HD)

Every 180 Days or 500 Deadman Hours (HD)

For Severe or Extreme operating condition
service intervals, see Table 4-1 on page 4-2 .

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

Component Task

Battery Check the weight stamped on the battery in the pallet truck against the minimum
and maximum allowable weights on the spec tag for the pallet truck. Report any pallet
trucks that are running with batteries below the minimum or over the maximum
allowable weight. Inspect all battery connectors and leads for damage and cuts in
protective coatings. Make sure the battery has no more than 0.5 inch (13 mm) free
play in any direction.

Brakes During normal operation, with a rated load and traveling at top speed, the pallet
truck should stop within approximately six feet. Stopping distance depends on the
load, floor, and tire condition. Examine for signs of oil on the friction disc and mating
surfaces. If oil is present, disassemble the brake and replace the friction disc. Clean
the mating surfaces. Measure the thickness of the friction disc. Replace the friction
disc if worn to 0.20 in. (5 mm).
Measure for correct gap between the coil housing and pressure plate. When applied,
the gap should be between 0.008 and 0.010 in. (0.20 to 0.25 mm).
Failure to keep the brakes adjusted causes premature pad and rotor wear and
excessive motor heat.

Contactor Inspect contactor tips for burnt or pitted surfaces. Failure to replace the tips may
prevent the contactor from opening or closing, causing unscheduled downtime. With
the truck OFF and the battery disconnected, check the plunger for smooth operation
with no binding. If binding occurs, the pallet truck may malfunction or exhibit
intermittent fault codes. See “Contactor Tip Inspection” on page 4-7.

Control Handle Make sure steering function is smooth and responsive, without binding or excess
Assembly play. Verify lift/lower function is smooth and controllable. Verify travel function is
smooth and responsive through full range of acceleration and plugging. Verify no
codes on display. Verify function of all switches.

Arm Angle Check the adjustment. See “Arm Angle Switches Adjustment” on page 7-49.
Switches

Drive Unit Inspect for leaks. Check fluid level. Check drive unit axle for play.

Electrical Cables Inspect all power cables for nicks or cuts. Give special attention to those cables that
are not stationary, for example, cables to the traction motor. Replace any cable that is
damaged or shows signs of excessive heat. Failure to do so may cause intermittent
system shutdowns and/or electronic failures.

Forks, Pull Rod, Check the lift-limit switch for lift motor cut-out. Adjust if necessary.
and Lift Linkage Check for wear on the pull rod. Check all lift linkage bushings for wear. When
replacing bushings, inspect the pins for wear. Replace the pins if any wear is evident.
Check for wear at the lower link or fork heel. Adjust downstops as necessary. See
“Downstop Adjustment” on page 7-76.

Frame and Tractor General visual inspection of structural members for cracks, including but not limited
Checks to the tractor and forks.

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Model 102XM Maintenance Manual Section 4. Scheduled Maintenance

Every 180 Days or 500 Deadman Hours (HD)

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

Component Task

Hardware Check bolt torque of major components (motors, brake, drive unit, and hydraulic
unit). Tighten any loose hardware. Replace any broken or missing hardware. See
“Appendix” on page A-1.

Horn Check that the horn operates when you press the horn button.

Hydraulic Hoses Inspect all hydraulic hoses for leaks, nicks, cut, chafing, and bulges. Replace
damaged hoses as soon as possible. Inspect all fittings for leaks. Repair any leaks
immediately.

Hydraulic Reservoir Check fluid level. See “Hydraulic Fluid” on page 7-63.

Lubrication Lubricate all grease points. Lubricate all pivoting shafts on the control handle with
spray lube. See “Grease Fittings” on page 4-8.

Motors Check condition of brushes, springs, and holders. Check that the brush length
exceeds the minimum length. Inspect the commutator. Blow out the inside of the
motor with compressed air. See “Motors, General” on page 7-54.

Shorts to Frame Check for electrical shorts to frame. See “Shorts to Frame Test” on page 5-5. Wipe
down the inside of the compartment.

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

Warning Decals Replace any unreadable or damaged decals.

Load Wheels and Examine for bond failure, chunking, and excessive or uneven wear. Inspect the load
Drive Tires wheel bearings for binding or excessive play. Apply grease.

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Section 4. Scheduled Maintenance Model 102XM Maintenance Manual

Every 360 Days or 2000 Deadman Hours (HD)

Every 360 Days or 2000 Deadman Hours (HD)

Perform all 180 day/500 deadman hour maintenance tasks plus the following every 360 days/2000
HD.

Component Task

Drive Unit Change fluid. See “Drive Unit Housing Lubrication” on page 7-29.

Hydraulic Reservoir Change hydraulic fluid.

Clean screen and magnet. See “Filter Screen and Inlet Tube” on page 7-66.

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Model 102XM Maintenance Manual Section 4. Scheduled Maintenance

Contactor Tip Inspection

Contactor Tip Inspection

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

When repairing contactors, use only

Raymond authorized contactor kits.

When you inspect contactor tips, obey these

guidelines:
• Darkened points do not indicate burning
• Burning indicates a loss of contact point
material
• Replace the contact points if there is not
sufficient contact point material to last
until the next regular inspection or severe
pitting is evident
Figure 4-1. Severely Pitted Contactor

• The silver alloy part of the point is usable

contact material; the copper backing is not
usable contact material
• Do not file, use sandpaper, or emery cloth
on the contact points to remove
discoloration or minor irregularities. This
practice produces a surface more
susceptible to sticking
• If a cone and crater appear, replace the
tips.

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Section 4. Scheduled Maintenance Model 102XM Maintenance Manual

Grease Fittings

Grease Fittings
Figure 4-2. Load Wheel Axle (Cold Storage and
Corrosion Protection Options only)
1665_044.tif

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Model 102XM Maintenance Manual Section 5. Troubleshooting

Section 5. Troubleshooting

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Section 5. Troubleshooting Model 102XM Maintenance Manual

List of Troubleshooting Charts and Tables

List of Troubleshooting
Charts and Tables
How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 5-3
Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 5-4
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-4
Shorts to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-4
Shorts to Frame Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-5
DC Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 5-7
DC Motor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-7
Shunt-Wound Motor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-7
Compound Wound Motor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-7
Mica Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-7
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-7
Commutator Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-8
Open Circuit Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-9
Motor Resistance Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-9
Grounded Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-10
Short-Circuited Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-10
Short-Circuited Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-10
Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-11
List of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-12
Symptom Table: Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-13
BDI does not Reset to 100% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-13
Horn Does Not Sound When Horn Button Pushed. No Fault Codes.. . . . . . . .. . .. 5-13
Green/Red LED on Keypad Not Illuminated When Key Pressed. . . . . . . . . . .. . .. 5-14
Symptom Tables: Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-15
No Lift, Lift Motor Does Not Run, Travel is OK . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-15
No Lift or Slow Lift, Lift Motor Does Run . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-16
No Lower, Lift and Travel OK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-16
Unable to Pick Up a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-17
Slow Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-17
Load Drifting/Settling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-17
No Lift or Lower. No Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-18
Symptom Tables: Travel (Forward/Reverse) System . . . . . . . . . . . . . . . . . . . . . .. . .. . 5-19
Slow Travel, Lift/Lower OK. No Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-19
Truck Does Not Accelerate Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-19
No Travel Mode. No Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 5-20

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Model 102XM Maintenance Manual Section 5. 1Troubleshooting

How to Use This Chapter

How to Use This Chapter

Section 5. 1Troubleshooting

This section contains a set of general

troubleshooting guidelines and a set of
troubleshooting tables for symptoms not
accompanied by a fault code. If the truck is
displaying an error code, refer to Chapter 6 for
details about the individual codes.

Use the Symptom Tables beginning on

page 5-13 to identify possible causes of
problems that are not accompanied by a fault
code on the Operator Display

If the troubleshooting symptom tables do not

isolate the problem, or if the symptoms are not
consistent or repeatable, approach the problem
in a systematic and logical manner.

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Section 5. 1Troubleshooting Model 102XM Maintenance Manual

Electrical Troubleshooting Guidelines

Electrical Use an ohmmeter to check for wiring continuity

and shorts.
Troubleshooting Use a Digital MultiMeter (DMM), such as a
Guidelines Fluke meter, for all measurements. Analog
meters can give inaccurate readings and load
down sensitive electronic circuits enough to
General cause failure. Make sure meter cables are
connected to the correct meter jacks and that
the correct function and scale are selected.

When measuring voltage, connect the positive

Block the lift truck so that the drive tire meter lead to the connector or probe point
is off the floor whenever a marked (+) in the test. Connect the negative
troubleshooting procedure requires meter lead to the connector or probe point
turning the truck ON. This prevents marked (–).
accidents caused by unexpected lift
truck travel. Whenever measuring resistance, turn the truck
OFF and disconnect the battery connector.
Use extreme care when the truck is Battery current can damage an ohmmeter.
jacked up for any reason. Keep hands Isolate the component from the circuit.
and feet clear while jacking the lift
truck. After the lift truck is jacked, place For troubleshooting DC electric motors, see “DC
solid blocks or jack stands beneath it to Electric Motors” on page 5-7.
support it. Do not rely on the jack alone.
See “Jacking Safety” on page 2-9. For information on pin, connector, and harness
connections, see “Wiring Harness” on page 7-39
and “List of Electrical Symbols” on page 5-12.

Unless otherwise directed, disconnect Shorts to Frame

the battery connector when you check
electrical circuits or components with an Shorts to frame is an industry term for
ohmmeter. Electrical current can cause unintentional current leakage paths between
damage to the ohmmeter. normally isolated electrical circuits and their
metal enclosures.
Many problems are caused by a faulty or dirty
battery. Make sure the battery is clean. Check Shorts to frame may be metallic connections,
the electrolyte level and state-of-charge. See such as a wire conductor contacting metal
“Battery” on page 7-32. through worn insulation. More often, shorts to
frame are resistive “leakage” paths caused by
Save time and trouble by looking for simple contamination and/or moisture.
causes first.
These leakage paths can result in unwanted
Visually inspect all wiring and electrical electrical noise on the metallic pallet truck
components for: structure and can cause incorrect operation.
• Loose connections or connectors
Shorts to frame are caused by:
• Loose or broken terminals
• Accumulation of dirt
• Damaged terminals, blocks, or strips
• Battery electrolyte leakage
• Broken wiring and shorted conditions
(especially those that are close to metal • Motor brush dust
edges or surfaces)

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Model 102XM Maintenance Manual Section 5. 1Troubleshooting

Electrical Troubleshooting Guidelines

• Motor brush leads touching the housing ampere scale and work toward the lowest.
• Breakdown in insulation A reading of more than 0.001A (1mA)
indicates a serious short. Do not continue
• Bare wires until this condition is corrected. The meter
• Pinched wiring harness may be damaged if you proceed before
• Incorrect mounting of circuit cards correcting this condition.
a. Install another battery in the pallet
Shorts to frame can occur at numerous truck and repeat this procedure from
locations on a pallet truck, including: Step 1.
• Batteries b. If the current is less than 0.0002A
• Motors (0.2mA), go to Step 4. If the current is
greater than 0.0002A (0.2mA) and less
• Cables, wiring, and harnesses than 0.001A (1mA), remove the battery
• Heatsinks from the truck, then continue with Step
• Bus bars 4. Make sure the battery case does not
touch the truck frame during the
• Solenoids remaining tests.
• Contactors
4. With the battery disconnected (or removed
• Terminal strips and disconnected) from the truck, use a
• Switches DMM to measure the resistance from
truck frame to truck B+, to truck B– (not
• Power panel insulation
battery B+ and B–), and to all fuses and
• Circuit card mounts motors. A reading of less than 1000 ohms
indicates a serious short. Do not continue
Shorts to Frame Test until this condition is corrected. The meter
may be damaged if you proceed before
To test for shorts to frame: correcting this condition. To correct the
condition, follow steps a through e.
1. Turn the key switch OFF and disconnect
the battery connector. a. To identify the cause of the short to
frame, disconnect circuit components
2. To test the battery for shorts to case,
until the low resistance condition
connect a 12V test light to the battery case
disappears. Do not reconnect
from battery B+, and then to the battery
components one at a time, but leave
case from battery B–. If the light
them disconnected until the low
illuminates at all, even momentarily, there
resistance reading disappears. Prevent
is a serious problem with the battery,
disconnected terminals or connectors
either external contamination or internal
from touching the truck frame or other
damage. Do not continue until this
conductive surfaces.
condition is corrected. The meter may be
damaged if you proceed before correcting b. The most likely areas to check are:
this condition. • Motors
a. Install another battery in the truck and • Heatsinks
repeat this procedure from Step 1.
• Power cables
b. If the test light does not light, continue
• Power circuit components
to the next step.
• Control circuit components
3. Use a DMM set on the ampere function to
measure the current leakage from the c. Repair or replace the component
battery case to battery B+ and from the causing the low resistance condition.
battery case to battery B– (not truck B+ Repeat Step 4.
and B–). Begin measuring at the highest

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Section 5. 1Troubleshooting Model 102XM Maintenance Manual

Electrical Troubleshooting Guidelines

d. Reconnect all other components d. Reconnect all other components

previously disconnected, one at a time, previously disconnected, measuring
measuring resistance between steps. If current between steps. If a reading is
a reading is less than 1000 ohms when more than 0.001A (1mA) when
reconnecting a component, that reconnecting a component, that
component or its wiring is faulty; repair component or its wiring is faulty.
or replace as appropriate. Repair or replace as appropriate.
e. When, after all components are 7. When, after all components are
reconnected, and you get readings reconnected, you get a reading less than
greater than 1000 ohms, continue with 0.001A (1mA) there is no short to frame
the next step. condition with the truck or the battery. If
you previously removed the battery from
5. Reconnect the battery connector and turn
the truck, re-install the battery.
the key switch ON. If the battery was
previously removed, make sure the battery
case does not touch the truck frame.
NOTE: The functions being checked must be
energized. Example: to check for shorts
to frame in the travel circuit, travel must
be requested.
6. Use a DMM set to the current function to
measure current leakage to the truck
frame from truck B+, B– (not battery B+
and B–), and all fuses and DC motor
terminals. Begin measuring at the highest
ampere scale and work toward the lowest.
If the current is less than 0.001A (1mA), go
to step 7. If the current is more than
0.001A (1mA), continue with the following
steps.
a. To identify the cause of the short to
frame, disconnect circuit components
until the leakage current reads less
than 0.001A (1mA). Do not reconnect
components one at a time, but leave
them disconnected until the leakage
current reads less than 0.001A (1mA).
Prevent disconnected terminals or
connectors from touching the truck
frame or other conductive surfaces.
b. The most likely areas to check are:
• Motors
• Heatsinks
• Power cables
• Power circuit components
• Control circuit components
c. Repair or replace the component(s)
causing the leakage current.
Repeat Step 6.

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Model 102XM Maintenance Manual Section 5. 1Troubleshooting

DC Electric Motors

DC Electric Motors Figure 5-3. Mica Inspection

1881_003.tif

Segments
Mica
DC Motor Types
• A shunt-wound motor, such as the
traction motor, has four external
connections: two armature (A) and two
field (E). See Figure 5-1. NORMAL
Figure 5-1. Shunt-Wound Motor Circuits UNDERCUT High Mica
motor-shunt.tif

A2 E2
HIGH MICA

The commutator must be smooth and clean to

provide maximum brush life. When
commutators are not correctly maintained,
A1 E1 carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
• A compound motor, such as the lift motor, the armature.
has only two external connections because
the armature and field windings are Good commutation is indicated by a dark
connected internally. See Figure 5-2. brown polished commutator and an evenly
polished brush wearing surface. See Table 5-1,
Figure 5-2. Compound Wound Motor Circuits
motor-compound.tif
“Commutator Surfaces.”

If the commutator appears rough, pitted, or has

signs of burning or heavy arcing between the
commutator bars, remove the motor for service.

Service
If the commutator requires service, you must
remove the armature from the motor.

DO NOT use a stone to even out high and low

spots on the commutator.

Servicing a motor for an abnormal commutator

Inspection surface condition and high mica or mica
undercutting requires special equipment at a
Inspect the commutator for surface condition
motor rebuilding facility.
and high mica. Most armatures have the mica
undercut. If the armature on your motor does
not, do not attempt to cut it. See Figure 5-3.

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Section 5. 1Troubleshooting Model 102XM Maintenance Manual

DC Electric Motors

Table 5-1. Commutator Surfaces

Condition Probable Cause Commutator Surface

Good Condition-Light Film Uniform coloring indicates satisfactory operation Brushwear01.tif

of machine and brushes. Film color is largely an

effect of thickness; therefore, provided the film is
uniform, it is perfectly acceptable.

Brushwea03.tif
Satisfactory This is not a good condition but in our experience
Condition-Light and Dark it is known that machines having this
Pattern commutator pattern have operated with
satisfactory results for long periods of time. This
condition can appear in alternating bars as
shown or every 3rd or 4th bar. This is related to
the winding design of the armature or difficulty
caused from split windings crossing in the same
slot.

Unsatisfactory Frequently due to under-loaded operation, Brushwear04.tif

Condition-Streaky Film machine grossly over-brushed or brush grade

With No Commutator Wear incorrect for particular machine application.
Atmosphere and environmental conditions can
contribute.
Brushwear05.tif
Unsatisfactory Patchy colors of varying densities and shape. Due
Condition-Uneven Film to unclean operating conditions or incorrect
physical condition of commutator.

Brushwear06.tif
Unsatisfactory Condition- These areas can be isolated or regular.
Film With Dark Areas Commutator out-of-round. This can be caused by
vibration or mechanical deficiencies in
equipment operation, bearings, couplings, and so
forth.

Unsatisfactory Bars are low on entry and leaving edges giving Brushwear07.tif

Condition-Example of Poor rise to the brushes riding on the middle of the

Commutator Machining bars.

Brushwear08.tif
Unsatisfactory Bars are low in the middle giving rise to the
Condition-Example of Poor brushes riding on entry and leaving bar edges.
Commutator machining This and the previous illustration indicate the
need for better maintenance.

Unsatisfactory This is a further development of the third Brushwear09.tif

Condition-Streaky Film example. Brush grade, machine applications and

With commutator Wear working environment are all suspect. Earlier
corrective action should have been taken.

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Model 102XM Maintenance Manual Section 5. 1Troubleshooting

DC Electric Motors

Condition Probable Cause Commutator Surface

Unsatisfactory Darkening of commutator in sequences two pole Brushwear10.tif

Condition-Double Pole pitches apart is due to armature fault, bad coil,

Pitch riser bars or equalizer connections.

Brushwear11.tif
Unsatisfactory Storage of machines, for lengthy periods, with
Condition-Brush Contact brushes in position. This can also result from
Mark operation of machine in prolonged stall
conditions.

Unsatisfactory Illustration shows high mica in every slot. Same Brushwear12.tif

Condition-Bar Edge effect can occur on one bar only. Similar

Burning-Cause High Mica conditions can be caused by a high or low bar.

Brushwear13.tif
Unsatisfactory Related to over-loaded machines and low brush
Condition-Small Bright pressure. Due to sparking under brush that gives
Spots rise to spots being of a random distribution. If
not corrected, results in scored commutator.

Open Circuit Motor Test 2. With the motor at room temperature,

connect the leads of a digital ohmmeter
An open circuit is an electrical circuit within the between the individual circuits in the
motor that is broken. This can be caused by: motor.
• bad brushes or brush springs 3. Observe the measurements given in
Table 5-2.
• a broken wire in the field or armature
winding 4. If the meter indicates high resistance in
the armature, check the condition of the
• a loose or bad connection brushes before replacing the motor.
To test a motor for an open circuit: 5. If an open circuit is found in a motor, the
motor must be disassembled by a motor
1. Isolate the motor from the truck circuit by rebuilding facility to isolate the problem to
removing the power cables. Use two the field or armature circuit.
wrenches to avoid twisting the terminal
stud.
Table 5-2. Motor Resistance Readings

Acceptable Unacceptable Resistance

Motor Terminals
Resistance Readings Readings

Traction Armature A1 to A2 0.01 to 0.10 ohms Greater than 0.10 ohms

(Drive)
Field E1 to E2 0.8 to 1.7 ohms Less than 0.5 ohms or
(S1 to S2) Greater than 2.0 ohms

Lift A to S 0.020 to 0.030 ohms Greater than 0.1 ohms

NOTE: Measure all readings at room temperature. See Figure 5-2 on page 5-7.

Publication:1010183, Issued: 20 Mar 2014 5-9

Section 5. 1Troubleshooting Model 102XM Maintenance Manual

DC Electric Motors

Grounded Motor Test Short-Circuited Winding

In a grounded motor, an unintentional electrical A short-circuited winding is one where the
connection exists between the current-carrying insulation on the field or armature has broken
conductors and the motor housing. This can be down at two or more points. The breakdown
caused either by direct contact or through creates a low resistance path, permitting
conductive foreign material. current to flow from one turn of the coil to
another adjacent coil turn, without actually
The ground may be caused by: flowing through the coil wire. The result is a
• insulation breakdown decrease in the total resistance of the motor
winding and an increase in the current flow.
• brush leads touching the motor housing The severity of the short circuit depends on its
• build-up of carbon dust or other materials location.

To test a motor for grounds: A shorted motor may be indicated by:

1. Isolate the motor from the truck circuit by • Slow or sluggish operation
removing the power cables. Use two • Running faster than normal
wrenches to avoid twisting the terminal
studs. • Overheating

2. Attach one lead of a megohm meter or a • Blowing a power fuse

digital ohmmeter to a motor terminal and • On DC motors, severe burning or
the other lead to an unpainted surface of discoloring on one or two commutator
the motor housing. Set the ohmmeter to segments every 90° of rotation
the highest scale.
3. If the ohmmeter reads resistance of less These symptoms can also be caused by
than 100,000 ohms, the motor is problems other than the motor itself, such as:
grounded. Clean, repair, or replace the • Brake too tight or dragging
motor as necessary. • Wheel bearings too tight
• Faulty transmission
Short-Circuited Armature • Binding in an attached pump
A short circuit in the armature causes heating,
Testing a motor for short-circuited windings
and can result in burning of:
requires special equipment at a motor
• Armature coil rebuilding facility.
• Brush wires
• Commutator segments

Visual inspection may reveal this condition.

Positive determination of a short-circuited

armature requires special equipment at a motor
rebuilding facility.

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Model 102XM Maintenance Manual Section 5. 1Troubleshooting

Hydraulic Troubleshooting Guidelines

Hydraulic
Troubleshooting
Guidelines
When you measure the voltage at solenoids,
make sure the hydraulic lines and components
are fully installed.

Use an ohmmeter to measure wiring continuity

to solenoids. Use an ammeter to measure for
the correct current to the solenoids and
contactor coils.

Unless otherwise directed, disconnect

the battery connector when you
examine electrical circuits or
components with an ohmmeter.
Electrical current can damage to the
ohmmeter.

Visually inspect all hydraulic lines and

components for:
• Leaking connections or connectors
• Loose or broken fittings
• Damaged tubing, hoses, vents, or seals

Inspect the hydraulic system for the correct

pressure and that the relief valve is functioning
correctly. See “Hydraulic Pump Pressure Relief
Valve Adjustment” on page 7-68.

Check the hydraulic reservoir fluid level. If

necessary, add fluid; fill until fluid is visible to
within 1 in. (25.4 mm) below the fill port elbow.
The usable reservoir capacity is 0.8 qt. (0.75 L).
See “Lubrication Equivalency Chart” on
page A-2.
NOTE: Always check hydraulic fluid level with
forks fully lowered and when hydraulic
fluid is cold.

Cap any open hydraulic lines to prevent

contamination.

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Section 5. 1Troubleshooting Model 102XM Maintenance Manual

List of Electrical Symbols

List of Electrical Symbols Refer also to the electrical schematics and the
wiring harness component procedures.

Table 5-4. List of Symbols

Symbol Description Function Remark

A1 Traction Power Amplifier Traction Motor Controller

A2 Electronic tiller arm card Vehicle Controller located in control handle head

A6 Operator display Displays various functions

A17 Keypad PIN inputs and access Trucks with keypad

maintenance modes

B+ Battery Positive 24V

B– Battery Negative 24V

CB1 Circuit Breaker Drive/Pump Motor Circuit 110 amp

F50 Fuse Keypad and Tiller Arm Card 10 amp (vehicle manager)

F51 Fuse Main Control 10 amp (Inputs/Outputs)

H1 Horn

J11 Wire Connection Handle Stem Base

J41 Wire Connection Service Key (CAN)

K4 Relay Main (Master Control)

K10 Contactor Main

K30 Contactor Lift Pump Motor

M1 Motor Drive

M3 Motor Lift Pump

R1 Resistor Pre-charge PTC

S17 Switch Key Trucks with key switch

S18 Switch Horn

S21 Switch Main ON/OFF (single)

S22 Switch Main ON/OFF (dual)

S24 Switch Arm Angle A

S25 Switch Arm Angle B

S36 Switch Lift-Limit

Y1 Coil Brake

Y10 Coil Lower Valve

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Model 102XM Maintenance Manual Section 5. 1Troubleshooting

Symptom Table: Electrical System

Symptom Table:
Electrical System
NOTE: Reference electrical schematics.

BDI does not Reset to 100%

Possible Cause Action

Incorrect wiring Make sure wire #1 is on the top post of the main contactor and
wire #2 is on the bottom post of the main contactor.
Low static voltage If the voltage is below 25.2 volts after a charging cycle, charge the
battery pack 5 times consecutively.
NOTE: The voltage must be at or above 25.2 volts for the truck to reset and stay at 100%.
Low voltage during travel VM Software versions prior to 003 required the battery voltage to
remain above 25.2 volts during 20 seconds of travel. This was
changed in version 003 and above to only require the voltage to be
above 25.2 volts at key ON.
Main contactor wired incorrectly Verify that wire number 1 is on the top post of the contactor and
wire number 2 is on the bottom post,
Low voltage at key ON If voltage is below 25.2 volts at key ON after charging the battery,
troubleshoot the battery and charger.
Refer to “PalletPro Field™ Troubleshooting Guide,” RPIN
PLT-07-R001.
Poor wiring connection or bad VM 1. Check the battery voltage displayed on the VM using the
“Service Display” on page 3-15.
2. Compare the displayed voltage to the voltage read at the
battery using a volt meter.
3. If there is more than a 0.5 volt difference, measure the
voltage at the VM, J11-1 with respect to J11-3.
4. If the voltage is the same as what was read at the battery,
replace the VM.
5. If the voltage is different, troubleshoot the wiring between the
VM and the battery.
6. If no poor connections are found, replace the VM.

Horn Does Not Sound When

Horn Button Pushed. No Fault
Codes.
Possible Cause Action
Faulty horn switch/wiring in the Repair or replace as necessary.
handle head
Faulty Horn Replace the horn.
Faulty traction power amplifier Replace if necessary.

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Section 5. 1Troubleshooting Model 102XM Maintenance Manual

Symptom Table: Electrical System

Green/Red LED on Keypad Not

Illuminated When Key Pressed.
Possible Cause Action
No power supplied to the vehicle Check the control wires, especially wires #1, 20, 22 (red in the
manager control handle arm cable), and 40 (black in the control handle arm
cable).
Faulty Connectors Repair and replace the faulty connectors (check connector J11 at
the control handle arm base, the connector into the vehicle
manager, and connector J5 to the motor controller).
F50 Open Make sure the control fuse has not opened.
Key switch jumper not connected Connect the key switch jumper.
Faulty LED(s) Check the LED(s) if the truck functions normally but the LED(s)
are not lighting correctly.

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Model 102XM Maintenance Manual Section 5. 1Troubleshooting

Symptom Tables: Lift/Lower System

Symptom Tables:
Lift/Lower System
NOTE: If it is determined that a component
failed as a result of hydraulic fluid
contamination, replace the failed
component and flush, fill, and bleed the
hydraulic system. See “Hydraulic Fluid”
on page 7-63.
NOTE: Reference electrical schematics and
hydraulic schematic.

No Lift, Lift Motor Does Not

Run, Travel is OK

Possible Cause Action

Bad lift-limit switch With the main ON/OFF switch OFF, the battery disconnected, and
the forks lowered, check for continuity through the lift-limit switch.
Replace if necessary.
Bad lift pump contactor With the main ON/OFF switch ON, the PIN-key code entered, the
green ON ( | ) key on the keypad pressed, and the lift switch
depressed, do the main contactor (K10) and the pump contactor
(K30) energize? If not, measure the voltage between the pump
contactor coil terminals. If B+ voltage is present, replace the pump
contactor.
Bad VM With the main ON/OFF switch ON, the PIN-key code entered, the
green ON ( | ) key on the keypad pressed, and the lift switch
depressed, does the pump contactor (K30) energize? If not, check
for lift input at the CAN (see “Service Display” on page 3-15). If no
input is detected, replace the VM.
NOTE: Check for mechanical problems in the handle head before
replacing the VM.
Bad wiring continuity or wiring shorts With the main ON/OFF switch OFF and the battery disconnected,
check for continuity and wiring shorts in the wiring harness or
cables.
Bad lift pump motor brushes... With the main ON/OFF switch ON, the PIN-key code entered, the
green ON ( | ) key on the keypad pressed, and the lift switch
depressed, does the pump contactor (K30) energize? If YES,
measure the voltage between B– and the lift pump motor terminal.
If OK, check the lift motor brushes...
...or bad lift pump motor... ...if the brushes are OK, test the pump motor.

Publication:1010183, Issued: 20 Mar 2014 5-15

Section 5. 1Troubleshooting Model 102XM Maintenance Manual

Symptom Tables: Lift/Lower System

No Lift or Slow Lift, Lift Motor

Does Run
Possible Cause Action
Battery problems Replace the battery with a fully-charged battery.
Mechanical binding in the lift Repair the lift mechanism.
mechanism
Low hydraulic pressure or relief valve Check the hydraulic pressure setting and adjust if necessary. See
setting “Hydraulic Pump Pressure Relief Valve Adjustment” on page 7-68.
Relief valve contaminated or bad. With the main ON/OFF switch OFF and the battery disconnected,
(Unable to get the correct hydraulic remove the pressure relief valve. Check for damage or
pressure) contamination. Replace the valve or flush the system and replace
the hydraulic fluid. See “Hydraulic Fluid” on page 7-63.
Bad lift pump motor or brushes Check the lift pump motor brushes. If OK, replace the pump motor.
Contamination found in the pump Flush the system and replace the hydraulic fluid.
Bad pump If the lift motor is OK, remove the motor from the pump and rotate
the pump by hand. Replace the pump if not OK.

No Lower, Lift and Travel OK

Possible Cause Action
Bad lower solenoid valve... With the main ON/OFF switch ON, cycle the lower switch. Does
the lower solenoid valve energize? If YES, disconnect the battery,
then slowly loosen, but DO NOT REMOVE, the hydraulic line at the
hydraulic pump assembly. Permit the forks to slowly lower. Have
rags and a drain pan ready to catch the fluid.
... if the forks do not lower, check for Replace the lift cylinder or repair the lift mechanism.
mechanical binding in the lift cylinder
or the fork mechanism...
...if the forks lower, remove and Inspect for free movement and for signs of contamination. Clean
inspect the solenoid valve... the solenoid valve or flush the system, clean the filter, and replace
the hydraulic fluid.
If no contamination is found, repair or replace the solenoid valve or
the pump assembly.
...check for a bad VM With main ON/OFF switch ON, the PIN-key code entered, the green
ON ( | ) key on the keypad pressed, and the lower button
depressed, check for lower signal input at the CAN (see “Service
Display” on page 3-15). If no signal is detected, replace the VM.
NOTE: Check for mechanical problems in the handle head before
replacing the VM.

5-16 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 5. 1Troubleshooting

Symptom Tables: Lift/Lower System

Unable to Pick Up a Load

Possible Cause Action
Load too large for the lift truck Check the load weight. Check the lift pressure setting.
capacity
Battery problems Replace the battery with a fully-charged good battery.
Incorrect lift pressure adjustment Check and adjust the lift pressure setting.
Contaminated or bad pressure relief Check for contamination in the hydraulic fluid.
valve If contamination is present, flush, fill, and bleed the hydraulic
system. Clean the relief valve.
If no contamination is found, replace the relief valve.
Bad lift pump or motor Replace the lift pump or motor.

Slow Lower
Possible Cause Action
Bad lift/lower solenoid valve Repair or replace the solenoid valve.
Plugged or malfunctioning flow Check for contamination in the hydraulic fluid.
control valve If contamination is present, flush, fill, and bleed the hydraulic
system. Clean the relief valve.
If no contamination is found, replace the flow control valve.
Contamination in the lowering Inspect the solenoid for contamination or binding.
solenoid valve
Mechanical binding in the lift Adjust or replace the mechanism.
mechanism
NOTE: If the pump hits relief and lower is attempted, lowering is slow. Release the lower button
momentarily, then continue to lower. Normal lower speed should resume.

Load Drifting/Settling
Possible Cause Action
Contaminated or bad check valve Check for contamination in the hydraulic fluid.
If contamination is present, flush, fill, and bleed the hydraulic
system. Clean the check valve.
If no contamination is found, replace the check valve.
Leaking or contaminated lowering Check for contamination in the hydraulic fluid.
solenoid valve If contamination is present, flush, fill, and bleed the hydraulic
system. Clean the solenoid valve.
If no contamination is found, replace the solenoid valve.
Load too large for the lift truck Check the load weight. Check the lift pressure setting.
capacity

Publication:1010183, Issued: 20 Mar 2014 5-17

Section 5. 1Troubleshooting Model 102XM Maintenance Manual

Symptom Tables: Lift/Lower System

No Lift or Lower. No Fault

Codes.
Possible Cause Action
Throttle magnet-actuator arm (in the Check with the service display and repair as needed.
control handle) out of adjustment Bad VM. If no other problems are noted but the VM does not detect
the presence of the magnet, replace the VM.
Incorrect VM software installed. NOTE: This is only possible if the VM was recently replaced.
Lowering may not occur if the incorrect software was inadvertently
installed (the drive function will also not function correctly). Check
for the correct software part number and replace the VM if not
correct.

5-18 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 5. 1Troubleshooting

Symptom Tables: Travel (Forward/Reverse) System

Symptom Tables: Travel NOTE: Refer to electrical and hydraulic

schematics.
(Forward/Reverse)
System
Slow Travel, Lift/Lower OK. No Fault Codes

Possible Cause Action

Truck configured for slow speed Check the truck configuration.
Battery problems Replace the battery with a fully-charged, good battery.
Binding drive wheel Jack and block the truck. Disable the brake. See “Mechanically
assembly/traction motor Releasing the Brake” on page 7-21. Check that the drive wheel spins
freely. If not, repair or replace.
Binding brake disc Check the “Air Gap Adjustment” on page 7-20.
Check for dragging brake caused by poor or incomplete brake release.
Listen for an audible click to indicate full brake release.
Bad traction motor Repair or replace the traction motor or the brushes.
(may test OK with no load, but fail
under load) or worn brushes
Open Arm Angle Switch Check for correct operation of the arm angle switch “A” and correct if
necessary. Check the wiring, the traction power amplifier, and the
switch adjustment. The arm angle switch “A” is open-circuited. See
“Arm Angle Switches” on page 8-2.

Truck Does Not Accelerate Correctly

Possible Cause Action

Truck configured for slow Check the truck configuration.
acceleration
Battery problem Verify a correct, fully-charged, good battery (24V) is installed in the
truck.
Binding or mechanical problem Jack and block the truck. Turn the main ON/OFF switch OFF. Check
the brake, the wheel bearings, and the load wheels to see if there is a
mechanical problem. Repair or replace.
Bad motor brushes or motor With the main ON/OFF switch OFF and the battery disconnected,
check the traction motor brushes and the motor. See “Motor Brush
Inspection” on page 7-54. Repair or replace.
Bad traction power amplifier If all other possible causes check out, replace the traction power
amplifier.

Publication:1010183, Issued: 20 Mar 2014 5-19

Section 5. 1Troubleshooting Model 102XM Maintenance Manual

Symptom Tables: Travel (Forward/Reverse) System

No Travel Mode. No Fault Codes.

Possible Cause Action

Arm Angle Switch Failure Check the arm angle switch adjustment, wiring, and the traction power
amplifier. The Arm Angle switch “A” or “B” is open-circuited. See “Arm
Angle Switches” on page 8-2.
Throttle magnet-actuator arm (in Check with the service display and repair as needed.
the control handle) out of Bad VM. If no other problems are noted but the VM does not detect the
adjustment presence of the magnet, replace the VM.

5-20 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 6. Messages and Codes

Section 6. Messages and Codes

Publication:1010183, Issued: 20 Mar 2014 6-1

Section 6. Messages and Codes Model 102XM Maintenance Manual

List of Messages and Codes

List of Messages and Codes

Messages and Caution Codes . . . . . . . . . . . . ................ . . . . . . . . . . . . . 6-3
Code ‘TEST’ . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-3
Code ‘SLO’ . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-3
Code ‘Sro’ (C14) . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-3
Code C19 . . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-4
Code HPd (C20). . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-4
Code C28 . . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-5
Code C29 . . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-6
Code C35 . . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-6
Code Lo (C41) . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-6
Code Hi (C42) . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-7
Code C43 . . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-7
Code Hot1 (C44) . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-8
Code C46 . . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-8
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . ................ . . . . . . . . . . . . . 6-9
Code E101 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-9
Code E104 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . . 6-9
Code E106 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-10
Code E107 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-10
Code E108 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-11
Code E110 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-11
Code E112 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-11
Code E114 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-12
Code E115 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-12
Code E118 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-13
Code E140 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-13
Code E141 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-13
Code E142 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-14
Code E150 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-14
Code E151 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-15
Code E157 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-15
Code E159 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-15
Code E160 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-16
Code E161 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-16
Code E200 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-17
Code E201 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-17
Code E202 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-17
Code E214 . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . . . 6-18

6-2 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 6. Messages and Codes

Messages and Caution Codes

Messages and Caution

Section 6. Messages and Codes

Codes
Code ‘TEST’

Code Title TEST

Operator Display 'TEST'

System Response Truck functions are not allowed.

Alarm Sounds No

Reason New VM was installed that was not loaded with software.

Tests to Run None

How to Clear Code is cleared after the software is loaded in the VM.

Code ‘SLO’
Code Title Creep Speed

Operator Display 'SLO'

NOTE: This can be mistaken for a code 075 if the display is read upside-down.
There is no code 075.

System Response Travel Limited to Creep Speed

Reason Click-to-Creep feature activated.

Tests to Run None

How to Clear With the handle in brake position, quickly click the speed control twice to
deactivate creep speed.

Code ‘Sro’ (C14)

Code Title SRO (Static Return to Off)

Operator Display 'Sro'

Error (E) and Parameter Control (C) Indicators Blinking.

System Response Truck is disabled (Emergency Reverse is Active).

Alarm Sounds No

Reason Brake is not applied when the truck is turned ON. Handle is in the brake released
range prior to the system being powered ON.

Tests to Run Confirm arm angle switch function.

How to Clear Apply the brake.

Publication:1010183, Issued: 20 Mar 2014 6-3

Section 6. Messages and Codes Model 102XM Maintenance Manual

Messages and Caution Codes

Code C19
Code Title Default Parameter Warning

Operator Display C19

System Response No effect on performance.

Alarm Sounds No

Reason New default parameters have been loaded into the RAM.

Tests to Run None

How to Clear Self clears after the timer expires.

Code HPd (C20)

Code Title HPD – Directional/Speed Control Warning (High Pedal Disable)

Operator Display 'HPd'

Error (E) and Parameter Control (C) Indicators Blinking.

System Response Travel is disabled, all other systems active. Emergency reverse is active.

Alarm Sounds No

Reason Directional/Speed Control was not in neutral position at power on or when the
brake is released, or failure of the Hall Effect sensor in the speed control circuit.
Side button controls were activated when the brake was released.

Tests to Run Confirm the directional/speed control is in neutral, and the handle sensors and
wiring are correct. Examine the function of the side button controls and for shorts
to the related wiring harness.

How to Clear Return the directional/speed controls to the neutral position.

6-4 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 6. Messages and Codes

Messages and Caution Codes

Code C28
Code Title Main ON/OFF Switch Warning

Operator Display C28

System Response Truck functions are not allowed after this code is set.

Alarm Sounds No

Reason Traction power amplifier could not be reset via the CAN-bus at power-on, or the
traction power amplifier reports the Main ON/OFF switch is open.

Tests to Run 1. Main ON/OFF switch not activated when the key switch was turned ON.
2. Low voltage to the traction power amplifier (especially while lifting or driving)
due to over-current or short-circuit.
a. Try a known-good battery.
3. PTC R1 missing, faulty, or tripped (should be 18 ohms).
Note: A very high resistance is possible due to excessive current while the main
contactor is open. It should automatically recover.
a. Carefully check to see if R1 is hot (tripped). If so, unplug the battery and
allow it to cool. Locate the low impedance path that tripped R1 and correct.
4. Check the K30 Relay.
5. Wire #24 near 0V.
a. Check that J5 is connected, check the fuse, and check the wiring.
6. Check for Shorts to frame.
a. Check for 24V at J5-16.
7. Short or open circuit in the CAN wiring, or electrical noise in the CAN wiring
due to a bad connection or outside interference, both at power-on.
a. Check the CAN wiring.
8. Faulty traction power amplifier.
a. Check the power wiring.
How to Clear Code Turn the Main ON/OFF switch to ON.

Publication:1010183, Issued: 20 Mar 2014 6-5

Section 6. Messages and Codes Model 102XM Maintenance Manual

Messages and Caution Codes

Code C29
Code Title Time to Service Warning

Operator Display C29

System Response No effect on performance.

Alarm Sounds No

Reason See Service Parameter 25 on page 3-13.

Tests to Run 1. Time to perform service.

2. Service interval not reset after the last servicing.

How to Clear Code See Service Parameter 25 on page 3-13.

Code C35
Code Title Arm Angle Switch Error

Operator Display C35

System Response Normal travel controls are disabled. The truck responds only to activations of the
Emergency Reverse switch if the traction motor is rotating in the tractor-first
direction.

Alarm Sounds Yes (3 beeps, once, when error code is generated)

Reason The arm angle switch is out of adjustment or damaged. At the same time, the
traction motor is detected rotating.

Tests to Run Test the arm angle switches and wires.

How to Clear Apply the brake and have the switch adjusted or replaced.

Code Lo (C41)
Code Title Battery Undervoltage Warning

Operator Display 'Lo'

Error (E) and Battery Indicator (D) Blinking.

System Response Travel performance may be limited due to low voltage.

Alarm Sounds No

Reason Battery voltage is below approximately 17V. The battery is discharged or there is
excessive load on the battery.

Tests to Run Measure the battery voltage at JT1-1. Use the service key to read the voltage. See
“Service Display” on page 3-15.

How to Clear The battery needs to be charged. Examine the battery and battery connections. The
fault is cleared when the battery voltage increases above 17V.

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Model 102XM Maintenance Manual Section 6. Messages and Codes

Messages and Caution Codes

Code Hi (C42)
Code Title Battery Overvoltage Warning

Operator Display 'Hi'

Error (E) and Battery Indicator (D) Blinking.

System Response Travel performance may be limited.

Alarm Sounds No

Reason Battery voltage is over approximately 32V. This can be caused by the wrong type of
battery installed in the truck or an overcharged battery.

Tests to Run Measure the battery voltage at JPT1-1. See “Service Display” on page 3-15. See also
“Code Lo (C41)”.

How to Clear Make sure that the correct size battery is installed in the truck. The fault is cleared
when the battery voltage drops below 32V.

Code C43
Code Title Traction Power Amplifier Thermal Cutback

Operator Display C43

System Response Travel performance reduced.

Alarm Sounds No

Reason High or low temperature (such as above 185°F (85°C) or below –13°F (25°C)) at the
TA heatsink.

Tests to Run 1. Operating in an extreme environment.

2. Excessive load on the vehicle.
3. Check the brake adjustment.
4. Incorrect traction power amplifier mounting.
5. Bad traction power amplifier. Check TA for error code.

How to Clear Code is cleared when the traction power amplifier heatsink temperature recovers.

Publication:1010183, Issued: 20 Mar 2014 6-7

Section 6. Messages and Codes Model 102XM Maintenance Manual

Messages and Caution Codes

Code Hot1 (C44)

Code Title Motor Temperature Hot Cutback

Operator Display Hot1

System Response Travel performance may be limited.

Alarm Sounds No

Reason Traction motor temperature is above 248°F (120°C). Resistance of the temperature
sensor should be 591 Ohms at room temperature.

Tests to Run Use an accurate temperature measuring device to verify the temperature reading on
the service display. See “Service Display” on page 3-15.

How to Clear Permit the motor to cool down. Replace the temperature sensor.

Code C46
Code Title Severe Traction Motor Thermal Cutback

Operator Display C46

System Response Truck functions are allowed, but the maximum speed value sent to the traction
power amplifier is reduced.

Alarm Sounds No

Reason Very high traction motor temperature or extreme operation detected.

Tests to Run 1. Operating in an extreme environment.

2. Excessive load on the vehicle.
a. Check the brake adjustment.
3. Airflow to the motor restricted.
4. Problem with the motor wiring.
5. Faulty traction motor.

How to Clear Code is cleared when the temperature recovers.

NOTE: Caution Error Codes above 50 are

logged. See following for how to clear
code and allowed activity during error.
Some codes can be cleared by cycling
the key switch OFF/ON.

6-8 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 6. Messages and Codes

Error Codes

Error Codes
NOTE: Error Codes are 100 and above. Error
codes are logged. No truck activity is
allowed during error. Some codes can be
cleared when the truck is cycled
OFF/ON (unless otherwise noted).

Code E101

Code Title Traction Amp Type Error

Operator Display E101

System Response No truck function active.

Alarm Sounds No

Reason Incorrect Traction Power Amplifier installed on the truck.

Tests to Run Determine correct TA P/N.

How to Clear Replace with the correct TA.

Code E104
Code Title Brake Output Error

Operator Display E106

System Response No truck function active.

Alarm Sounds No

Reason Traction power amplifier cannot detect the presence of the brake coil.

Tests to Run 1. Open circuit due to brake or wiring.

a. Check the brake and wiring. The brake coil should be approximately 24
ohms.
b. Check the brake release switch and wiring.
2. Master control relay missing or stuck open.
3. Main contactor open circuit (especially after it has closed).
4. Communication error due to the traction power amplifier handset.
a. Unplug the handset from the traction power amplifier and allow the
handset to completely boot before turning the truck ON.
5. Bad traction motor or motor cables.
6. Faulty traction power amplifier.
a. Check the traction power amplifier for an error code.
How to Clear Examine for shorted component or related wiring. Replace as needed.

Publication:1010183, Issued: 20 Mar 2014 6-9

Section 6. Messages and Codes Model 102XM Maintenance Manual

Error Codes

Code E106
Code Title Digital Output or Traction Motor Field Over-current

Operator Display E106

System Response No truck function active.

Alarm Sounds No

Reason Traction power amplifier saw excessive current being drawn by a component
connected to a digital output or the traction motor.

Tests to Run 1. High current through a digital output. Check the coils and wires of all outputs
from the traction power amplifier. The brake coil should be 24 ohms, K10
should be 40 ohms, and K30 should be 40 ohms.
2. Open or shorted lift or traction motor. Check the motors and wires for opens or
shorts. The traction motor armature should be 0.4 ohms and the field should
be 1.3 ohms. The lift motor armature should be 0.4 ohms.
3. Shorts to frame - check for shorts to frame.
4. Bad traction power amplifier - replace the traction power amplifier.

How to Clear Examine for a shorted component or related wiring. Replace as needed.

Code E107
Code Title Contactor Off Error (Below software version 3.6)

Operator Display E107

System Response No truck function active.

Alarm Sounds No

Reason Main contactor did not close. Open or short in the main contactor coil. Resistance
of coil should be approximately 37 Ohms.

Tests to Run Examine the contactor circuit for opens or shorts in the related wiring harness. See
“Service Display” on page 3-15.

How to Clear Examine for open Main Contactor or related wiring. Repair or replace as needed.

6-10 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 6. Messages and Codes

Error Codes

Code E108
Code Title Contactor Weld Error (Below software version 3.6)

Operator Display E108

System Response No truck function active.

Alarm Sounds No

Reason Main Contactor welded (detected on start-up). Inspect contact tips for welding.
Check for B+ at the B+ connection of the traction power amplifier.

Tests to Run See “Service Display” on page 3-15.

How to Clear Examine for welded contact tips. Repair or replace as needed.

Code E110
Code Title Braking System Fault

Operator Display E110

System Response No truck function active.

Alarm Sounds No

Reason Traction power amplifier detected problem with braking functions.

Possible Cause/ 1. Short-circuit in brake circuit.

Corrective Action a. Check the brake and wiring. The brake coil should be 24 ohms.
2. Faulty traction power amplifier.

Code E112
Code Title Arm Angle Sequence Fault

Operator Display E112

System Response No truck function active.

Alarm Sounds No

Reason Incorrect sequence of arm angle inputs.

Possible Cause/ 1. Bad Battery - check voltage.

Corrective Action 2. Arm angle input stuck ON or OFF.
3. Problem with the arm angle input wiring.
4. Problem with the tiller arm.
a. Check for correct sequence of the arm angle switches.
5. Communication error due to traction power amplifier handset.
a. Unplug the handset from the traction power amplifier and allow the
handset to completely boot before turning the truck ON.

Publication:1010183, Issued: 20 Mar 2014 6-11

Section 6. Messages and Codes Model 102XM Maintenance Manual

Error Codes

Code E114
Code Title Traction Motor Speed Fault

Operator Display E114

System Response No truck function active.

Alarm Sounds No

Reason Traction power amplifier detected a stalled traction motor.

Possible Cause/ 1. Traction motor stalled.

Corrective Action 2. Excessive traction motor load at low speed.
a. Check the brake adjustment.
3. Faulty traction power amplifier.

Code E115
Code Title Contactor Off, Welded or Missing, or Faulty Power Amp
(starting with software version 3.6)

Operator Display E115

System Response No truck function active.

Alarm Sounds No

Reason Traction power amplifier could not close (contactor OFF), contactor welded, or
contactor missing.

Possible Cause/ Contactor did not close (contactor OFF).

Corrective Action 1. Problem with the main contactor tips.
a. If contactor clicks prior to getting this code, try polishing the contactor tips
with a clean pencil eraser. If this does not work or there is permanent
contactor damage, replace the contactor.
2. Low voltage.
a. Try closing the contactor with a good battery.
3. Short in the contactor coil.
a. Replace the contactor.
Contactor welded.
1. Main contactor tips welded.
2. Short circuit in the contactor circuit.
a. Check the contactor, wiring (coil), and cabling. The coil should be 24 ohms.
Contactor missing.
1. Open circuit in the contactor circuit.
a. Check the contactor, wiring (coil), and cabling. The coil should be 24 ohms.
2. Faulty traction power amplifier.
a. Check the power wiring.

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Model 102XM Maintenance Manual Section 6. Messages and Codes

Error Codes

Code E118
Code Title K4 MCR Welded (starting with software version 3.6)

Operator Display E118

System Response No truck function active.

Alarm Sounds No

Reason MCR detected welded at startup.

Possible Cause/ 1. MCR tips welded.

Corrective Action 2. Short circuit in the MCR circuit.
a. Check the MCR wiring (tips).

Code E140
Code Title Checksum Error

Operator Display E140

System Response No truck function active.

Alarm Sounds No

Reason Software check sum not the same as the stored value.

Tests to Run None

How to Clear Code may clear on cycling the key switch OFF/ON. If not, replace the VM.

Code E141
Code Title Software Problem

Operator Display E141

System Response No truck function active.

Alarm Sounds No

Reason Vehicle Manager found a problem with the software.

Tests to Run 1. Missing or bad software.

a. If applicable, try downloading new software.
2. Bad Vehicle Manager - Replace the VM.

How to Clear Code is cleared when the problem is resolved and the key switch is cycled OFF/ON.

Publication:1010183, Issued: 20 Mar 2014 6-13

Section 6. Messages and Codes Model 102XM Maintenance Manual

Error Codes

Code E142
Code Title Traction Power Amplifier Disable Error

Operator Display E142

System Response No truck function active.

Alarm Sounds No

Reason Traction power amplifier detected a major fault.

Tests to Run None

How to Clear 1. Severe overvoltage - Check the battery voltage to the traction power amplifier.
2. Shorts to Frame - Check for shorts to frame.
3. High current through a digital output - Check the coils and wires of all
outputs from the traction power amplifier. The brake coil should be 24 ohms,
K10 should be 40 ohms, and K30 should be 40 ohms.
4. Open or shorted lift or traction motor - Check the motors and wires for opens
or shorts. The traction motor armature should be 0.4 ohms, the field should
be 1.3 ohms, and the Lift motor armature should be 0.4 ohms.
5. Bad Traction Power Amplifier - Replace the traction power amplifier.

Code E150
Code Title CAN Bus Communication Error

Operator Display E150

System Response No truck function active. Code may be displayed briefly then goes out.

Alarm Sounds No

Reason VM has not detected any response from the TA to CAN messages. Bad connection
or terminal crimp or a damaged wire between the TA and VM. Check for low battery
voltage.

Tests to Run N/A

How to Clear Examine the VM, TA, and related wiring. Repair or replace as needed.

6-14 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 6. Messages and Codes

Error Codes

Code E151
Code Title CAN Bus Communication Error

Operator Display E151

System Response No truck function active.

Alarm Sounds No

Reason Vehicle Manager could not send CAN data to the TA.

Tests to Run 1. Short or open circuit in the CAN wiring.

2. Electrical noise in the CAN wiring due to a bad connection, outside
interference, or low voltage (especially while lifting or driving) possibly due to
overcurrent or short circuit.
a. Check the CAN wiring.
b. Try driving using a known-good battery.
3. Bad Vehicle Manager - Replace the VM.

How to Clear Code is cleared when the problem is resolved and the key switch is cycled OFF/ON.

Code E157
Code Title CAN Bus Off Error

Operator Display E157

System Response No truck function active.

Alarm Sounds No

Reason TA did not reply to the CAN messages.

Tests to Run N/A

How to Clear Examine the VM, TA, and related wiring. Repair or replace as needed.

Code E159
Code Title CAN Bus Overrun Error

Operator Display E159

System Response No truck function active.

Alarm Sounds No

Reason TA did not reply to the CAN messages.

Tests to Run N/A

How to Clear Examine the VM, TA, and related wiring. Repair or replace as needed.

Publication:1010183, Issued: 20 Mar 2014 6-15

Section 6. Messages and Codes Model 102XM Maintenance Manual

Error Codes

Code E160
Code Title Emergency Reverse (Belly Button)/Hall Supply Error

Operator Display E160

System Response No truck function active.

Alarm Sounds No

Reason Faulty hall effect sensor in the handle (VM).

Tests to Run None

How to Clear Determine the cause of the faulty sensor and repair or replace as needed. The VM is
the likely cause.

Code E161
Code Title Lower Valve Error

Operator Display E161

System Response No truck function active.

Alarm Sounds No

Reason Traction power amplifier could not detect the presence of the lower valve coil.

Tests to Run None

Possible Cause/ 1. Open or short circuit in the lower valve, wiring, or coil. The coil should read 40
Corrective Action ohms.
2. Master control relay open.
3. Main contactor open circuit.
4. Communication error due to the traction power amplifier handset.
a. Unplug the handset from the traction power amplifier and allow the
handset to completely boot before turning the truck ON.
5. Faulty traction power amplifier.

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Model 102XM Maintenance Manual Section 6. Messages and Codes

Error Codes

Code E200
Code Title Traction Motor Field Open

Operator Display E161

System Response No truck function active.

Alarm Sounds No

Reason Traction power amplifier detected an open circuit in the traction motor field winding.

Tests to Run None

Possible Cause/ Open circuit in the traction motor field winding circuit.
Corrective Action 1. Check the traction motor field wiring and field windings in the motor. The field
should read 1.3 ohms.
2. Replace the traction power amplifier.

Code E201
Code Title Traction Motor Armature Error

Operator Display E201

System Response No truck function active.

Alarm Sounds No

Reason Traction power amplifier detected an armature circuit fault.

Tests to Run 1. Incorrect traction motor armature circuit or cabling. The armature should
read 0.4 ohms.
2. Bad traction power amplifier.
a. Check the traction power amplifier for an error code.
How to Clear Code is cleared when the problem is resolved and the key switch is cycled OFF/ON.

Code E202
Code Title Traction Power Amplifier Sensor Error

Operator Display E202

System Response No truck function active.

Alarm Sounds No

Reason Phase current sensor fault.

Tests to Run See “Service Display” on page 3-15.

How to Clear 1. Abnormal vehicle operation causing current spikes.

2. Faulty traction power amplifier.

Publication:1010183, Issued: 20 Mar 2014 6-17

Section 6. Messages and Codes Model 102XM Maintenance Manual

Error Codes

Code E214
Code Title Traction Power Amplifier CAN Time-out

Operator Display E214

System Response No truck function active.

Alarm Sounds No

Reason Traction power amplifier did not receive CAN data from the vehicle manager or
traction power amplifier self-test failed.

Tests to Run None

How to Clear Examine the VM, TA, and related wiring. Repair or replace as needed.

6-18 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 7. Component Procedures

Section 7. Component Procedures

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Section 7. Component Procedures Model 102XM Maintenance Manual

List of Component Procedures by Component System

List of Component Drive Unit Housing Lubrication . . 7-29

Gear Oil Level Check . . . . . . . 7-29
Procedures by Changing Gear Oil . . . . . . . . . 7-29

Component System Electrical Components . . . . . . . . . . . . . 7-31

Battery . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Swing-out Battery Pack . . . . . . . . 7-32
Component Locator Photos . . . . . . . . . . 7-5 Removal (single battery) . . . . . 7-32
Finish and Accessories . . . . . . . . . . . . . 7-7 Installation (single battery) . . . 7-32
Tractor Covers . . . . . . . . . . . . . . . . . . . 7-8 Removal
Tractor Cover Removal . . . . . . . . . . 7-8 (entire battery pack) . . . . . . 7-32
Tractor Cover Installation . . . . . . . . 7-8 Installation
(entire battery pack) . . . . . . 7-33
Tractor Bumper . . . . . . . . . . . . . . . . . . 7-9
Maintenance-Free Batteries . . . . . 7-33
Bumper Removal . . . . . . . . . . . . . . 7-9
Battery Maintenance . . . . . . . . . . 7-33
Bumper Installation . . . . . . . . . . . . 7-9
Battery Exterior Cleaning . . . 7-33
Steering and Controls . . . . . . . . . . . . . 7-11 Charging a Battery . . . . . . . . . 7-34
Control Handle Head . . . . . . . . . . . . . 7-12 Adding Water to a Battery . . . 7-35
Control Handle Disassembly . . . . . 7-13 Battery Specific Gravity . . . . . 7-35
Horn Button/Switch Specific Gravity Check . . . 7-36
Replacement . . . . . . . . . . . . 7-13 Battery Voltage Check . . . . . . 7-36
Lift/Lower Button Battery Storage . . . . . . . . . . . 7-36
Replacement . . . . . . . . . . . . 7-14 Power Cables . . . . . . . . . . . . . . . . . . . 7-37
Push Button Replacement. . . . 7-14 Power Cable Repair . . . . . . . . . . . 7-37
Emergency Reverser Wiring Harness . . . . . . . . . . . . . . . . . . 7-39
Replacement . . . . . . . . . . . . 7-14 Wiring Harness Terminology . . . . 7-39
Control Handle Stem . . . . . . . . . . . . . 7-16 Wiring Harness Inspection . . . . . . 7-39
Control Handle Stem Removal . . . 7-16 Wiring Harness Repair . . . . . . . . . 7-40
Control Handle Stem Wiring Harness Soldering
Reassembly . . . . . . . . . . . . . 7-17 Procedures. . . . . . . . . . . . . . 7-40
Drive and Brake . . . . . . . . . . . . . . . . . 7-19 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Fuse Test/Inspection . . . . . . . . . . 7-41
Drive Unit Assembly . . . . . . . . . . . . . 7-20
Electromagnetic Brake Assembly . 7-20 Circuit Breaker . . . . . . . . . . . . . . . . . . 7-42
Brake Disc Location . . . . . . . . 7-20 Circuit Breaker Test/Inspection . . 7-42
Air Gap Adjustment . . . . . . . . 7-20 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
Friction Disc Replacement. . . . 7-21 Horn Removal . . . . . . . . . . . . . . . 7-43
Mechanically Releasing Horn Installation . . . . . . . . . . . . . 7-43
the Brake . . . . . . . . . . . . . . 7-21 Traction Power Amplifier . . . . . . . . . . . 7-44
Electric Brake Release Cleaning the Traction Power
Kit Installation. . . . . . . . . . . 7-22 Amplifier . . . . . . . . . . . . . . . 7-44
Drive Wheel . . . . . . . . . . . . . . . . . . . . 7-23 Traction Power Amplifier
Drive Wheel Removal . . . . . . . . . . 7-23 Removal. . . . . . . . . . . . . . . . 7-44
Tire Replacement . . . . . . . . . . . . . 7-23 Traction Power Amplifier
Drive Wheel Installation . . . . . . . . 7-24 Installation . . . . . . . . . . . . . 7-44
Drive Unit . . . . . . . . . . . . . . . . . . . . . 7-25 Contactors . . . . . . . . . . . . . . . . . . . . . 7-45
Drive Unit Removal. . . . . . . . . . . . 7-25 Main Contactor . . . . . . . . . . . . . . 7-45
Drive Unit Disassembly. . . . . . 7-25 Main Contactor Removal . . . . 7-45
Drive Unit Assembly . . . . . . . . 7-26 Main Contactor Installation . . 7-45
Drive Unit Installation. . . . . . . 7-28 Main Contactor, Sealed . . . . . . . . 7-45
Sealed Main Contactor
Removal . . . . . . . . . . . . . . . 7-45

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Model 102XM Maintenance Manual Section 7. Component Procedures

List of Component Procedures by Component System

Sealed Main Contactor Hydraulic Unit . . . . . . . . . . . . . . . . . . 7-64

Installation . . . . . . . . . . . . . 7-46 Hydraulic Unit Removal . . . . . . . . 7-64
Lift Motor Solenoid . . . . . . . . . . . . 7-46 Hydraulic Unit Installation . . . . . . 7-64
Master Control Relay . . . . . . . . . . . . . 7-47 Hydraulic Reservoir . . . . . . . . . . . . . . 7-65
Master Control Relay Reservoir Removal . . . . . . . . . . . . 7-65
Inspection/Test. . . . . . . . . . . 7-47 Reservoir Installation . . . . . . . . . . 7-65
Switches (General) . . . . . . . . . . . . . . . 7-48 Filter Screen and Inlet Tube . . . . . . . . 7-66
Testing/Inspecting Switches . . . . . 7-48 Filter Screen and Inlet
Main ON/OFF Switch . . . . . . . . . . 7-48 Tube Removal . . . . . . . . . . . 7-66
Main ON/OFF Switch Filter Screen and Inlet
Inspection . . . . . . . . . . . . . . 7-48 Tube Installation . . . . . . . . . 7-66
Main ON/OFF Switch Hydraulic Pump . . . . . . . . . . . . . . . . . 7-67
Removal. . . . . . . . . . . . . . . . 7-48 Hydraulic Pump Removal . . . . . . . 7-67
Main ON/OFF Switch Hydraulic Pump Installation. . . . . 7-67
Installation . . . . . . . . . . . . . 7-48 Hydraulic Pump Pressure Relief
Arm Angle Switches . . . . . . . . . . . 7-49 Adjustment . . . . . . . . . . . . . . . . . 7-68
Arm Angle Switches Relief Valve Settings . . . . . . . . . . . 7-68
Adjustment . . . . . . . . . . . . . 7-49 Relief Valve Setting Check . . . . . . 7-68
Arm Angle Switches Relief Valve Setting Adjustment . . 7-68
Removal. . . . . . . . . . . . . . . . 7-50
Hydraulic Cylinder . . . . . . . . . . . . . . . 7-69
Arm Angle Switches
Cylinder Removal . . . . . . . . . . . . . 7-69
Installation . . . . . . . . . . . . . 7-50
Cylinder Disassembly. . . . . . . . . . 7-70
Arm Angle Switches
Cylinder Inspection . . . . . . . . . . . 7-70
(Plastic Switch Bridge) . . . . . 7-50
Cylinder Assembly . . . . . . . . . . . . 7-70
Switch Bridge
Cylinder Installation. . . . . . . . . . . 7-70
Replacement . . . . . . . . . 7-51
Lift-Limit Switch . . . . . . . . . . . . . . 7-53 Hydraulic Solenoid . . . . . . . . . . . . . . . 7-72
Lift-Limit Switch Adjustment . . 7-53 Solenoid Removal . . . . . . . . . . . . . 7-72
Key Switch . . . . . . . . . . . . . . . . . . 7-53 Solenoid Installation. . . . . . . . . . . 7-72
Key Switch Inspection . . . . . . . 7-53 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Motors, General . . . . . . . . . . . . . . . . . 7-54 Pallet Forks and Load Wheels . . . . . . . 7-74
Motor Brush Inspection . . . . . . . . 7-54 Load Wheels. . . . . . . . . . . . . . . . . 7-74
Motor Brush Replacement. . . . . . . 7-54 Removal and Replacement . . . 7-74
Motor Brush Spring Tension . . . . . 7-55 Load Wheel Pull Rod . . . . . . . . . . 7-74
Brush Spring Tension Removal and Replacement . . . 7-74
Inspection . . . . . . . . . . . . . . 7-55 Carrier Frame Linkage . . . . . . . . . 7-75
Terminal Nuts . . . . . . . . . . . . . . . . 7-56 Downstops . . . . . . . . . . . . . . . . . 7-76
Traction Motor . . . . . . . . . . . . . . . . . . 7-57 Lower Link and Pivot
Brush Replacement. . . . . . . . . . . . 7-57 Block Inspection . . . . . . . . . 7-76
Motor Disassembly . . . . . . . . . . . . 7-57 Downstop Adjustment . . . . . . 7-76
Traction Motor Installation . . . . . . 7-57 Skid Shoe Blocks . . . . . . . . . . . . . 7-78
Lift Motor . . . . . . . . . . . . . . . . . . . . . 7-59 Skid Shoe Adjustment . . . . . . 7-78
Lift Motor Removal . . . . . . . . . . . . 7-59 Options . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Lift Motor Installation . . . . . . . . . . 7-59
Cold Storage Conditioning . . . . . . . . . . 7-80
Lift Motor Brush Replacement. . . . 7-59
Cold Storage Hydraulic Fluid . 7-80
Hydraulic Components . . . . . . . . . . . . 7-61
Hydraulic Components . . . . . . . . . . . 7-62
General Guidelines . . . . . . . . . . . . 7-62
Hydraulic Fluid . . . . . . . . . . . . . . . . . 7-63
Hydraulic Fluid Level Check . . 7-63
Changing Hydraulic Fluid . . . . . . . 7-63

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Section 7. Component Procedures Model 102XM Maintenance Manual

List of Component Procedures by Component System

7-4 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 7. Component Procedures

Component Locator Photos

Component Locator Photos

Section 7. Component Procedures

Figure 7-1. Tractor Interior

6349-005.jpg

Main Lift Motor

Contactor Solenoid
Battery
Connector

Traction
Power
Amplifier Fill/Vent
Plug

Master
Control
Relay
Hydraulic
Solenoid

Hydraulic
Reservoir

Horn

Drive Unit
(behind
bumper)
Hydraulic Cylinder

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Section 7. Component Procedures Model 102XM Maintenance Manual

Component Locator Photos

Figure 7-2. Model 102XM General Information
6349-002.jpg

Control Handle

Battery

Drive Unit

Pallet Forks and

Load Wheels

7-6 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 7. Component Procedures

Finish and Accessories

Finish and Accessories

Publication: 1010183, Issued: 20 Mar 2014 7-7

Section 7. Component Procedures Model 102XM Maintenance Manual

Tractor Covers Finish and Accessories

Tractor Covers Tractor Cover Installation

NOTE: For replacement parts information refer To install the tractor covers:
to the Parts Manual. 1. Place the lower cover in position, then
install the two captivating screws located
The tractor covers are designed to be easily at the top of the lower cover.
removed and re-installed for service and 2. Slide the upper cover back into the
maintenance. original position.
3. Secure the upper cover by engaging the
Tractor Cover Removal captivating clasps located on the top of the
upper cover.
1. Grasp the upper cover at the location
shown. Lift the cover upward to disengage
the captivating clasps. See Figure 7-3.
2. Remove the two captivating screws located
at the top of the lower cover, then remove
the lower cover.
Figure 7-3. Upper Cover Removal (decals omitted)
6349-004.jpg

Grasp Upper
Cover Here

Lower Cover

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Model 102XM Maintenance Manual Section 7. Component Procedures

Finish and Accessories Tractor Bumper

Tractor Bumper Bumper Installation

NOTE: For replacement parts information refer To install the bumper:

to the Parts Manual. 1. Apply thread-locking compound to the
screws.
The tractor bumper is designed to be easily 2. Attach the new bumper to the pivot frame
removed and re-installed for service and using screws and lock washers.
maintenance.
3. Attach the bumper using the four lower
mounting holes first. Then attach the lift
Bumper Removal limit switch bracket and bumper with the
remaining screws.
1. Remove the tractor covers. See “Tractor
Covers” on page 7-8. 4. Torque screws to 18 to 24 ft. lb. (24.4 to
32.5 Nm).
2. Remove the eight screws and lock washers
securing the bumper and lift limit switch 5. Install the tractor covers. See “Tractor
bracket to the pivot frame. Covers” on page 7-8.
Figure 7-4. Bumper Removal
6349-004.jpg

Mounting Screws
(Right Side)
Lift-Limit Switch
Bracket

Mounting Screws
(Left Side)

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Section 7. Component Procedures Model 102XM Maintenance Manual

Tractor Bumper Finish and Accessories

7-10 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 7. Component Procedures

Steering and Controls Tractor Bumper

Steering and Controls

Publication: 1010183, Issued: 20 Mar 2014 7-11

Section 7. Component Procedures Model 102XM Maintenance Manual

Control Handle Head Steering and Controls

Control Handle Head NOTE: For replacement parts information refer

to the Parts Manual.
Figure 7-5. Control Handle Head
4111-000-1.cgm,4111-000-2.cgm

20 19

21 19a
18

18a

17
22

23 15

24 14
25 13 11

26

10

27
16
28
30

32 12
29
33

35 31
36

31 7
34
6
4
35
5

1
8
9

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Model 102XM Maintenance Manual Section 7. Component Procedures

Steering and Controls Control Handle Head

Item Item Item

Description Description Description
No. No. No.
1 Screw 13 Vehicle manager 25 Gasket
2 Keypad 14 Push button (option) 26 Signal button
3 Screw, 2 x M5 x 45 - 15 Top cover 27 Push button (option)
2 x M5 x 60
4 Handle 16 Display card 28 Wire, hold down
5 Cover, keypad (Optional) 17 Push button 29 Screw
6 Top Plate 18 Emergency reverse 30 Directional/Speed
button Control Thumb Wheel
7 Screw 19 Push button (not used) 31 Sliding bearing
8 Bottom plate 20 Plate 32 Control stop
9 Grommet 21 Holder 33 Arm
10 Screw, M4 x 40 22 Push button, lift/lower 34 Axle
11 Spring 23 Arm 35 Spring holder
12 Lower cover 24 Display glass 36 Spring

Control Handle Disassembly Horn Button/Switch Replacement

1. Remove screw [1], then unplug and 1. Remove the horn button [26, 27]. See
remove the keypad [2]. Figure 7-6.
2. Remove the four screws [3] that secure the
top cover assembly to the handle. Hold the
top cover [15] firmly while removing the Do not use excessive force when prying
screws. on the button or you can damage the
3. Disconnect the cable connected to the locking tabs.
vehicle manager [13].
4. For access to the vehicle manager [13], Figure 7-6. Horn Button Removal
P0011000.wmf
remove the screws [10] securing the lower
cover [12].

Static electricity! Risk of static discharge

that can damage the electronics. Make
sure to take the necessary precautions
before working with the electronics.

5. Carefully lift off the lower cover [12].

NOTE: Place your finger between the lower
cover [12] and button [18] to hold the 2. Disconnect the connection for the switch
directional/speed control thumb wheel on the vehicle manager [13].
[30] in place. 3. Press out the switch from its mounting in
the top cover assembly.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Control Handle Head Steering and Controls

Lift/Lower Button Replacement Emergency Reverser Replacement

1. Remove the lift/lower button [22] by 1. Remove the push button following steps 1
placing a screwdriver in the hole [A]. See and 2 in the Push Button Replacement
Figure 7-7. procedure. See Figure 7-9.
Figure 7-7. Lift/Lower Button Removal Figure 7-9. Remove the Push Button
P0011001.wmf P0011002.wmf

A A

2. Unscrew the holder [21] so that the arm

[23] comes loose.
2. Insert a screwdriver and carefully pry the
Emergency reverser button loose. See
Push Button Replacement Figure 7-10.
1. Press the push button [19] sideways. Figure 7-10. Emergency Reverser Button Removal
P0011002.wmf
2. Insert a screwdriver and carefully pry the
button loose. See Figure 7-8.
Figure 7-8. Push Button Removal
P0011002.wmf

3. Unscrew the button’s holder and arm

[19a].

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Model 102XM Maintenance Manual Section 7. Component Procedures

Steering and Controls Control Handle Head

NOTE: If the Emergency reverser button is

removed for any reason, verify that the
magnet arm is not loose in the up and
down direction. (It is normal for the arm
to move slightly from side to side.) See
Figure 7-11. A loose arm in the up and
down direction can result in “odd” truck
behavior, such as unexpected travel.
Figure 7-11.

Acceptable arm Unacceptable

movement arm movement

3. Install the Emergency reverser button in

the control head.
4. Install the push button in the control
head.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Control Handle Stem Steering and Controls

Control Handle Stem Figure 7-13. Cover Removed

6055-015.tif

Wiring Harness
NOTE: For replacement parts information refer Connector
to the Parts Manual. Retaining Bolt
NOTE: When replacing the handle stem on
trucks prior to S/N 8097, obtain kit
(P/N 312677/KIT). The old handle stem
is no longer available. The kit contains a
new handle stem and a new arm angle
switch bracket. You must replace both
the handle stem and the arm angle Arm Angle
switch bracket. Do not mix old and new. Switch
Connections
Retaining Bolt
Control Handle Stem Removal
1. Press the red OFF ( O ) key on the keypad.
Disconnect the battery connector.
Before removing the cap screws in the
2. Remove the hex head cap screw securing
next step, make sure you are holding
the stem mount up-stop cushion cover.
the handle. When the cap screws are
See Figure 7-12.
removed, the handle will fall.
Figure 7-12. Removing Up-stop Cushion Cover
6349-014.jpg
4. Remove the three Allen head cap screws
Cap Screw located at the base of the control handle
stem. See Figure 7-14.
Figure 7-14. Allen Head Cap Screws
6349-015.jpg

Allen Head
Cap Screws

Up-stop Cushion Cover

Use care when releasing the handle

when the up-stop cushion cover is 5. Carefully remove the control handle stem
removed. With the cover removed, the and mount.
handle can over-travel and cause
damage to items at the base of the
handle stem. Never push the handle
further up with the cover removed.

3. Disconnect the wiring harness connector

and arm angle switch connections. See
Figure 7-13.

7-16 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section 7. Component Procedures

Steering and Controls Control Handle Stem

Control Handle Stem

Reassembly
1. During reassembly, make sure that the
brake release cam assembly is in the
correct position before installing.
2. Position the control handle mounting base
on the pivot assembly.
3. Reinstall the three Allen head cap screws.
4. Thread the wiring harness through the
handle base.
5. Reattach the control handle head unit if
removed.
6. Reconnect the handle harness connector
and arm angle switch connections. Install
the cable ties in their original locations on
the handle harness.
7. Install the control handle cover.
8. Connect the battery connector. Press the
green ON ( | ) key on the keypad.
9. Test the operation of the truck.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Control Handle Stem Steering and Controls

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Model 102XM Maintenance Manual Section 7. Component Procedures

Drive and Brake Control Handle Stem

Drive and Brake

Publication: 1010183, Issued: 20 Mar 2014 7-19

Section 7. Component Procedures Model 102XM Maintenance Manual

Drive Unit Assembly Drive and Brake

Drive Unit Assembly Air Gap Adjustment

The nominal gap between the coil housing and

The drive unit assembly includes the the pressure plate in the applied position is
electromagnetic brake assembly, drive wheel, 0.008 to 0.010 in. (0.2 to 0.25 mm).
drive unit, and traction motor.
1. Press the red OFF ( O ) key on the keypad.
NOTE: For replacement parts information refer Disconnect the battery connector.
to the Parts Manual.
2. Block the drive wheels to prevent any
movement while the brake repairs are in
Electromagnetic Brake process.
Assembly 3. Remove the drive unit cover.
NOTE: For replacement parts information refer 4. Remove the rubber brake boot to access
to the Parts Manual. the brake.
5. Loosen the three 4 mm Allen head brake
assembly mounting bolts. See Figure 7-16.
Figure 7-16. Brake Gap Adjustment
Allow the brake to cool completely 8133_004a.tif

before servicing.
Adjusting Air gap Mounting
Screw Bolt
Brake Disc Location Stainless 0.008 - 0.010 in.
(0.2 - 0.25 mm)
Steel
Brake
The electromagnetic brake assembly is Plate
mounted directly to the traction motor. See
Figure 7-15.
Figure 7-15. Brake Location
6349-025.jpg

Electromagnetic
Brake

Friction Disc Pressure Plate Coil Housing

6. Turn the adjusting screws while checking

the air gap at several points with a
0.008 in. (0.2 mm) feeler gauge.
7. Tighten the mounting bolts to 50 in. lb.
(5.6 Nm). Recheck the gap with the feeler
gauge.
8. Install the rubber brake boot to protect the
brake from moisture and dirt.
9. Install the drive unit cover.
10. Connect the battery connector. Press the
green ON ( | ) key on the keypad.
11. Test the operation of the truck.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Drive and Brake Drive Unit Assembly

Friction Disc Replacement 10. Connect the battery connector. Press the
green ON ( | ) key on the keypad.
Replace the friction disc when its total 11. Test the operation of the truck.
thickness is reduced to 0.20 in. (5.5 mm).
1. Press the red OFF ( O ) key on the keypad. Mechanically Releasing the Brake
Disconnect the battery connector.
2. Block the drive wheels to prevent any If the brake cannot be electrically released,
movement while the brake repairs are in perform the following:
process. 1. Remove the drive unit cover.
3. Remove the drive unit cover. 2. Loosen the three 4 mm Allen head
4. Remove the rubber brake boot to access mounting bolts evenly until the clamping
the brake. force on the friction disc is low enough to
allow the truck to roll.
5. Loosen and remove the three 4 mm
mounting bolts and remove the brake coil 3. Move the truck to the desired location.
assembly. See Figure 7-17. 4. Adjust the gap and torque mounting bolts.
NOTE: If not already present on the truck, See “Air Gap Adjustment” on page 7-20.
install a stainless steel brake plate over 5. Install the drive unit cover.
the top of the existing brake plate.
6. Replace the friction disc on the hub.
Inspect friction plate for wear. Replace the
friction plate if the surface is worn
unevenly.
7. Install the brake coil assembly on the
motor end. Adjust the gap and torque the
mounting bolts beginning with step 6 in
“Air Gap Adjustment” on page 7-20.
Figure 7-17. Friction Disc Replacement
3370-000.cgm

Adjusting Screw (x3) Mounting Bolt (x3)

Hub

Friction Disc Brake Coil

Assembly

8. Install the rubber brake boot to protect the

brake from moisture and dirt.
9. Install the drive unit cover.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Drive Unit Assembly Drive and Brake

Electric Brake Release Kit Installation Figure 7-20.

An Electric Brake Release kit is available for

trucks ordered without this option. File an
S207 and refer to the following installation
procedures:
1. Remove the main harness for trucks with
serial numbers 07893 and below.
8. Secure the relay to the relay bracket with
2. Install the new main harness (trucks with
2 screws. Mount the relay so the two
serial numbers 07894 and above come
terminals that are spread the furthest
from the factory with the new harness
apart are on the left and the mounting
installed).
hole on the bracket is facing downward.
NOTE: Not all connections will be used at this 9. Remove the top bolt holding the Curtis
time. controller in place and mount the relay
3. Wires 26 and 26A will be connected assembly reusing the removed bolt.
together. Disconnect the two wires and let Figure 7-21.
them hang. They will be used in a later
step.
4. Cut the cable ties securing wires 20, 51,
and 57 and let the wires hang for use later.
5. Remove the mounting screws from the
switch housing and remove the switch
housing from the truck.
Figure 7-18.

10. Connect the new switch harness to all

connection points as shown.
11. Cable tie the switch harness to the main
harness as needed. Make the installation
as neat as possible.
12. Before operating the truck, read the
operating procedures for Electrically
Released Brake Option.
6. Install the switch and the harness to the
switch bracket as shown.
Figure 7-19.

7. Place the housing back on the truck and

use the new longer screws to go through
the housing and through the switch
bracket. Secure with the new nuts.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Drive and Brake Drive Wheel

Drive Wheel Tire Replacement

NOTE: For replacement parts information refer Any misalignment of the tire and hub while the
to the Parts Manual. tire is being pressed on the hub can cause
damage to the hub. For this reason, chamfers
are provided on the outside edge of the hub and
Drive Wheel Removal on the end of the inside diameter of the tire’s
metal insert. The chamfers help to center the
1. Press the red OFF ( O ) key on the keypad
hub and tire during pressing and to reduce the
and disconnect the battery connector.
possibility of misalignment.

Use extreme care whenever the truck is To prevent damage, the hub must be
jacked up. Keep hands and feet clear installed on the circular ram with the
from the vehicle while jacking the truck. chamfered side up.
After the truck is jacked, put solid blocks
beneath it to support it. DO NOT rely on 1. Check the inside surface of the metal
the jack alone to support the truck. For insert on the new tire. Remove any scaling
details, see “Jacking Safety” on or rust with sandpaper. Clean the inside of
page 2-9. the metal insert.
2. Place a circular ram on the press table.
2. Remove the bumper. See “Bumper The length of the ram must be longer than
Removal” on page 7-9. the width of the old tire to permit complete
3. Jack and block the truck under the tractor removal of the old tire. The outside
frame. diameter of the ram must be small enough
to fit loosely in the insert of the tire but
4. Remove the five drive wheel mounting must be large enough to rest squarely on
nuts. See Figure 7-22. the flat surface on the outer edge of the
Figure 7-22. Drive Wheel Nuts hub. See Figure 7-23.
1581 007.tif
Figure 7-23. Tire Replacement
2453_200.tif

Drive
Wheel
Nuts (5)

5. Remove the drive wheel.

3. If the outside edge of the hub is not flush

with the edge of the metal insert in the old
tire, measure how far the hub is recessed
inside the tire. The new tire must be

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Section 7. Component Procedures Model 102XM Maintenance Manual

Drive Wheel Drive and Brake

placed in the same position the old tire Drive Wheel Installation
was installed on the hub. You can use a
spacer (slightly smaller in diameter that 1. Inspect the drive wheel studs for damage
the inside diameter of the tire insert and or looseness. Replace any damaged studs.
the same thickness as the depth of the Use the following procedure to tighten
recess) to obtain the correct amount of loose studs.
recession. a. Remove and clean the studs.
4. Position the hub assembly with the old tire b. Install two lug nuts, jammed together,
on top of the circular ram so the outside of to the end of the stud. This allows
the wheel is positioned upward. The tightening of the studs using a torque
outside edge of the hub has a chamfer to wrench.
help guide the new tire on the wheel. The
chamfered edge must always be the c. Apply thread accelerator/primer
leading edge when a tire is pressed on the (P/N 990-666) to the studs.
hub. d. Apply thread-locking compound
5. Center the hub assembly on top of the ram (P/N 990-571) to the studs.
and make sure they mate squarely. e. Install the studs and torque to 23 to
6. Position the new tire with its chamfered 28 ft. lbs. (32 to 38 Nm).
insert facing the hub. Align the new tire NOTE: Do not over-tighten the studs. If
and the hub so they are concentric. tightened to more than 30 ft. lbs.
7. Begin pressing the new tire on the hub (41 Nm), the studs start to cut new
and the old tire off the wheel. Run the threads and go in too far, hitting the lip
press slowly for the first few inches of seal. If the lip seal is damaged due to
travel because this is the critical step of studs being installed too far, the axle
the operation. If the tire starts to cock, must be replaced.
stop the press immediately and realign the
f. Remove the nuts on the studs. Make
tire. Use a soft-headed mallet to realign
sure the studs do not rotate.
the tire on the hub.
2. Install the wheel and tire assembly on the
NOTE: If the new tire does not press on with a
drive axle of the truck.
minimum pressure of 5 tons
(68,947 kPa), replace the hub. 3. Install the five drive wheel mounting nuts.
Torque the nuts in at least three steps,
8. Release the press. Remove the wheel, tire starting with a low torque [5 ft. lbs.
assembly, and the old tire from the press (7 Nm)]. Torque nuts in a star pattern to
table. Inspect the wheel and tire assembly. make sure that the lugs are centered in
the mounting holes. Torque to 55 ft. lbs.
(75 Nm) on the final pass.
4. Remove the blocks.
5. Install the bumper. See “Bumper
Installation” on page 7-9.
6. Reconnect the battery connector. Press the
green ON ( | ) key on the keypad.
7. Test the operation of the truck.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Drive and Brake Drive Unit

Drive Unit Figure 7-25. Terminal Block

6349-007.jpg

Drive Unit Removal

1. Lower the forks, press the red OFF ( O )
key on the keypad. Disconnect the battery
connector.
2. Remove the bumper. See “Bumper
Removal” on page 7-9.
Terminal Block
Connections

Use extreme care whenever the truck is 9. Remove the ten Allen head bolts that
jacked up. Keep hands and feet clear secure the drive unit and bearing
from the vehicle while jacking the truck. assembly to the frame.
After the truck is jacked, put solid blocks
beneath it to support it. DO NOT rely on
the jack alone to support the truck. For
details, see “Jacking Safety” on
The drive unit may fall free from its
page 2-9.
mounting after the bolts are removed.
3. Jack the truck and block the frame.
10. Remove the drive unit and steer bearing
4. Remove the drive wheel. See “Drive Wheel” assembly by lowering through the
on page 7-23. pivot-frame mount.
5. Remove the tractor cover. 11. Feed the control wiring harness and power
6. Remove the stem mount cover. Disconnect cables through the drive unit pivot mount.
the handle harness and arm angle
sensors. Drive Unit Disassembly
7. Remove the three Allen head cap screws
NOTE: The drive unit capacity is 0.4 qt. (0.4
that secure the control handle assembly to
liters). Make sure to have a correct size
the drive unit assembly. See Figure 7-24.
waste container for collecting the
Figure 7-24. Control Handle Assembly Removal removed gear case lubricant.
6349-015.jpg

1. After draining the gear case lubricant,

thoroughly clean the outside with solvent
Allen Head or other non-corrosive cleaning fluid. Air
Cap Screws dry all parts, and proceed with the
disassembly of drive unit.
2. Remove the nine hex head cap screws [3]
securing the gear case cover [2]. Remove
the gear case cover.
3. Remove the retaining ring [20] that
secures the top (pinion) gear [4].
4. Remove the top (pinion) gear [4] and
Woodruff key [21] attached to the traction
8. Disconnect the cables/wire from the
motor armature shaft.
terminal block on the drive unit. See
Figure 7-25. 5. Remove the traction motor if required. See
“Traction Motor” on page 7-57.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Drive Unit Drive and Brake

6. Remove the traction motor bearing,

bearing shim, and seal from the gear case
if required.
Make sure that the motor end cap is
7. Remove the 2nd stage gear set [5] from the installed before proceeding to the next
gear case. step.
NOTE: The 2nd stage axle [25] has an M8
tapped hole in the end. It can be 8. Install the pinion gear [4], woodruff key
removed with the gear [5] in place. [21], and the retaining ring [20] on the
armature shaft.
8. Remove the retaining ring [27] from the
9. Use gasket eliminator (P/N 990-411) on
drive axle [17] then remove the output gear
the mating surface and install the gear
[7].
case cover [2].
9. Press the drive axle [17] through the inner
10. Torque the cover bolts [3] to 15.8 ft. lb.
and outer gear case bearings [13].
(23 Nm).
10. Remove the old bearings [13], spacer [19],
and seal [16] from the gear case.
Thoroughly clean the case.

Drive Unit Assembly

1. Install the new bearings [12 and 18] in the
gear case [1] and cover [2] for the 2nd stage
gear set.
2. Install the new bearings [13], spacer [19],
and seal [16] in the gear case for the drive
axle.
3. Place the case in a fabricated assembly
base and carefully press the drive axle [17]
in the gear case [1].
4. Position the drive unit on the work bench
with the gear case side up. Install the
output gear [7] in the case and secure with
the retaining ring [27].
5. Install the 2nd stage gear set [5].
6. Install the traction motor bearing [14],
bearing shim [28], and seal [15] in the gear
case if removed previously.
NOTE: The seal must be installed correctly with
its open side and seal ring positioned
towards the bearing.
7. Carefully slide the traction motor [29]
armature shaft into the gear case if
removed previously. See “Traction Motor”
on page 7-57.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Drive and Brake Drive Unit

Figure 7-26. Drive Unit, Exploded View
2550-000.cgm

28 15 29
9 14

21
4

20
5
3 25

17

16
13
2 19
12

10 13 11
18

27 7

Table 7-1. Legend:

Item No. Description Item No. Description

1 Housing, Gear Case 16 Seal
2 Cover, Gear Case 17 Drive Axle
3 Screw 18 Bearing, Sealed
4 Pinion, Drive 1st Stage 19 Spacer, Bearing
nd
5 Gear Set, 2 Stage 20 Ring, Retaining
7 Gear Set, Output 21 Key, Woodruff
9 Bearing, Steering 22 Cap Screw, Allen Head
10 Plug, Fill/Level 23 Hub, Wheel (not shown)
11 Plug, Drain 25 Axle, 2nd Stage
12 Bearing, Sealed 26 Key, Output (not shown)
13 Bearing Set, Cup and Cone 27 Ring, Retaining
14 Bearing, Motor 28 Shim
15 Seal, Motor 29 Motor, Traction

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Section 7. Component Procedures Model 102XM Maintenance Manual

Drive Unit Drive and Brake

Drive Unit Installation capacity is 0.4 qt. (0.4 liters). Install the
fill/level plug.
12. Install the stem mount cover and tractor
cover.
Make sure the main ON/OFF switch is
13. Install the battery, reconnect the battery
OFF and the battery connector is
connector, and the turn the main ON/OFF
disconnected before you start.
switch ON. Press the green ON ( | ) key on
the keypad.
1. Install the steer bearing assembly if it was
removed previously. 14. Check the controls for correct operation.
2. Reinstall the drive unit assembly through
the pivot frame while feeding the harness
and cables through the pivot frame mount.
3. Secure the assembly with the ten Allen
head bolts removed previously.
4. Feed the wire harness and power cables
through the pivot tube.
5. Reconnect the cables/wire to the terminal
block on the drive unit.
Figure 7-27. Correct Wiring Harness Installation
6349-008.jpg

Harness
Guide Post

NOTE: Make sure the wiring harness is routed

between the bumper and the harness
guide post to prevent damage.
6. Install the drive wheel. See “Drive Wheel”
on page 7-23.
7. Unblock and lower the truck.
8. Install the bumper. See “Bumper
Installation” on page 7-9.
9. Install the control handle.
10. Reconnect the wiring harness.
11. Make sure the drive unit is filled to the
correct level with gear oil. The drive unit

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Model 102XM Maintenance Manual Section 7. Component Procedures

Drive and Brake Drive Unit

Drive Unit Housing Lubrication

Gear Oil Level Check

The drive unit capacity is 0.4 qt. (0.4 liters).

1. Remove the fill/level plug [10]. See
Figure 7-28.
Figure 7-28. Drive Unit Fill/Drain Plugs
1665 039.tif

Drain Plug
Fill/Level Plug

2. Check the oil level. When the truck is level,

the oil must be up to the bottom of the
fill/level plug [10] opening.
3. If necessary, add the specified oil through
the fill/level plug [10] opening, but do not
overfill.
4. Install the fill/level plug [10] securely.

Changing Gear Oil

1. Remove the drain plug [11] from the
bottom of the drive unit housing and
permit the oil to drain. See Figure 7-28.
2. After the oil has drained completely, flush
the housing with a suitable solvent and
allow it to drain.
3. Install the drain plug [11].
4. Fill the drive unit housing with the
specified gear oil through the fill/level plug
[10] opening. See “Lubrication Equivalency
Chart” on page A-2.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Drive Unit Drive and Brake

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Drive Unit

Electrical Components

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Section 7. Component Procedures Model 102XM Maintenance Manual

Battery Electrical Components

Battery Figure 7-29. Multiple Battery Wiring Hookup

1790_001.tif

The pallet truck may be equipped with a

multiple (swing-out) battery pack or a
maintenance-free battery and charger.

Before working on the battery, see

“Battery Safety” on page 2-6. Batteries
can weigh more than 500 pounds
(227 kg). Use extreme care during
replacement. Use a suitable battery
replacement device or hoist for lifting.

Swing-out Battery Pack

NOTE: For replacement parts information refer
to the Parts Manual.

Removal (single battery)

Installation (single battery)
1. After the truck is stopped and the handle
is returned to the full up position, press 1. Position the fully-charged and tested
the red OFF ( O ) key on the keypad. batteries in the battery pack.
2. Disconnect the battery connector found at 2. Reconnect the battery cables to the battery
the top of the tractor cover. Remove the terminals in accordance with the battery
battery cover. wiring hookup shown on the decal in the
3. Lift up on the top battery frame to get battery frame.
access to the lower two batteries. 3. Reconnect the battery connector, reinstall
4. As the frame is lifted, swing the battery the battery cover, press the green ON ( | )
toward the center of the forks. key on the keypad, and test the operation
of the pallet truck.
5. The cables may now be disconnected from
the battery terminals and the batteries
may be serviced or replaced if necessary. Removal (entire battery pack)
See Figure 7-29. 1. Press the red OFF ( O ) key on the keypad.
2. Disconnect the battery connector found at
the top of tractor cover.
3. Remove the bolt from the battery retainer
bracket.
4. Position the battery replacement device
above the battery and attach it to the
battery manufacturer’s designated lift
points.
5. Remove the battery with the lifting device.
6. Put the discharged battery on the charging
stand.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Battery

Installation (entire battery pack) Battery Maintenance

1. With a fully charged and tested battery on
the lifting device, position the lifting device Battery Exterior Cleaning
in accordance with the manufacturer’s
1. Read, understand, and follow procedures,
recommendations.
recommendations, and specifications in
2. Position the battery in the compartment. the battery and battery charger
Make sure the battery has no more than manufacturer’s manuals.
1/2 in. (13 mm) of “free play” movement in 25l6s014.tif

the battery compartment in any direction.

3. Remove the lifting device from the area.
4. Install the bolt through the battery
retainer bracket.
5. Reconnect the battery connector, turn the
key switch ON ( | ), and test the operation
of the truck.

Maintenance-Free Batteries 2. Wear personal protective equipment. See

“Battery Safety” on page 2-6.
NOTE: For replacement parts information refer
3. Turn the truck OFF ( O ) and disconnect
to the Parts Manual.
the battery connector. Remove the battery
from the lift truck.
The truck may be equipped with a
maintenance-free battery and charger pack. 4. Inspect the battery cables to make sure
The specific gravity need not be measured on a they are not frayed or loose. Inspect the
maintenance-free battery. Please follow battery connector to make sure there is no
manufacturer’s recommendations for service of foreign material inside the connector.
these batteries. 5. Make sure the filler plugs are tight and the
vent holes in the filler plugs are open. See
A maintenance-free battery still requires some Figure 7-30.
care. The battery must be kept clean and dry
Figure 7-30. Battery Filler Plugs and Vent Holes
and may be washed to remove any accumulated 09g6s047.tif

foreign matter. See “Battery Exterior Cleaning”

Cable
on page 7-33.
Vent Hole

Filler Plug

6. Keep the top of the battery clean and dry.

Corrosion, dust, and moisture provide a
conducting path to short-circuit cells or
create grounds.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Battery Electrical Components

Charging a Battery

Do not use soda solution to clean the top To charge a battery, direct current is passed
of the battery while it is installed in the through the battery cells in the direction
truck. Water can seep into the electrical opposite to that of discharge. Charging time is
compartments and cause serious 5% to 20% longer than discharge time.
damage.
The most important element in battery service
7. Tighten the battery filler plugs. and prolonging battery life is correct charging.
Make sure you follow the approved method for
8. Wash dirty batteries (or any that have had each application, following the battery and
electrolyte spilled on them) with a solution battery charger manufacturer’s instructions.
of 1 lb. (0.45 kg) of baking soda added to
1/2 gal (1.9 liters) of hot water.
9. Use a brush with flexible bristles to clean
the entire top of the battery with the soda The vent holes in the filler plugs must be
solution. Wait until all foaming stops, open to permit hydrogen gas to escape
indicating that the battery exterior is from the cells. When you charge the
neutralized. battery, make sure the polarity
connections are correct. The positive
10. Rinse the battery with clean water. lead of the charger must be connected to
11. Dry the battery completely before the positive terminal, and the negative
re-installing it. lead must be connected to the negative
12. Reinstall the battery in the truck, using a terminal.
suitable battery moving device. Reconnect
the battery connector. 1. Familiarize yourself with the following:

13. Apply a thin coat of petroleum jelly to the • Charging rate, starting rate, and finish
battery posts and cable terminals. rate
• Time available for charge
• Overheating, excessive gassing, or
overcharging
• Variations between cell voltage
2. Battery performance varies depending on
the type of application. If you use more
than one truck, one battery, and one
charger, keep the same batteries and
charger assigned to each truck. This
makes it easier to diagnose any battery or
charging problem.
3. Consult your battery and battery charger
manufacturer’s manual for specific
charging procedures.
4. Wear personal protective equipment. See
“Battery Safety” on page 2-6.
5. Press the red OFF ( O ) key on the keypad,
and disconnect the battery.
6. Inspect the battery.
7. Examine the electrolyte level in each cell.
Electrolyte must cover the top of the

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Battery

battery plates. If electrolyte level is below Adding Water to a Battery

the plates, add just enough water to cover
the plates. Do not fill to level yet. Water must be added to battery cells
Electrolyte level increases during charging. periodically. Frequency and quantity depend on
See “Adding Water to a Battery” on the water level above the plates and the amount
page 7-35. of gassing during charge.
8. Using a hydrometer, measure and record
the specific gravity of each cell. See Guidelines:
“Battery Specific Gravity” on page 7-35. • Wear personal protective equipment. Use
9. Measure and record the voltage of each only distilled water or water approved by
cell. the battery manufacturer. See “Battery
Safety” on page 2-6.
10. To get the maximum use out of each
battery, recharge only when effectively • Before charging, make sure battery plates
discharged. Routinely recharging batteries are covered with electrolyte. Add water, if
when only partially discharged decreases necessary, only to cover plates.
battery life. At maximum recommended • Electrolyte level increases during charging.
discharge, the specific gravity must read To prevent overflow, add water to fill port,
1.140 to 1.160 or less. if necessary, after charging, and after
11. Make sure that the filler plugs are clean hydrometer and voltmeter readings are
and the vent holes are open. Tighten all taken.
filler plugs. • Keep the outside of the battery case clean
and dry.

NEVER plug the battery charger into the Battery Specific Gravity
truck. This severely damages the truck’s
electrical system. Plug the charger ONLY Specific gravity readings for lead acid batteries
into the connector from the battery. with electrolyte temperatures at 80°F (27°C)
change with the state-of-charge as follows:
12. Charge the battery, following specific
instructions in your battery and battery Charge Specific Gravity
charger manufacturer’s manual. 100% 1.280 to 1.300
13. Using a hydrometer, measure the specific 75% 1.250 to 1.260
gravity of each cell. No amount of charging
increases battery capacity or increases 50% 1.200 to 1.210
specific gravity above its fully charged level 25% 1.150 to 1.160
(specific gravity 1.280 to 1.300).
0% 1.080
14. If, after charging, the electrolyte level is
below the fill port, add water to move it to Most industrial deep-cell discharge batteries
the fill level. Do not overfill the cells or are considered discharged when 20% of the
permit electrolyte to spill on the battery charge remains (specific gravity 1.140).
case. See “Adding Water to a Battery”.
NOTE: Maintenance-free batteries do not
In general, a lead-acid battery may be charged require specific gravity measurements.
at any rate in amperes that does not cause
excessive gassing or produce electrolyte
temperatures above 110°F (43°C).
Temperatures of 120°F (49°C) are permitted
only for short periods of time.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Battery Electrical Components

Specific Gravity Check Battery Storage

1. Wear personal protective equipment. See
“Battery Safety” on page 2-6. Before you store a battery, make sure the
electrolyte is at the correct level in all cells, the
2. Insert the nozzle of the hydrometer into
filler plugs are tight, and the battery is fully
the battery cell and draw enough
charged.
electrolyte into the tube to permit the float
to ride free.
Store the battery in a clean, cool, dry location
3. Leave the hydrometer nozzle in the battery away from radiators and other sources of heat.
and read the specific gravity of the cell. Refer to the storage instructions in your battery
4. If there is not enough electrolyte in the manufacturer’s manual.
battery to get a hydrometer reading then:
Measure the electrolyte level and the specific
a. Add just enough water to cover the
gravity every 30 days during storage. Whenever
battery plates.
the specific gravity is less than 1.230, charge
a. Charge the battery, then take readings. the battery.
5. Record the specific gravity reading on the
battery maintenance chart.

Battery Voltage Check

Perform a voltage check on each cell after

performing the specific gravity check.
1. Attach a voltmeter to the positive and
negative terminals of each cell. Voltage
readings change with the state-of-charge.
See “Battery Specific Gravity” on
page 7-35.

Charge Voltage Reading

100% 2.14
75% 2.07
50% 1.95
25% 1.80

2. Record the voltage reading for each cell on

the battery maintenance chart. There
must be a difference of less than 0.2V
between cells.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Power Cables

Power Cables Table 7-2. Cable Jacket Strip Length - Short barrel

AWG Lug P/N Strip Length

Check the power cables for damage:
1/0 1002215/001-004 11/16 in. (17 mm)
• Evidence of overheating
• Burned spots in the cable 2/0 1002215/005-008 13/16 in. (21 mm)
• Nicks in the insulation 3/0 1002215/009-012 1 in. (25 mm)
• Damaged or overheated terminal lugs 4/0 1002215/013-015 1-1/16 in. (27 mm)
• Damaged mounting hardware or brackets

Replace damaged cables or mounting hardware Table 7-3. Cable Jacket Strip Length - Long barrel
as necessary.
AWG Lug P/N Strip Length
Power cables are marked on the insulation near
1/0 1002217/001-003 1-9/16 in. (40 mm)
the terminal lug with the location where they
belong. If the marking is missing or is not 2/0 1002217/004-006 1-9/16 in. (40 mm)
readable, remark the cable with the correct
information. 3/0 1002217/007-009 1-9/16 in. (40 mm)

NOTE: Replace terminal lugs in the field using 4/0 1002217/010-011 1-11/16 in. (43 mm)
the appropriate crimping tools.
Crimping tool, lugs, and heat-shrink are
available through the Parts Distribution 5. Insert the cable into the terminal.
Center. Failure to use correct cables, 6. Place the cable and terminal into the tool
terminal hardware, and torque values die and crimp. Refer to Figure 7-31 and
can result in overheating and damage to Figure 7-32 for what completed crimps
components. should look like.

Figure 7-31. Short Barrel Terminal

Power Cable Repair FIG1_LUGS.jpg

Traditional lug crimping techniques for power

cables on DC motors may not meet the higher
current requirements of AC motors. Use
Manual Crimp Tool (P/N 1069861) when
crimping power cables for all AC motors. This
tool may also be used to repair power cables for
DC motors, yielding enhanced repair.
1. Remove the failed cable(s) from the truck.
2. Using the removed cable(s) for reference,
cut an appropriate amount of replacement
cable of the same gauge.
3. Set the adjustment screw on the manual
crimp tool head to match the cable gauge.
4. Referring to Table 7-2 and Table 7-3, strip
the cable jacket to fit the terminal to be
crimped.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Power Cables Electrical Components

Figure 7-32. Long Barrel Terminals
FIG2_LUGS.jpg

7. Apply heat-shrink tubing (P/N 611-035) to

the terminal after crimping.
a. For short barrels, use 1.75 in. (45 mm)
of tubing. Apply 1 in. (25 mm) over the
jacket extending 0.75 in. (19 mm) over
the terminal barrel.
a. For long barrels, use 2.5 in. (64 mm) of
tubing. Apply 1 in. (25 mm) over the
jacket extending 1.5 in. (38 mm) over
the terminal barrel.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Wiring Harness

Wiring Harness To find electrical connectors on the truck, refer

to the Electrical Schematics.

Wiring Harness Inspection

Use correct electrostatic discharge
Make sure the truck is OFF and the battery
precautions. See “Static Safety” on
connector disconnected before working on
page 2-11.
harnesses. Whenever working on the truck, use
care around wiring harnesses.
NOTE: For replacement parts information refer
to the Parts Manual. • Do not pull on wires.
• Carefully connect and disconnect all
The wiring harness is designed to connect the connectors.
electrical components of the pallet truck.
• Do not pry apart connectors with
Figure 7-33. Wiring Harness unspecified tools.
6349-008.jpg

• Examine and maintain any added

materials used to dress or protect the wire.
This includes spiral wrap, brackets, cable
ties, fasteners, flexible conduit, and so
forth.
• Check harness wires for abrasions,
scrapes, nicks in the wire, damage from
overheating or burns, or other general
insulation damage.
• Replace terminations with exposed wire
visible at the connectors. Damaged
terminations, exposed wires, or damaged
connectors can cause operational failure of
All wires in the harness are marked with a wire the truck.
identification number. These numbers
correspond to wire identification given in the During troubleshooting and repairs, it is
Electrical Schematics. sometimes necessary to unmate a connector,
move a harness, cut a cable tie, or remove the
wire from a bracket. Note carefully the location
Wiring Harness Terminology of the wire and all protective or securing
attachments before moving the harness.
The term “connector JPx” means a mated
connector consisting of two connector halves. After repair, return or replace all protective
One half contains male connectors, or pins (P); and/or securing hardware to its original
the other half contains female connectors, or condition. Protective materials are necessary to
jacks (J). provide reliable performance of the interconnect
system.
When you disconnect a mated JP connector,
you have two connector halves. The individual In addition to the wire identification number
connector halves are designated by “Jx” and printed every 1 to 1.5 in. (25.4 to 38.1 mm) on
“Px.” the wire, there is a wire marker at each
termination. If the marker is missing or
For example, connector JP2 is the mated unreadable, remark the wire to permit easier
connector in the control handle. J2 represents identification.
the jack connections. P2 represents the pin
connections.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Wiring Harness Electrical Components

NOTE: It is normal to find unused connectors Wiring Harness Soldering

for uninstalled options that have had
heat shrink applied over them and have
Procedures
been strapped to the harness.
To prevent damage from excessive heat when
soldering small components in assemblies,
Wiring Harness Repair follow these guidelines:
• Make sure the soldering tip is clean. A
Make sure the truck is OFF and the battery dirty tip does not transfer heat well and
connector disconnected before working on encourages long dwell time and greater
harnesses. When pulling a wire out through a pressure. Apply light pressure on the
bundle, cut off the pin or socket so it does not terminal.
snag. When replacing wires, in some cases you
can tape or solder one end of a new wire to one • Flux: rosin base
end of the failed wire. Then you can pull the old • Solder: 60/40 rosin core or equivalent
wire out of the bundle and pull the new wire • Solder Iron: 15-20 watt “pencil-type”
into the bundle, all at the same time. Make sure maximum
to disconnect the old wire from the new wire.
• Tip Size: 3 mm (0.118 in.) diameter x
In other cases, it is easier to secure a new wire 30 mm (1.182 in.) long screwdriver tip.
to the outside of the existing wire bundle with Make sure the tip is clean.
cable ties of an appropriate size. The failed wire • After soldering, clean the terminals with a
can be left in the bundle, or can be pulled by brush dampened with an alcohol-based
one end to remove it from the bundle. cleaner (P/N 990-600/FOF). Do not allow
any cleaner to seep into the switches or
When replacing wires, follow these guidelines: potentiometers, or contact contamination
• Use the appropriate tools to remove and may occur.
insert terminations at each connector.
• Remove damaged terminations and
discard. Never reuse a termination from a
wire.
• Do not cut away a terminal lug and reuse
the wire strands that were crimped into
the original lug.
• When stripping wire, use new wire strands
for new terminations. Make sure to use a
new wire with extra length to allow for
cutting and stripping of the ends to install
new terminations.
• Use a new wire that is the same gauge
(typically gauge 18 AWG), size, type, and
color as the wire it is replacing.
• Use a hand stripper capable of stripping
by wire gauge number. Use care not to
nick or cut any of the wire strands.
Discard and replace a wire with damaged
strands. Insert the correct length wire
strands into the termination before
crimping.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Fuses

Fuses
NOTE: For replacement parts information refer
to the Parts Manual.

Under extreme operating conditions, fuses (F50

and F51) protect the electrical circuits and
components from excessive current or voltage
overloads. See Figure 7-34.
Figure 7-34. Fuse/Circuit Breaker Location
6349-012.jpg

Fuse F50 Fuse F51

Fuse Test/Inspection
Examine each fuse for signs of overheating,
discoloration, cracking, or other physical
damage. Replace the fuse if you find damage.

To test a fuse, remove it or isolate it from the

electrical circuit. Do this by removing the fuse
from the truck or by removing all the
connections from one side of the fuse.

Use an ohmmeter set to Rx1 scale and measure

the resistance across the fuse. The resistance
must be less than 1 ohm.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Circuit Breaker Electrical Components

Circuit Breaker
NOTE: For replacement parts information refer
to the Parts Manual.

Under extreme operating conditions the current

demand on the battery may exceed the rating
for the main circuit breaker (M1) and force it
open. This causes the truck to become
inoperable until the circuit breaker
automatically resets itself.

Circuit Breaker Test/Inspection

Examine the circuit breaker for signs of
overheating, discoloration, or other physical
damage. Replace the circuit breaker if you find
damage. See Figure 7-35.
Figure 7-35. Circuit Breaker Location
6349-013.jpg

Circuit Breaker
CB1

To test a circuit breaker, remove the circuit

breaker from the truck or isolate it from the
electrical circuit by removing all the
connections from one side. Let it cool (or reset
itself).

Use an ohmmeter set to Rx1 scale and measure

the resistance across the circuit breaker. The
resistance must be less than 1 ohm.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Horn

Horn Horn Installation

1. Attach the horn to the electrical panel and
NOTE: For replacement parts information refer tighten the mounting bolt.
to the Parts Manual.
2. Attach the two wires.
3. Reconnect the battery connector, press the
Horn Removal green ON ( | ) key on the keypad, and test
1. Press the red OFF ( O ) key on the keypad. operation.
Disconnect the battery connector. 4. Press the red OFF ( O ) key on the keypad.
2. Remove the tractor cover. Disconnect the battery connector.
3. Disconnect the two wires from the horn. 5. Install the tractor cover.
See Figure 7-36. 6. Reconnect the battery connector.
Figure 7-36. Horn Location
6349-009.jpg

Horn

4. Remove the horn mounting bolt.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Traction Power Amplifier Electrical Components

Traction Power Amplifier Traction Power Amplifier

Removal
NOTE: For replacement parts information refer
1. Press the red OFF ( O ) key on the keypad
to the Parts Manual.
and disconnect the battery connector.
The traction power amplifier is installed in the 2. Remove the tractor cover.
tractor compartment. See Figure 7-37. 3. Discharge the capacitors in the traction
Figure 7-37. Traction Power Amplifier Location power amplifier by connecting a load (such
6349-009.jpg as a contactor coil or a horn) across the
amplifier’s B+ and B– terminals.
4. Push the locking tab and disconnect the
J5 connector from the traction power
amplifier. See Figure 7-37.
5. Disconnect the three power cables
Traction
(terminals B+, B– and M–) on the traction
Power power amplifier. Do not stress the power
Amplifier cable connections. Disconnect wiring
J5 Connector harness connectors (terminals F1 and F2).
6. Remove the three hex head cap screws
securing the traction power amplifier to
the electrical panel. Remove the traction
power amplifier.

Do not open the traction power Traction Power Amplifier

amplifier. Opening the traction power Installation
amplifier could cause damage it and
voids the warranty. NOTE: All traction power amplifiers are preset
to factory default specifications.

Cleaning the Traction Power 1. Secure the traction power amplifier to the
electrical panel with the three previously
Amplifier removed hex head cap screws.
1. Press the red OFF ( O ) key on the keypad 2. Connect the three power cables (terminals
and disconnect the battery connector. B+, B– and M–) on the traction power
2. Remove the tractor cover. amplifier. Torque screws to 12 ft. lb.
(16.3 Nm) maximum. Do not stress the
3. Discharge the capacitors in the traction
cable connections and put strain on
power amplifier by connecting a load (such
internal components.
as a contactor coil) across the amplifier’s
B+ and B– terminals. 3. Connect the J5 connector and wiring
harness connectors (terminals F1 and F2)
4. Clean the traction power amplifier with a
to the traction power amplifier.
moist rag. Let it dry before connecting the
battery. 4. Connect the battery connector and press
the green ON ( | ) key on the keypad.
5. Make sure the power cable connections
are tight. Do not stress the cable 5. Test the operation of the truck.
connections or put strain on internal 6. Press the red OFF ( O ) key on the keypad.
components.
7. Install the tractor cover.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Contactors

Contactors Main Contactor Installation

1. Secure the contactor to the electrical panel
NOTE: For replacement parts information refer with the two screws removed earlier.
to the Parts Manual.
2. Secure the bus bar and cable to the
contactor with the nuts.
Contactors (K10 and K30) control the
transmission of battery power to the drive and 3. Connect the wires to the X and Y
lift motors. terminals.
4. Install the tractor cover.
Main Contactor 5. Connect the battery connector. Press the
green ON ( | ) key on the keypad.
Main Contactor Removal 6. Test the operation of the truck.
1. Press the red OFF ( O ) key on the keypad.
Disconnect the battery connector. Main Contactor, Sealed
2. Remove the tractor cover.
A sealed main contactor is available for trucks
3. Disconnect the wires from the X and Y used in cold storage or corrosive applications.
terminals on the contactor coils. See All trucks ordered after July 6, 2009 with the
Figure 7-38. following options include the sealed main
Figure 7-38. Main Contactor K10 contactor: Cold Storage Conditioning, Corrosion
6349-013.jpg
Protection Package, or Extreme Environment
Corrosion Package. A kit is available from the
Parts Distribution Center for earlier trucks.
X and Y
Terminals
Sealed Main Contactor Removal
1. Press the red OFF ( O ) key on the keypad.
Disconnect the battery connector.
2. Remove the tractor cover.
Bus Bar 3. Disconnect the wires from the X and Y
terminals on the contactor coils. See
Figure 7-38.
4. Remove the nuts securing the bus bar and
cables to the contactor. Note the location
for assembly later. See Figure 7-38.
4. Remove the nuts securing the bus bar and 5. Remove the two screws holding the
cables to the contactor. Note the location contactor assembly to the electrical panel.
for assembly later. See Figure 7-38.
5. Remove the two screws holding the
contactor assembly to the electrical panel.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Contactors Electrical Components

Sealed Main Contactor Installation Lift Motor Solenoid

1. Reuse the main contactor mounting Figure 7-40. Lift Motor Solenoid K30
screws [5] and mounting holes in the 6349-028.jpg

control panel and mount the new bracket

[6]. See Figure 7-39. Lift Motor
Figure 7-39. Sealed Main Contactor Solenoid
6349-013.jpg
(start
4 5 switch)
6

2
1

See “Lift Motor” on page 7-59.

8 7 3

2. Attach the 2 male terminals [3] to the coil

terminals on the sealed contactor.
3. Using the screws [4] provided with the kit,
mount the sealed contactor [7] to the
bracket [6].
4. Attach the B+ power cable to the
contactor.
5. Install the new cable [8] supplied with the
kit.
6. Attach wire #24 to the positive terminal
and wire #64 to the negative terminal of
the contactor coil.
7. Connect the battery connector. Press the
green ON ( | ) key on the keypad.
8. Test the truck for correct operation.
9. Press the red OFF ( O ) key on the keypad.
Disconnect the battery connector.
10. Install the upper tractor cover.
11. Connect the battery connector. Press the
green ON ( | ) key on the keypad.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Master Control Relay

Master Control Relay

The master control relay (K4) should be
regularly tested for correct operation.

Master Control Relay

Inspection/Test
1. Remove the tractor cover.
2. With the battery connected, press the
green ON ( | ) key on the keypad.
3. Use a voltmeter to check the voltage
between wire #26 (terminal 4) and wire
#24 (terminal 2).
Figure 7-41. Master Control Relay
6349-012.jpg,309984-000.cgm

Wire #26 Wire #24

The voltmeter should read approximately

24V.
4. Move the control handle down into the
operating position. The voltmeter should
now read 0V. If not, replace the master
control relay.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Switches (General) Electrical Components

Switches (General) Main ON/OFF Switch Inspection

1. With the battery plugged in and the Main
NOTE: For replacement parts information refer ON/OFF switch in the ON position, battery
to the Parts Manual. voltage B+ must be present on the two
terminals of the switch.
Refer to the Electrical Schematics to identify the
2. Test the Main ON/OFF switch with an
electrical circuit location of the switch.
ohmmeter after disconnecting the battery
and removing the wires from the switch
Testing/Inspecting Switches terminals.

Examine the switch for signs of arcing, In the OFF position, the ohmmeter must read
overheating, discoloration, cracking, or other greater than 1 megohm, and in the ON position,
physical damage. Replace the switch if you see the ohmmeter must read less than 1 ohm. If
such damage. not, replace the switch.
1. To test a switch, isolate it from the
electrical circuit. Do this by removing all Main ON/OFF Switch Removal
the connections from the switch, making
sure all wires are labeled and identified for 1. Disconnect the battery connector.
later reconnection. 2. Remove the tractor cover.
2. Use an ohmmeter set to a low resistance 3. Disconnect the wires from the switch.
scale to measure the resistance across the 4. Remove the Main ON/OFF switch.
switch. In the closed position, the switch
must have a resistance of less than 1 ohm.
In an open position, the switch must show
Main ON/OFF Switch Installation
a resistance greater than 10 megohms. 1. Install the new Main ON/OFF switch.
2. Connect the wires to the new Main
Main ON/OFF Switch ON/OFF switch terminals.
3. Reconnect the battery connector and verify
A Main ON/OFF switch (S21) is provided on operation.
earlier versions of trucks. Later versions have a
dual rocker switch instead of a keypad as 4. Install the tractor cover.
standard equipment. In the OFF ( O ) position,
battery power to all control functions is
interrupted. In the ON ( | ) position, battery
potential is provided to all control functions via
the traction power amplifier. See Figure 7-42.
Figure 7-42. Main ON/OFF Switch Location
6349_023.jpg

Main ON/OFF
Switch

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Switches (General)

Arm Angle Switches 1. Press the red OFF ( O ) key on the keypad.
Disconnect the battery connector.
S24 and S25 determine brake activation and
truck travel speed. Each switch is activated by
the control handle position. The control handle
must be in T1 or T2 position in order for the B Use extreme care when the truck is
switch (S25) to be closed, permitting travel. jacked up. Keep hands and feet clear
See Figure 7-43. from the vehicle while jacking the truck.
Figure 7-43. Brake Actuation After the truck is jacked, DO NOT rely on
10733_102xmHandle_brakes.eps
the jack alone to support the truck. For
details, see “Jacking Safety” on
page 2-9.

2. Jack the truck and block the frame.

3. Remove the tiller arm stem mount cover.
4. Loosen the two screws holding the switch
on the tiller arm stem mount. Slide the
switches out as far as possible. See
Figure 7-45.
Figure 7-45. Switch Mounting Screws
Arm_Angle_Switch_Screws.JPG

Screws
Arm Angle Switches Adjustment
NOTE: We recommend that you do not adjust
the switches except for those on trucks
with the old (non-machined) tillers. If
there is suspicion that the switches
need adjustment, we recommend that
you replace the switch bridge with the
new plastic part that holds the switches
in the correct position without
adjustment.

The arm angle switches are found at the base of

the tiller arm stem.
Figure 7-44. Arm Angle Switch Locations
6349-015.jpg 5. Make sure that the base of the tiller arm
makes solid contact with the switch lever.
Arm Angle Arm Angle
Switch S24 Switch S25 6. Make sure that continuity changes at the
A Switch (S24) near the middle of tiller
arm movement.
7. The B Switch (S25) must operate within 6°
of the full up or down position. Make sure
the switch does not bottom out when fully
compressed.
8. Install the tiller arm stem mount cover.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Switches (General) Electrical Components

9. Remove the blocks. Reconnect the battery Arm Angle Switches (Plastic Switch
connector. Press the green ON ( | ) key on Bridge)
the keypad.
10. Test the operation of the truck. A plastic switch bridge was introduced. The
plastic switch bridge can be used to service
Arm Angle Switches Removal handles originally built with the metal switch
bridge as long as the tiller arm is machined
1. Lower the forks completely. above the right cam. See Figure 7-46. Handles
2. Press the red OFF ( O ) key on the keypad. without the machining must be serviced with a
Disconnect the battery connector. different switch bridge or replaced.
3. Remove the tiller arm stem mount cover. Figure 7-46. Tiller Arm Machining Identification

4. Disconnect the wires on the switch. Old

Style
5. Remove the mounting bracket from the New
tiller arm stem mount. Style
6. Remove the screws holding the switch on
the mounting bracket.
7. Remove the switch.

Arm Angle Switches Installation

1. Mount the switch to the mounting bracket.
2. Connect the wires to the switch.
Look for machining
3. Install the mounting bracket. in this area.
4. Reconnect the battery connector. Press the
green ON ( | ) key on the keypad. Differences are:
5. Test drive the truck. • The new plastic bridge mounts to the
6. Adjust the switch if necessary. handle stem base with a single screw. The
bridge has a formed post that fits in the
7. Press the red OFF ( O ) key on the keypad.
unused screw hole.
Disconnect the battery connector.
Figure 7-47. Plastic Switch Bridge Mounting
8. Install the tiller arm stem mount cover.
9. Reconnect the battery connector. Switch Bridge
Mounting Screw

P-Clamp
Mounting
Screw

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Switches (General)

• The switches mount to the bridge with a 4. Bend the two lower terminals (the center
single screw in the lower switch hole. See terminal and the one under the actuating
Figure 7-48. The upper switch hole is arm pivot, not the one under the roller) of
mounted on a molded post on the switch switch up (towards the third terminal)
bridge. The switch rollers face upward on about 20 to 30º. See Figure 7-48. The
the new switch bridge. diagonal orientation of the terminals
Figure 7-48. Correct Switch Mounting causes them to bend to the side to some
extent; do not try to force the terminals to
remain centered. The top (unused)
terminal may be bent if it is in the way. Do
not bend the lower terminals more than
necessary to fit in the stem head.
5. Place the switch onto the bracket, with the
mounting hole (under the roller) on the
molded bracket post. Secure the switch to
the bracket using a blunt end self-tapping
screw. Tighten just enough to prevent
• The P-Clamp holding the harness must wiggle in the switch as this screw is going
face inward (toward the center of the into plastic.
handle). 6. Remove the existing switch bridge
Figure 7-49. Correct P-Clamp Orientation assembly; do not disconnect the wires.
7. Remove the P-clamp. Reorient the tiller
harness to the inboard side of the bolt to
clear the switch. See Figure 7-49. Reinstall
the P-clamp holding the tiller harness.
NOTE: Make sure tiller harness is routed under
the pivot pin and between the flange on
the spring drum and the plastic washer.
8. Orient the bridge assembly as it will go in
the truck: rollers up and facing the tiller.
Remove the wires from the existing switch
bridge assembly and install on the new
switches: the wires must remain on the
same sides of the truck. Quick connects
from the old middle terminals go on the
new middle terminals and those from the
old upper terminals go on the new lower
terminals (closest to the switch lever
pivot).
Switch Bridge Replacement
9. Position the bridge assembly on the stem
head. Insert the projecting post into one of
Use the following procedure to replace an
the tapped holes in the stem head. Make
existing switch bridge with the new plastic
sure it is seated, or the bridge will break.
switch bridge.
Apply thread-locking compound
1. Lower the forks completely. (P/N 990-536) to the button head screw.
2. Press the red OFF ( O ) key on the keypad. Install the screw through the bridge into
Disconnect the battery connector. the other tapped hole in the stem head.
Torque to 15 in. lbs. (1.7 Nm). Use care not
3. Remove the stem mount cover.
to over-tighten or you may damage the
bridge.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Switches (General) Electrical Components

10. If operating in freezers or applications that 14. Press the red OFF ( O ) key on the keypad.
are subject to sticky substances: Disconnect the battery connector.
a. Apply Dow Corning Electrical 15. Install the stem mount cover.
Compound (P/N 302249-000) around 16. Reconnect the battery connector.
the switch arm as shown in
Figure 7-50.
Figure 7-50.

b. For further protection, apply Electrical

Compound to the surface that the
switch arm roller rides on.
c. For terminal protection, apply a
generous coating Electrical Compound,
enough so some squeezes out when the
harness is connected to the switch
terminals, before installing the harness
connectors. Make sure the connectors
are well seated, as this material is an
insulator rather than a conductor.

Do not use the Dow Corning Electrical

Compound in dusty environments. The
compound may retain powder
contamination and interfere with switch
actuation.

11. Reconnect the battery connector. Press the

green ON ( | ) key on the keypad.
12. Test the truck to make sure that the top
brake, bottom brake, and the speed
transition between are functioning
correctly.
13. Adjust the switch if necessary.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Switches (General)

Lift-Limit Switch Figure 7-52.

For standard conditioning,

When the forks are fully raised, the lift-limit
use outside mounting holes
switch (S36) turns the hydraulic pump motor
OFF. This keeps the pump from trying to extend For cold storage, use inside Lift-Limit
the lift cylinder beyond its maximum travel. See mounting holes Actuating
Figure 7-51. Bracket
Figure 7-51. Lift-Limit Switch
6349-022.jpg
Adapter
Block

Lift-Limit Switch
Once the
switch is
mounted,
this small
hole can be Mount the switch and
seen the adapter block on
directly the right side of the
above the bracket, away from
switch the drive unit.

Lift-Limit Switch Adjustment

Key Switch
1. Raise the forks until they reach their fully
raised position. If the lift-limit switch does A two-position (ON/OFF) rotary key switch
not shut the pump down when the lift (S17), located on the main console, energizes all
cylinder reaches its upper limit, the relief truck control functions when in the ON
valve on the hydraulic pump makes a position, provided the Main ON/OFF switch is
high-pitched squeal, indicating that the in the ON position.
relief valve is opening.
NOTE: Newer version trucks are equipped with
2. Press the red OFF ( O ) key on the keypad. a dual ON/OFF rocker switch as
Disconnect the battery connector. standard. Rotary key switches are
3. Remove the upper cover to access the available as an option.
lift-limit switch.
4. Loosen the bolt and slide the switch up or Key Switch Inspection
down in the bracket to activate (cut power
off) when the lift is 1/2 to 1 in. (12.7 to 1. Remove the tractor cover.
25.4 mm) before the fully raised position. 2. With the battery plugged in and the key
5. Tighten the bolt. switch ON, battery voltage B+ must be
present on the two terminals of the switch.
6. Reconnect the battery connector. Press the
green ON ( | ) key on the keypad. Lower 3. Turn the key switch to OFF, disconnect
the forks and then lift them until they the battery and remove the wires from the
reach their fully raised position. The switch terminals.
lift-limit switch must cut power off to the 4. Test the key switch for continuity with an
pump when the lift cylinder reaches 1/2 to ohmmeter.
1 in. (12.7 to 25.4 mm) before its fully
raised position. In the OFF position, the ohmmeter must read
greater than 1 megohm, and in the ON position,
the ohmmeter must read less than 1 ohm. If
not, replace the switch.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Motors, General Electrical Components

Motors, General 3. Clean brushes and holders. Wipe the

commutator with a dry, lint-free cloth. DO
NOT USE lubricants of any kind on or
NOTE: For replacement parts information refer around the commutator.
to the Parts Manual.
4. Check brush holders for solid connection
to the mounting support. Tighten the
Motor Brush Inspection mounting screws as necessary.
Figure 7-53. Traction Motor Brush, Typical Location 5. Check the cap screws holding the brush
MTRBRUSH.tif
cross connectors to the brush holder body.
6. Make sure the motor terminals are
secured tightly to the motor frame. Be
careful not to strip the threads or crush
the insulating parts.
7. Check all the cap screws around the frame
for tightness.
8. Keep the outside frame of the motor clean
and free from dirt. Maintain a free air
passage around the motor to permit heat
radiation.

Motor Brush Replacement

Conduct a partial inspection of the traction If one brush needs replacement, always replace
motor after every 1,000 hours of truck the entire set of brushes.
operation. If you work in an abnormally severe
or caustic environment or if you have a rigorous Use only genuine Raymond brushes. Using
duty cycle, inspect the motor more frequently. another type of brush could damage the
commutator or cause excessive brush wear.
Set up and rigidly adhere to a strict inspection
schedule to obtain the maximum efficiency If the end of the brush is not already contoured
from the electrical equipment. to fit the commutator, use the following
procedure to seat the brush to the commutator.
Each partial inspection of the motor must
include the following: NOTE: If the motor commutator is not
accessible, form the brush contour
1. Inspect the brushes for wear and for using a brush seating stone.
correct contact with the commutator.
Record the level of wear on the brushes. 1. Move the motor brush springs out of your
This history gives you an indication of way.
whether a brush must be changed or if it 2. Wrap a piece of 00 sandpaper around the
can wait until the next inspection. Refer to commutator. DO NOT use emery cloth to
page 7-55 for acceptable brush length and seat brushes.
general motor information.
3. Move the brushes back down in their
NOTE: Overloading a unit is ultimately reflected holders so that the face of the brushes
in the motor and brush wear; therefore, matches the curve of the commutator.
you must take this into account when 4. Remove the sandpaper.
considering brush replacement.
5. Blow any dust out of the motor with clean,
2. Check brush spring tension. See “Motor compressed air at a maximum of 30 psi
Brush Spring Tension” on page 7-55. (207 kPa).

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Motors, General

Motor Brush Spring Tension 9. Refer to the table below for correct spring
tension.
Brush Spring Tension Inspection
Minimum Spring
1. Press the red OFF ( O ) key on the keypad. Motor
Brush Length Tension
Disconnect the battery connector.
Traction 0.59 in. 20 oz. min.
2. Remove the traction motor cover. Motor (15 mm) (568 grams)
3. Slide the brush up slightly in its holder. Lift Motor 0.35 in. 32 to 40 oz.
4. Insert a paper strip between the brush (9 mm). (908.8 to
face and the commutator. See Figure 7-54. 1136 grams)
Figure 7-54. Motor Brush Spring Tension Inspection
8B16032S.eps 10. Repeat steps 3 through 9 for the
remaining brushes.

Leather
Coil Loop
Spring

Paper

5. Place a small leather loop around the coil

spring for the brush. If the brush spring
has a loop at the brush, hook the spring
scale directly to the spring.
6. Attach a 5 lb. (2.27 kg) spring scale to the
leather loop.
7. While gently pulling the scale outward,
slowly pull the paper strip in the direction
that the commutator normally rotates.
8. When the paper strip starts to move freely,
the spring scale reads the spring brush
tension.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Motors, General Electrical Components

Terminal Nuts Check these torques each time you check the
motors and the traction power amplifier. Use
two wrenches to avoid twisting the terminal
stud. See Figure 7-55.
Do not attempt to repair power cable
terminal lugs without approved tools. If Stud Motor Cable Stud Terminal
a power cable has worn or damaged Size Securing Nut Securing Nut
lugs, either replace the cable or replace 3/8 in. 100 to 120 in. lb. 140 to 160 in. lb.
the lugs using the procedure described (M10) (11.2 to 13.6 Nm) (15.8 to 18.1 Nm)
in “Power Cable Repair” on page 7-37.
5/16 in. 90 to 110 in. lb. 110 to 140 in. lb.
Do not substitute other kinds of nuts for (M8) (10.2 to 12.4 Nm) (12.4 to 15.8 Nm)
the flanged nuts. Failure to use correct
cables, flanged nuts, and torque values 1/4 in. 40 to 50 in. lb. 50 to 60 in. lb.
can result in overheating and damage to (M6) (4.5 to 5.6 Nm) (5.6 to 6.8 Nm)
components.

Figure 7-55. Motor Terminal Nuts

CABLENUT.tif

Terminal
Stud

Motor
Cable Flat
Securing Washer
Nut
Fiber
Washer
Stud
Terminal Motor
Securing Housing
Nut

Whenever you disconnect and reconnect any

power cables to the motors or traction power
amplifier, always tighten the cable securing
nuts with a torque wrench to prevent
over-tightening them and damaging the motor
or traction power amplifier.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Traction Motor

Traction Motor bolts that secure the assembly to the

motor end bell cover.
NOTE: For replacement parts information refer 6. Remove the brake disc from the brake
to the Parts Manual. hub.
7. Remove the retaining ring that secures the
Brush Replacement brake hub. Remove the hub and woodruff
key.
1. Press the red OFF ( O ) key on the keypad. 8. Remove the four screws and lock washers
Disconnect the battery connector. holding the brush end bell to the housing.
2. Remove the tractor covers. 9. Separate the end bell from the motor
3. Remove any shields around the motor end housing. The armature comes out with the
cover to expose the brushes. See end bell.
Figure 7-56. 10. To remove the end bell from the armature,
Figure 7-56. Traction Motor Brush Shield remove the snap ring that holds the
6349-025.jpg
bearing in the end bell. If needed, press off
the bearing and replace.

Brush
Shield Traction Motor Installation
1. Thoroughly clean all parts with solvent or
other non-corrosive cleaning fluid. Air dry
all parts.
NOTE: Assemble the traction motor in a
dirt-free area.
2. If previously removed, install the traction
motor bearing, bearing shim, and seal in
4. Lift the spring off the brush, pull the the gear case.
brush out of the holder.
NOTE: The seal must be replaced any time the
5. Follow the brush replacement
motor is removed from the housing.
instructions. See “Motor Brush
Replacement” on page 7-54. The seal must be installed correctly with
6. Replace the shields around the motor end its open side and seal ring positioned
that were removed in step 3. towards the bearing.
3. Reinstall the end bell cover, with the brush
Motor Disassembly plate attached, on the motor armature
shaft.
1. Press the red OFF ( O ) key on the keypad. 4. Carefully slide the traction motor
Disconnect the battery connector. armature in the motor housing.
2. Remove the tractor covers. 5. Attach the end bell cover to the motor
3. Disconnect the power cables from the housing with the four cap screws.
terminal block on the traction motor, 6. Install the pinion gear, woodruff key, and
noting their correct position. the retaining ring on the armature shaft.
4. Follow steps 1 through 5 in “Drive Unit 7. Use gasket eliminator (P/N 990-411) on
Disassembly” on page 7-25 to remove the the mating surface and install the gear
top (pinion) gear attached to the motor case cover.
armature shaft.
8. Make sure the drive unit is filled to the
5. Remove the electromagnetic brake correct level with gear oil. Install the
assembly by removing the three mounting

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Section 7. Component Procedures Model 102XM Maintenance Manual

Traction Motor Electrical Components

fill/level plug. See “Drive Unit Housing

Lubrication” on page 7-29.
9. Install the brake hub and woodruff key
then secure with the retaining ring.
10. Install the brake disc on the hub.
11. Install the brake coil assembly and attach
with three hex head cap screws.
12. Reattach the power cables and
electromagnetic brake wiring connections
to the terminal block.
13. Before testing operation, move the handle
from extreme left to right and down into
the operating position and back several
times. Check for any wire and cable
interference. Repair or adjust as
necessary.
NOTE: Check the traction motor cable routing.
Make sure the wires are not near the
drive tire. Secure wires with cable ties to
prevent damage.
14. Install the battery, reconnect the battery
connector, and the turn the main ON/OFF
switch ON. Enter your PIN-key code then
press the green ON ( | ) key on the keypad.
15. Test the operation of the truck.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Electrical Components Lift Motor

Lift Motor Lift Motor Brush Replacement

1. Remove the lift motor from the hydraulic
assembly before inspecting the brushes.
Lift Motor Removal
2. Remove the two screws from the motor end
1. Press the red OFF ( O ) key on the keypad. cover. Remove the end cover to access the
Disconnect the battery connector. brushes.
2. Remove the tractor covers. 3. Push each brush back into the holder to
3. Remove the hydraulic unit from the truck. disengage the springs. Remove the nuts
See “Hydraulic Unit” on page 7-64. and washers from the side of the drive end
head. Remove the brush assembly, then
4. Remove the two bolts from the end plate
remove each brush and replace with a new
that attach the motor to the adapter body.
one.
5. Separate the motor and the adapter body.
6. Remove the start solenoid from the side of
the motor housing for later reuse.

Lift Motor Installation

1. Stand the pump assembly on end, with
the adapter body facing up.
2. Set aside the pump drive coupling for later
reuse.
NOTE: The coupling is the mechanical
connection between the pump shaft and
the electric motor armature shaft. It
may have been removed with the motor.
3. Insert the pump drive coupling on the end
of the pump shaft. Fill the coupling cavity
with lubricant (P/N 990-638).
4. Rotate the pump or the motor shaft to
align the motor shaft correctly with the
coupling.
5. Install the new motor on the adapter body.
Rotate the pump or the motor shaft if
necessary to allow the motor to contact the
adapter body.
6. Insert the screws into the motor end plate,
through the motor and into the adapter
body.
7. Make sure the motor is mating flush with
the adapter body. Torque screws to 36 to
45 in. lb. (4 to 5 Nm) maximum.
8. Install the start solenoid.
9. Install the hydraulic unit. See “Hydraulic
Unit” on page 7-64.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Lift Motor Electrical Components

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Model 102XM Maintenance Manual Section 7. Component Procedures

Hydraulic Components Lift Motor

Hydraulic Components

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Section 7. Component Procedures Model 102XM Maintenance Manual

Hydraulic Components Hydraulic Components

Hydraulic Components
NOTE: For replacement parts information refer
to the Parts Manual.

General Guidelines
To prolong the life of your Raymond pallet
truck, follow these guidelines:
• Keep all fittings and connections tight to
prevent leaks. Use care when tightening
fittings. Over-tightening can cause
damage or distortion.
• Before you remove any component from
the hydraulic system, wash the
component and surrounding area with
cleaning solvent to prevent foreign matter
from entering the system. Cap and plug all
openings immediately.
• Whenever you remove a fitting with a pipe
thread, use a sealing compound on the
outside of the threads before you reinstall
the fitting. (Do not use Teflon® tape.) Make
sure all parts are clean.
• When you install a hose assembly, make
sure it is not twisted when the fittings are
tightened. Always use two wrenches on a
swivel-type fitting—one to hold the fitting
and the other to tighten the hose.
• Keep the hose clamps tight to prevent the
hoses from chafing and to avoid leaks.
• Route hoses so they do not rub on sharp
edges.
• Thoroughly clean up any spilled hydraulic
fluid.
• Store and handle hydraulic fluid with care
to prevent moisture and foreign matter
from entering the hydraulic system.
• Contaminated hydraulic fluid is a major
cause of hydraulic system failures. Keep
any service equipment, such as
containers, funnels, and hand pumps,
clean at all times. Cover them when not in
use.
• Dispose of waste fluid correctly.
• Do not overtighten cable ties used to
secure hoses. Hoses expand when in use.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Hydraulic Components Hydraulic Fluid

Hydraulic Fluid Figure 7-57. Hydraulic Connections

6349-027.jpg

Lift Cylinder
Hose
Hydraulic Fluid Level Check
NOTE: Always check the hydraulic fluid level
with the forks fully lowered and when
the hydraulic fluid is cold.

To prevent air from entering the lines:

1. Verify that the fluid level (with the forks
fully lowered) is filled and visible to within
1 in. (25.4 mm) below the fill port elbow.
See Figure 7-61. The usable reservoir
capacity is 0.8 qt. (0.75 liters).
2. Add the specified fluid if necessary. See
“Lubrication Equivalency Chart” on 5. Insert the hose in a waste fluid container.
page A-2.

Changing Hydraulic Fluid

Fluid is under pressure and may spray
NOTE: Store and handle the hydraulic fluid or splash. Point the hose away from
with extreme care to prevent moisture your body and hold firmly in a waste
and foreign matter from entering the fluid container.
hydraulic system.
NOTE: Contaminated hydraulic fluid is the 6. Connect the battery connector and press
major cause of hydraulic system the green ON ( | ) key on the keypad.
failures. Keep any service equipment, 7. Run the hydraulic pump by pressing the
such as containers, funnels, and hand lift button until all the hydraulic fluid is
pumps, clean at all times. Cover them pumped from the system.
when not in use. 8. Press the red OFF ( O ) key on the keypad.
1. Lower the forks. Disconnect the battery connector.
2. Press the red OFF ( O ) key on the keypad. 9. Reconnect the lift cylinder hose.
Disconnect the battery connector. 10. Remove the vent plug and fill the reservoir
3. Remove the upper tractor cover. to within 1 in. (25.4 mm) below the filler
port elbow with the recommended
4. Disconnect the lift cylinder hose at the
hydraulic fluid. See “Lubrication
hydraulic cylinder. See Figure 7-57.
Equivalency Chart” on page A-2.
11. Replace the vent plug.
12. Connect the battery connector and press
the green ON ( | ) key on the keypad.
13. Raise and lower the forks several times to
purge air from the system.
14. Return the forks to the lowest position and
do a check of the fluid level. Add fluid if
necessary.
15. Install the upper tractor cover.
16. Dispose of the waste fluid correctly.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Hydraulic Unit Hydraulic Components

Hydraulic Unit 4. Remove and cap the hydraulic line from

the hydraulic unit. Disconnect the
solenoid control wires.
Draining and cleaning the hydraulic reservoir is
5. Remove the bolts that attach the hydraulic
important to control the accumulation of
unit mounting bracket to the tractor
condensation and contamination that could
frame.
damage the hydraulic system.
6. Remove the hydraulic unit from the truck.
Condensation is caused by the repeated heating
and cooling of hydraulic fluid during normal Hydraulic Unit Installation
operation. Contaminants include dirt, rust,
scaling, and products of fluid deterioration. 1. Install the hydraulic unit on the tractor
frame and attach with the previously
removed screws.
Hydraulic Unit Removal
2. Install the hydraulic line on the hydraulic
Remove the hydraulic unit from the truck in unit.
order to separate the pump from the motor. 3. Fill the reservoir with the specified
1. Lower the forks completely. hydraulic fluid. See “Lubrication
Equivalency Chart” on page A-2. Use a
2. Press the red OFF ( O ) key on the keypad. funnel with a flexible neck. Fill the
Disconnect the battery connector. Remove reservoir to within 1 in. (25.4 mm) below
the tractor cover. the filler plug elbow. Use up to 0.8 qt.
3. Remove and tag all wires and cables (0.75 liters). See Figure 7-58.
connected to the pump motor. See 4. Install the vent plug. See Figure 7-58.
Figure 7-58.
5. Connect all wires and cables to the pump
Figure 7-58. Hydraulic Unit
6349-021.jpg
motor switch and hydraulic solenoid.
6. Connect the battery connector and press
Pump Motor
the green ON ( | ) key on the keypad.
7. Raise and lower the forks. Check all hoses
and fittings for leaks.
Lift Motor
Solenoid 8. Lower the forks.
9. Check the hydraulic fluid level in the
reservoir.
Adapter Body
(Pump)

Hydraulic
Solenoid

Fill/Vent
Plug

Hydraulic
Reservoir

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Model 102XM Maintenance Manual Section 7. Component Procedures

Hydraulic Components Hydraulic Reservoir

Hydraulic Reservoir
Reservoir Removal
1. Remove the hydraulic unit from the truck.
See “Hydraulic Unit Removal” on
page 7-64.
2. Remove the hose clamp that secures the
hydraulic reservoir to the adapter housing.
3. Tap the reservoir lightly to loosen. Wiggle
the reservoir sideways while pulling up on
the pump and motor at the same time to
remove.
4. Remove the reservoir and correctly dispose
of the old hydraulic fluid.
5. After the fluid has drained, flush the
inside of the reservoir with a suitable
cleaning solvent.
6. Dry the inside of the reservoir with clean,
dry compressed air.

Reservoir Installation
1. Inspect the reservoir O-ring and the inside
leading edge for burrs. Replace if
necessary.
2. Lubricate the O-ring (with applicable
hydraulic fluid) and install the O-ring.
3. Carefully install the reservoir on the
adapter housing and attach with a hose
clamp. Torque the hose clamp to 49 to
60 in. lb. (5.5 to 7 Nm).
4. Install the hydraulic unit in the truck. See
“Hydraulic Unit Installation” on page 7-64.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Filter Screen and Inlet Tube Hydraulic Components

Filter Screen and Inlet

Tube
Filter Screen and Inlet Tube Removal
1. Remove the reservoir. See “Reservoir
Removal” on page 7-65.
2. With the pump assembly inverted,
unthread and remove the inlet tube fitting
and sealing washer from the pump
housing.
3. Clean the filter screen and magnet at the
bottom of the inlet tube with a suitable
solvent. See Figure 7-59.
4. From the pump side, blow dry with clean,
dry compressed air.
Figure 7-59. Cleaning Filter Screen
3713_006.tif

Filter
Screen

Inlet
Tube

Filter Screen and Inlet Tube

Installation
1. Inspect the filter screen, magnet, and inlet
tube for damage. Replace if necessary.
2. Install the inlet tube sealing washer and
fitting in the pump housing. Torque to 245
to 275 in. lbs. (27 to 31 Nm).
3. Install the hydraulic reservoir. See
“Reservoir Installation” on page 7-65.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Hydraulic Components Hydraulic Pump

Hydraulic Pump
NOTE: For replacement parts information refer
to the Parts Manual.

Hydraulic Pump Removal

1. Remove the hydraulic unit from the truck
and put on a clean bench for disassembly.
See “Hydraulic Unit” on page 7-64.
2. Remove the reservoir to gain access to the
pump. See “Reservoir Removal” on
page 7-65.
3. Remove the inlet tube with the filter screen
from the pump housing.
4. Remove the two pump mounting bolts
then remove the pump from the adapter
body.

Hydraulic Pump Installation

1. Stand the motor assembly on end, with
the adapter body facing up.
2. Lubricate the O-ring with applicable
hydraulic fluid and install on the adapter
body facing up.
3. Insert the pump drive coupling on the end
of the motor armature shaft and fill the
cavity with lubricant (P/N 990-638).
4. Align the splines on the motor drive and
pump shaft. Gently push the pump pilot
on the adapter.
5. Secure the pump with the two pump
mounting bolts and torque to 40 to
45 in. lb. (4.5 to 5 Nm).
6. Check the inlet screen for clogging. Clean
with a suitable solvent. Install the inlet
tube fitting into the pump. Torque fitting
to 245 to 275 in. lb. (27 to 31 Nm).
7. Install the reservoir. See “Reservoir
Installation” on page 7-65.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Hydraulic Pump Pressure Relief Valve Adjustment Hydraulic Components

Hydraulic Pump 3. Press the green ON ( | ) key on the keypad.

Leave the control handle in the neutral
Pressure Relief Valve (vertical) position.
4. Press the lift button and observe the
Adjustment indicator on the pressure gauge. When the
forks reach the upper lift-limit, the pump
The hydraulic system is protected by a relief makes a high pitched squeal indicating
valve installed in the adapter body. The relief that the relief valve is opening.
valve is set by the manufacturer to open at a
specified pressure. Relief Valve Setting Adjustment
Relief Valve Settings If the relief valve opens at a lower or higher
pressure than the specified pressure, adjust the
Table 7-4. Truck Pressure Levels relief valve as follows:
Pressure Settings 1. Remove the hex cap covering the relief
Truck Capacity valve adjustment screw.
PSI kPa
2. As you depress the lift button, turn the
4,500 lb. (2,041 kg) 3,000 20,684 adjusting screw inward to increase the
pressure setting or outward to decrease
the pressure setting.
Relief Valve Setting Check
3. Check the indicator on the pressure
1. Attach a jumper wire across the terminals gauge. After the relief valve is correctly set,
of the lift-limit switch so the switch does release the lift button.
not shut the pump down when the forks 4. Reinstall the hex cap. Torque to 144 to
reach their upper limit. 180 in. lb. (16 to 20 Nm).
2. Retract the lift cylinder completely. Press 5. Recheck the relief valve setting.
the red OFF ( O ) key on the keypad.
Remove the 90° elbow. Replace the elbow 6. Lower the forks completely. Press the red
with a female run tee with a 1/8 in. NPT OFF ( O ) key on the keypad.
0 to 3,500 psi (0 to 24131 kPa) pressure 7. Remove the pressure gauge. Replace the
gauge. See Figure 7-60. elbow.
Figure 7-60. Checking Relief Valve Pressure 8. Press the green ON ( | ) key on the keypad.
Hydmtrpm.tif
Raise the forks. Inspect all hoses and
fittings for leaks.
9. Adjust the lift-limit switch to shut down
the pump when the forks reach their
upper limit. See “Lift-Limit Switch” on
page 7-53.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Hydraulic Components Hydraulic Cylinder

Hydraulic Cylinder Figure 7-61. Hydraulic Cylinder (shown extended)

6349-006.jpg

Slight fluid leakage indicates that the seal is

becoming worn. Replace the seal, wiper, and
retaining ring (Seal Kit P/N 939-028) when fluid
leakage becomes excessive.

Cylinder Removal
1. Remove the tractor cover.
2. Press the green ON ( | ) key on the keypad.
Leave the control handle in the neutral
(vertical) position. Hydraulic
Cylinder
3. Press the lift button, raise the forks to
maximum height and block them.

5. Press the red OFF ( O ) key on the keypad.

Use extreme care whenever the truck is Disconnect the battery connector.
jacked up. Keep hands and feet clear
from the vehicle while jacking the truck.
After the truck is jacked, put solid blocks
beneath it to hold it. Do not rely on the
jack alone to hold the truck. For details, Hot oil under pressure is present. Make
see “Jacking Safety” on page 2-9. sure the truck is safely blocked and the
pressure is released.
4. Lower the forks on the blocking to release
the pressure on the hydraulic cylinder. 6. Thoroughly clean the outside of the
Manually press down on the cylinder after cylinder before removing the hydraulic
the forks come to rest on the blocking to hose. Remove the hose from the cylinder.
disengage the cylinder from the tractor Cap and plug the fittings. See Figure 7-62.
frame. See Figure 7-61. Figure 7-62. Removing Hydraulic Line from Cylinder
6349-011.jpg

Hydraulic
Line

NOTE: Catch the hydraulic fluid under the

hydraulic cylinder in a suitable
container.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Hydraulic Cylinder Hydraulic Components

7. Remove the hardware (bolt from one side Cylinder Inspection

and the flange nut and washer from the
other side) securing the cylinder retainer 1. Thoroughly clean all parts and remove all
and the retainer spring to the tractor nicks and burrs with emery cloth.
frame. 2. Inspect the inside surface of the barrel
8. Lift the cylinder up and out of the tractor assembly for excessive wear or scoring.
frame. Some spillage of hydraulic oil may 3. Inspect the outside surface of the rod for
occur. nicks, scratches, or scoring.

Cylinder Disassembly Cylinder Assembly

1. Thoroughly clean the outside of the 1. Make sure all parts are cleaned and dried
cylinder. thoroughly. Lightly oil all metal parts
2. Pull the rod out until the end of the rod before reassembly.
and the retaining ring are visible through 2. Install a new seal in the barrel. Install a
the inlet port. See Figure 7-63. new wiper in the barrel with the lips facing
3. Insert a screwdriver into the inlet port and inward.
slide the retaining ring into the deep 3. Install a new retaining ring in the deep
groove in the piston rod assembly. groove of the piston rod end.
4. Remove the rod assembly from the barrel. 4. Oil the outside of the piston rod and
5. Remove the retaining ring from the piston carefully insert the rod into the barrel.
rod. 5. Push the rod into the barrel until the
6. Remove the wiper and seal from inside the retaining ring is seen through the inlet
barrel assembly. port.
Figure 7-63. Hydraulic Cylinder Disassembly 6. Insert a screwdriver into the inlet port and
6350-010.cgm slide the retaining ring into the lock
position.
Barrel 7. Extend the rod to the full out position to
make sure the retaining ring is locked in
place.

Rod Cylinder Installation

Wiper 1. Place the new cylinder into position in the
Seal tractor frame.
Retaining Ring NOTE: To prevent air from filling the cylinder,
Inlet Port install the cylinder with the rod
retracted.
2. Install the hardware (bolt on one side and
the flange nut and washer on the other
side) to secure the cylinder retainer and
the retainer spring to the tractor frame.
3. Connect the hydraulic hose.
4. Reconnect the battery connector and press
the green ON ( | ) key on the keypad.
5. Press the lift button to extend the cylinder.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Hydraulic Components Hydraulic Cylinder

6. Check the hydraulic reservoir fluid level. If

necessary, add fluid. See “Lubrication
Equivalency Chart” on page A-2.
7. Remove the blocking.
8. Slowly lift the truck to make sure that the
cylinder retainer and spring do not go
“solid” on the cylinder. There must be a
little (approximately 0.5 to 2 mm) daylight
at the middle of the lift stroke. See
Figure 7-64. If there is insufficient
clearance, add washers as needed on the
bolt side between the cylinder retainer and
truck frame. Re-check the clearance.
Figure 7-64. Cylinder Retainer and Spring Clearance

9. Lift and lower the forks several times. Look

for leakage around the fittings and
cylinder seal.
10. Recheck the hydraulic reservoir fluid level.
If necessary, add fluid.
11. Install the tractor cover.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Hydraulic Solenoid Hydraulic Components

Hydraulic Solenoid 4. Connect the wires to the terminals.

5. Reconnect the battery connector and press
the green ON ( | ) key on the keypad. Test
The hydraulic solenoid activates the hydraulic
the functions of the truck.
solenoid release valve that releases pressure on
the lift cylinder, lowering the forks. See 6. Press the red OFF ( O ) key on the keypad.
Figure 7-65. Disconnect the battery connector.
Figure 7-65. Hydraulic Solenoid 7. Install the tractor cover.
6349-021.jpg

Hydraulic Solenoid

Solenoid Removal
1. Make sure that the forks are fully lowered.
2. Press the red OFF ( O ) key on the keypad.
Disconnect the battery connector.
3. Remove the two wires from the terminals
on the solenoid.
4. Remove the nut holding the solenoid coil
to the solenoid valve.
5. Lift the solenoid coil off the solenoid valve
stem.
6. Remove the solenoid valve stem from the
manifold.

Solenoid Installation
1. Inspect the seat where the solenoid valve
stem seals against the manifold. The
sealing surface must be completely clean
and free from any nicks or damage.
2. Thread the solenoid valve body into the
manifold. Torque the valve body to 204 to
240 in. lbs. (23 to 27 Nm).
3. Install the solenoid coil and tighten the
nut. Torque the nut to 48 to 60 in. lbs.
(5 to 7 Nm).

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Model 102XM Maintenance Manual Section 7. Component Procedures

Mast Hydraulic Solenoid

Mast

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Section 7. Component Procedures Model 102XM Maintenance Manual

Pallet Forks and Load Wheels Mast

Pallet Forks and Load 9. Drive the axle through the load arm
casting and wheel. Align the “dimple” in
Wheels the axle with the set screw hole.
10. Install and tighten the set screw.

Load Wheels
Load Wheel Pull Rod
Load wheels are installed on each pallet fork
and are designed to support the rated load at Load wheel pull rods are installed on each fork
the forks fully raised height. and are designed to transfer the hydraulic
cylinder lifting action at the tractor end to the
load wheel fork.
Removal and Replacement
1. Lift the forks to maximum height and Removal and Replacement
block them. See “Jacking Safety” on
page 2-9. NOTE: It may be easier to work with the truck
upside down. Remove the battery before
2. Remove the axle set screw. See turning the truck over. Some oil may
Figure 7-66. leak from the hydraulic reservoir.
Figure 7-66. Removing Set Screw
6349-031.jpg
1. Extend the load wheel forks. Remove the
set screw and shaft connecting the wheel
fork to the pallet fork. See Figure 7-67.
Figure 7-67. Wheel Fork Set Screw Location (top view)
6349-030.jpg

Axle Set
Screw

Wheel Fork
Set Screw
3. Drive the axle out of the load arm casting
with a hammer and brass drift pin.
4. Push the wheel out. 2. Remove the pivot pin locking bolt and
5. If the bearings are to be reused, insert a drive the pivot pin out with a brass drift
brass drift pin into each end of the load pin.
wheel and knock the bearings out. 3. With the lower links out of the lift frame
6. Install the bearings in the new load wheel channels, the links can be separated and
with the shields facing out. the pull rod removed from the link pin.
Each link has one set screw at opposite
7. Place the new load wheel upright on a flat ends. The link can be pulled apart without
surface. Position the bearing over the load removing any other set screws.
wheel. Put a flat metal plate over the
bearing, and hammer the bearing in 4. Press new bushings in the pull rods, if
position with a plastic mallet. Make sure necessary.
the bearing is fully seated in the load 5. Reassemble the pull rods on the lower
wheel. links and press the links together so they
8. Align the wheel with the holes in the load fit in the frame channel.
arm casting.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Mast Pallet Forks and Load Wheels

6. Reinstall the pivot shaft and the retaining Figure 7-68. Lower Links
6349-029.jpg
bolt in the lower links.
7. Reconnect the pull rod to the wheel fork.
8. Place the truck upright and install the
battery. Connect the battery. Check the
reservoir fluid level. Test the operation of
the lift frame.

Carrier Frame Linkage

NOTE: For replacement parts information refer
to the Parts Manual.

The bushings on the lower links can be replaced

by removing the links from one side at a time
and pressing in new bushings.
1. Press the red OFF ( O ) key on the keypad
and disconnect the battery connector.

Use extreme care whenever the truck is

jacked up. Keep hands and feet clear
from the vehicle while jacking the truck.
After the truck is jacked, put solid blocks
beneath it to support it. DO NOT rely on
the jack alone to support the truck. For
details, see “Jacking Safety” on
page 2-9.

2. Jack and block the truck under the tractor

frame.
3. To separate the lift and carrier frames,
remove all battery connections before
removing the links.
4. Remove the upper and lower linkages and
lift the lift frame off the carrier frame. See
Figure 7-68.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Pallet Forks and Load Wheels Mast

Downstops Figure 7-70. Fork Heel Surface

The downstops control the height of the fork

heels above the floor when the truck is fully
lowered. Downstop screws contact the fork
frame arch to prevent the heels of the forks
from coming too close to the floor.

Excessive floor clearance may hinder pallet

entry and exit.
NOTE: Adjusting the downstops below the
height specified in the adjustment 0.15 in. 0.4 in.
procedure will not improve pallet entry (4 mm) (10 mm)
or exit.
NOTE: There should be 0.4 in. (10 mm) of metal
between the hole in the fork heel block
Lower Link and Pivot Block and the edge of the fork heel. The lower
Inspection links hang approximately 0.15 in.
(4 mm) below the fork heel. If the lower
It is important to inspect the lower links and links are worn even with the fork heel
the pivot block on a regular basis (see block, they must be replaced.
“Scheduled Maintenance” for recommended
intervals).
Downstop Adjustment
NOTE: It is acceptable to have slight scuff
marks at the fork heels and lower links. Adjustment of the downstops is necessary to
Any sign of metal removal indicates the accommodate drive tire and linkage wear.
downstops must be adjusted. If the Correct adjustment will help to prevent
lower links are worn even with the fork excessive wear of the lower links and lower link
heel block, they must be replaced. pivot blocks.
1. Park the truck on a smooth, level floor.
Downstop adjustment after inspection is key in
getting the maximum life from your truck. 2. Lower the forks completely.
Figure 7-69. Inspect these surfaces (truck lifted for clarity) 3. Turn the truck OFF and disconnect the
battery connector.
4. Remove the tractor covers.
5. Verify that the downstop adjustment
screws contact the fork frame arch, see
Figure 7-71. If the screws do not contact
the frame, loosen the lock nut then turn
the adjustment screw out of the pivot
frame.
NOTE: Make sure there is sufficient thread
engagement of the downstop adjustment
screw in the pivot frame when
adjustment is complete.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Mast Pallet Forks and Load Wheels

Figure 7-71. Downstop Adjustment 9. Hold the downstop screw in the correct
FIG1_023778.jpg
adjustment position with an allen wrench
Fork and firmly tighten the lock nut.
Frame
NOTE: Lock nuts that are not securely
Arch
tightened will not hold the adjustment.
10. Install the tractor covers.
11. Test the truck for correct operation.
NOTE: When downstop adjustment is
Downstop performed, it is recommended to inspect
Screw
the lower links and fork heels again in
Pivot Lock
approximately one month.
Frame Nut

6. Measure the clearance of the fork heels

from the floor. (Make sure to measure to
the fork heel, not the lower link that hangs
slightly below the fork heel.) Verify there is
a clearance of 0.6 in. (15 mm). Repeat
steps 5 and 6 until the correct
measurements are achieved.
Figure 7-72. Correct Adjustment / Clearance

0.6 in. 3.25 in.

(15 mm) (82.5 mm)

NOTE: The top of the forks should be 3.25 in.

(82.5 mm) from the floor when the
downstops are correctly adjusted.
7. Reconnect the battery connector and press
the green ON ( | ) key on the keypad.
8. Press the lift button to lift the fork frame.

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Section 7. Component Procedures Model 102XM Maintenance Manual

Pallet Forks and Load Wheels Mast

Skid Shoe Blocks 7. Worn skid blocks can be rotated 90

degrees for additional life.
Some trucks are supplied with skid shoe blocks Figure 7-74. Skid Blocks Reversed to Restore Clearance
to provide clearance from the floor to the
bottom of the truck. If your truck is equipped
with skid shoe blocks, they must be inspected
for wear and adjusted to prevent wear of
undercarriage components.

Skid Shoe Adjustment Raised Standard Lowered

1. Lower the forks completely. Position Position Position

2. Press the red OFF ( O ) key on the keypad.

Disconnect the battery connector. NOTE: The worn portion is shown irregular for
3. Jack and block the truck under the tractor illustration purposes only. Typically, a
frame. worn skid pad is nearly flat.

4. Adjust the skid blocks to the correct

position.
5. Apply thread-locking compound
(P/N 990-536) to the mounting bolts.
6. Torque the nut to 48 to 60 in. lbs.
(5 to 7 Nm).
Figure 7-73. Skid Blocks Installed

Raised Standard Lowered

Position Position Position

NOTE: The skid pad must be rotated 90 degrees

from standard to adjust to the raised or
lowered position.

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Model 102XM Maintenance Manual Section 7. Component Procedures

Options Pallet Forks and Load Wheels

Options

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Section 7. Component Procedures Model 102XM Maintenance Manual

Cold Storage Conditioning Options

Cold Storage Cold Storage Hydraulic Fluid

Conditioning When changing from any other type of cold

storage hydraulic fluid to fluid P/N 1017238:
New Raymond Walkie Pallet Trucks supplied 1. Drain the reservoir completely.
with a standard conditioning package are 2. Fill the reservoir with fluid.
designed to operate in an environment where
3. Install decal P/N 1074515 on the
temperatures range from 32° to 104°F (0° to
hydraulic unit.
40° C) in a continuous duty cycle.

Trucks supplied with a cold storage

conditioning package are designed to operate to
the following temperatures: Mixing with other types of cold storage
• 5°F (–15° C) in a continuous duty cycle fluids can cause “gelling” of the fluid
(generally stored in freezers with short and lead to premature pump failure.
ambient temperature exposure)
• –13°F (–25° C) for in and out operation
(stored at ambient temperature with short
trips in and out of the freezer condition)
NOTE: Trucks ordered as cold storage from the
factory are shipped with cold storage
hydraulic fluid; there is no need to
replace the fluid when installing the
truck.

When a truck is to be converted for use

in a cold storage environment, change
the fluid in the hydraulic reservoir
referring to the recommendations on the
Appendix.

See “Lubrication Equivalency Chart” on

page A-2 for recommended fluids in the
hydraulic reservoir and the drive unit.

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Model 102XM Maintenance Manual Section 8. Theory of Operation

Section 8. Theory of Operation

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Section 8. Theory of Operation Model 102XM Maintenance Manual

Definitions

Definitions Click-to-Creep
Click-to-creep enables creep speed travel with
Acceleration the control arm in the fully raised or lowered
position: “0” disables the option and “1” enables
The process where the truck’s acceleration the option. The default setting is “0”.
characteristic is determined when the truck
starts from a stop. This is a driver parameter Activate click-to-creep by quickly clicking the
(Acceleration). The range is from 30% to 90% in speed control in either direction twice with the
increments of 5%. Default is 80%. A lower tiller in the brake position. “SLO” blinks on the
number gives less aggressive acceleration. display when in click-to-creep mode.

Deactivate by clicking the speed control twice

Arm Angle Switches more. Click-to-creep mode deactivates
automatically after 10 seconds or immediately if
The Arm Angle Switches (S24 and S25) the Emergency Reverse (belly button) switch is
determine brake activation and truck travel pushed.
speed. Each switch is activated by the control
handle position. The control handle must be
positioned between B1 and B2 of the operating Continuity
range to permit travel. See Figure 8-1.
Figure 8-1. Arm Angle Switches and Brake Actuation A continuous and uninterrupted path between
6299-016.EPS two or more locations in an electrical circuit,
typically having a resistance of less than 1 ohm.

Controller Area Network (CAN)

Motor controller functions performed by the
electronic circuitry (VM) and Traction Power
Amplifier (TA) are communicated in the truck
through this network.
When the control handle is in position B1, the
parking brake engages. When the control
handle is moved to position T1, the brake Creep Speed
disengages, Arm Angle B switch (S25) closes
and enables slow travel. See Table 8-1. When Creep speed defines speed at low throttle
the control handle is placed in position T2, Arm positions. Creep speed range is adjustable from
Angle A switch (S24) also closes, enabling fast –10 to 10. The factory default value is –5. A
travel. When the control handle is placed in negative number enhances low speed
position B2, Arm Angle switch B opens, maneuverability. A positive number makes the
activating the parking brake. truck more responsive.
Table 8-1. Control Handle/Switch Positions
Current Limiting
Position A Switch B Switch Function
A protective function of the traction power
B1 Open Open Top Brake
amplifier that prevents excessive current levels
T1 Open Closed Slow Speed from damaging drive components.

T2 Closed Closed Fast Speed

B2 Closed Open Bottom Brake

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Model 102XM Maintenance Manual Section 8. Theory of Operation

Definitions

Deceleration (Neutral Braking) Overvoltage Cutoff

A truck feature that provides some plugging Occurs when there is very high voltage (greater
effect when the throttle is returned to the than 34V) at the power amplifier B+ connection.
neutral position. This is a Driver parameter Code C42 or E142 may be displayed and the
(Deceleration). The range is from 40 to 90% in truck must be restarted.
increments of 5%. Default is 65%. A lower
number gives less aggressive braking. See
“Programming Truck Parameters” on page 3-7.
PIN-Key Code
Trucks produced with a standard handle
Emergency Reverse mounted keypad are protected from
unauthorized operation by Personal
Emergency reverse function is activated when Identification Number (PIN) keypad entry codes.
the brake is released, truck is ON, and the Up to 10 operators can be assigned their own
emergency reverse switch is pressed. After the individual PIN-key code (of one to four digits) for
switch is released, normal controller operation access to the truck. Each operator can also set
is not resumed until neutral (no direction) is individual driver parameters. The default
selected and until the brake is cycled (brake operator PIN-key code is number 1. See “Setting
applied, then brake released). However, Individual PIN-key Codes” on page 3-9.
repeatedly pressing the emergency reverse
switch restarts the emergency reverse function
each time.
Pulse Width Modulation
Pulse Width Modulation (PWM), also called
Fault Codes “chopping”, controls the speed of the motor by
switching the battery voltage applied to the
The VM provides fault information by displaying motor ON and OFF very quickly.
fault codes on the LED display built into the
control handle head. See the “List of Messages
and Codes” on page 6-2 for a complete list of
Regenerative Braking
Caution and Error Codes. The TA provides fault
Regenerative Braking occurs when current,
information by flashing fault codes through two
generated by the motor during plugging, is
status LED indicators built into the TA cover.
permitted to flow back into the batteries.
Regenerative braking results in less motor
High Pedal Disable (HPD) heating. Regenerative braking also provides
some return of energy to the battery pack.
The HPD feature prevents the truck from
traveling while the throttle is applied. The
system is programmed to give the HPD warning
Short Circuit or “Short”
if there is a throttle request before the key is
A short circuit is an unspecified path in a
turned ON or brake release input.
circuit that provides unwanted full or partial
continuity between two or more locations in an
Open Circuit electrical circuit.

A lack of a continuous path between two or Example 1: Two insulated wires are physically
more electrical connections; usually greater next to each other and the insulation has worn
than one megohm resistance. off each of the wires. Because the conductors
are now touching each other, there is a short
circuit.

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Section 8. Theory of Operation Model 102XM Maintenance Manual

Definitions

Example 2: A power cable from the battery to a Tractor

junction post in the truck has had the
insulation worn away. Because the wire The body section of the truck that contains the
conductors are touching the tractor frame, motors, drive unit, controls, and handle.
there is a short circuit of the battery cable.

Truck Off Delay (Keypad only)

Speed Limiting
Sets the truck OFF delay time (energy saving
The VM limits maximum speed: feature). If this time delay passes while the
• “Max speed, Slow Mode” parameter truck is in a brake position and the truck is idle
determines the maximum speed value sent (no inputs requested), the VM powers the truck
by the VM to the traction power amplifier OFF. This is a programmable Driver parameter
(max. PWM) for the two directions of travel setting that ranges from 0 to 20 minutes. When
while in Slow speed mode. This is a the parameter is set to 0, or the truck has the
programmable parameter. key switch option, the truck never powers OFF.
See “Programming Truck Parameters” on
• “Max speed, Fast Mode” parameter
page 3-7.
determines the maximum speed value sent
by the VM to the traction power amplifier
(max. PWM) for the two directions of travel Undervoltage Cutoff
while in Fast speed mode. This is a
programmable parameter. Undervoltage protection automatically occurs
when there is very low voltage (less than 13V) at
Static Return to Off (SRO) the traction power amplifier B+ connection.
Code C41 is displayed and the truck must be
restarted.
The SRO feature prevents starting the truck
(direction selected) prior to the release of the
brake. SRO examines sequencing of the brake Vehicle Manager
(deadman) switch input and key switch input
relative to the direction input. The switch must Programmable motor control functions are
be activated before the directional/speed performed by the electronic circuitry (VM)
control is rotated. If a direction is selected housed within the control handle. See “Vehicle
before or simultaneously (within 50 ms) with Manager” on page 8-6.
the brake input, the TA does not command
travel.

Thermal Cutback (Traction

Power Amplifier)
Thermal cutback of the traction power amplifier
is below –13°F (–25°C) or above 185°F (85°C). At
185 to 203°F (85 to 95°C), the drive current
limit is linearly decreased from full set current
down to zero. At –13 to –40°F (–25 to –40°C), the
current limit is reduced to approx. half the set
current, resulting in reduced travel speed.
Below –40°F (–40°C) or above 203°F (95°C), the
allowed travel speed is 0%. This function sets
code C43 on the display when a thermal
cutback condition occurs. It may also be a
factor when codes C44 and C46 occur.

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Model 102XM Maintenance Manual Section 8. Theory of Operation

Truck Starting

Truck Starting
To start the truck, the battery is plugged in.
This supplies battery positive and negative to
the Traction Power Amplifier (TA) at the B– and
B+ connections. Because the main contactor
(K10) is still open, the B+ travels through the
PTC R1 to the TA. This allows the internal
capacitors of the TA to precharge. This voltage
is also used by the TA at J5-16 to power the
internal circuitry of the TA. The TA verifies the
correct voltage is at the capacitors prior to
closing the main contactor (K10). The Main
ON/OFF switch is in the ON position, the
PIN-key code is entered in the keypad, and the
green ON ( | ) key pressed (or optional key
switch is ON). The display will light.

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Section 8. Theory of Operation Model 102XM Maintenance Manual

Traction System

Traction System Direction/Speed Control

The following descriptions assume the battery is
Vehicle Manager charged and connected, and the truck is ON.

The VM is also sometimes referred to as the Control Handle Positioning

Electronic Tiller Arm Card (ETAC). The
programmable motor control functions are When the control handle is in the upright
performed by the electronic circuitry housed position, the parking brake is engaged. When
within the VM in the control handle. The basic the control handle is within 5 to 30 degrees of
functions of the VM include: the upright position, Arm Angle B Switch (S25)
• monitoring relative positioning of the closes and enables slow speed travel, the main
thumb controls to eighteen hall effect contactor closes, and the brake is allowed to
sensors for speed and direction control disengage (when travel is requested). When the
• monitoring the position of the emergency control handle is placed beyond 30 degrees
reverse button for emergency reversing of from the top, Arm Angle A Switch (S24) also
the truck direction closes, enabling fast speed operation. When the
control handle is placed in the bottom 5 degrees
• monitoring truck performance and of its operating range, Arm Angle B Switch
providing input data and commands to the opens, engaging the parking brake. When the
operator display control handle is returned to the full upright
• providing lift/lower input commands to position, the main contactor remains closed for
the power amplifier approximately 20 seconds then opens.
• monitoring horn switches S18-1 and
S18-2 for horn operation Travel Request
• monitoring and defining truck
When the thumb controls are rotated from
performance parameters
neutral:
• a forward travel signal is detected via hall
Power Amplifier effect sensors, by the Vehicle Manager
(VM). The VM determines if the request is
The basic functions of the power amplifier for forward (tractor-first) direction or
include: reverse (forks-first) direction based on
• the direction control section that controls which set of hall effect sensors are
the traction motor direction by activated.
manipulating the traction motor field • the VM verifies that the emergency reverse
polarity according to the directional inputs button is not activated.
from the VM
• the VM verifies the state of both switch
• the speed control section that controls the
S24 (Arm Angle A) and switch S25 (Arm
traction motor speed and torque by
Angle B) via a CAN message from the TA.
monitoring the position change of the Arm
Based on their position, the VM sends the
Angle A and Arm Angle B switches.
travel request via the CAN to the TA.
Variable motor speed is accomplished by
separate control of field and armature • if the main contactor (K10) is not closed,
currents. the TA supplies B– to pin J5-4, closing the
K10 contactor and the K4 MCR (Master
• the control circuit section that controls all Control Relay).
truck inputs and outputs (excluding
handle head inputs) • the TA releases the brake.

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Model 102XM Maintenance Manual Section 8. Theory of Operation

Traction System

• the TA then controls the voltage at M– for K5 are supplied B– at S20-8 and K5-1 any time
the traction motor armature and F1, F2 the battery is plugged in. K5-2 and S25 are
for the traction motor field. Voltage to the supplied with B+ from fuse F50 any time the
traction motor armature varies from battery is plugged in. To release the brake, S20
approximately 24V (0 mph) to must be closed, completing a path between
approximately 1.5V (full speed). Voltage to K5-4 and the brake coil. S20 also completes a
the traction motor field is about 7.6 volts, path between B– at S20-8 and the negative side
depending on travel direction. The TA of the brake coil. When the handle is moved
alternates the direction of current flow down and S25 closes, B+ is supplied to K5-2,
between F1 and F2 depending on travel closing the K5 relay tips. With the tips closed,
direction request. B+ is supplied from K5-4 through S20 to the
• the drive wheel starts to rotate in the positive side of the brake coil, releasing the
requested direction. During travel, the TA brake. When the control handle is moved to the
monitors armature and field current and full up position and S20 is still activated, S25
limits it as required. opens. The K5 relay also opens removing B+
from the brake coil. When this happens, the
transient voltage created from the brake coil
Emergency Reverse collapsing travels from the positive side of the
coil through S20-7 to S20-2 to the top of the
If the emergency reverse button (belly button) zener diode. The voltage created is higher than
hall effect switch is closed with the control battery voltage and reverse biases the diode,
handle lowered in travel mode (SW2 closed), the allowing flow through the diode, through S20-8
control system activates an immediate, rapid and S20-4 to the negative side of the brake coil,
acceleration in the reverse (forks-first) direction. allowing the voltage to dissipate.
The following occurs:
• the emergency reverse travel instruction is
transmitted through the CAN-bus to the
TA
• travel and speed inputs to the TA are
ignored
• the TA provides maximum torque inputs
to the TM immediately after the emergency
reverse button is activated
• travel in reverse (forks-first) direction
continues until the emergency reverse
button is released

When the emergency reverse mode is activated,

the TA ceases to respond to the normal travel
command from the directional/speed control.
To reset the truck for normal travel, return the
directional/speed control to the neutral
position and cycle the brake ON/OFF.

Electric Brake Release Switch

If the Master Control Relay (K4) cannot be

closed by the TA, an option for releasing the
brake is available. A manually activated Electric
Brake Release Switch (S20) and Electric Brake
Release Relay (K5) have been added. S20 and

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Section 8. Theory of Operation Model 102XM Maintenance Manual

Lift/Lower System

Lift/Lower System • Once maximum lift is reached, the

lift-limit switch (S36) opens, removing B+
from pin J5-15. Loss of the B+ voltage tells
The lift/lower system consists of an electrically the TA to remove the B– voltage supplied
operated hydraulic pump assembly and related to the lift contactor (K30).
components.
When the lift button is released:
The hydraulic pump assembly consists of a
• The pump contactor coil (K30) is
positive displacement rotary gear pump with
de-energized. This stops the lift motor and
reservoir mounted to an adapter. A DC electric
pump. The forks are held in position by
motor is mounted to the opposite side of the
hydraulic fluid trapped in the cylinder by
pump adapter. An adjustable relief valve, check
the check valve and the closed load
valve, and a solenoid operated load holding
holding solenoid valve (Y10).
valve are installed within the adapter.

With the forks elevated, the normally closed Lower

solenoid valve and the check valve prevent
hydraulic fluid from returning to the reservoir. When the battery is connected, the truck is ON,
and the lower button is pressed:
Lift • A lower request is detected by the VM via
hall effect sensors. The request for lower is
When the battery is connected, the truck is ON, converted into a CAN message and sent to
and the lift button is pressed: the TA.
• A lift request is detected by the VM via hall • Load holding solenoid valve (Y10) opens.
effect sensors. The VM checks the status • Hydraulic fluid in the lift cylinder returns
of the lift-limit switch (S36) to make sure it to the hydraulic reservoir through the load
is open. The VM also checks the battery holding valve and the flow control valve.
state-of-charge to verify lift is still allowed. The lowering speed is regulated by the flow
The request for lift is then converted into a control valve.
CAN message and sent to the Traction
• The forks lower.
Power Amplifier.
• The TA checks the state of the Main
Contactor (K10) and closes it if required.
• The TA supplies B– to the lift pump
contactor (K30) and it closes, applying B+
to the lift pump motor (M3).
• Hydraulic fluid is drawn into the lift pump.
• As the pump rotates, oil is forced out the
pressure port through the lift hose to the
lift cylinder. Oil cannot return to the
reservoir because of the closed check valve
and closed load holding solenoid valve.
• Hydraulic pressure in the lift cylinder lifts
the forks.
• The relief valve opens if the hydraulic
pressure exceeds the preset limit while
lifting.

8-8 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section A. Appendix

Section A. Appendix

Publication: 1010183, Issued: 20 Mar 2014 A-1

Section A. Appendix Model 102XM Maintenance Manual

Lubrication Equivalency Chart

Lubrication Equivalency Chart

Approved Raymond Lubricants

Where Used Type Specification Raymond Part Number

Drive Unit Gear Case (all Gear 75W - 90 Synthetic Gear Oil 990-655/001
applications) Lubricant API Service Classification (1 quart/0.9 liter)
GL-5 990-655/003
(1 gal./3.8 liters)

Hydraulic Reservoir Hydraulic ISO 46 990-616/04

(non-cold storage trucks) Fluid (1 quart/0.9 liter)
(+35 to +120°F) 990-616/01
(+1.6 to +48.8°C) (1 gal./3.785 liters)
990-616/03
(5 gal./18.9 liters)

Hydraulic Reservoir Hydraulic ISO 32 1017238/02

(–20 to +70°F) Fluid (1 gal./3.785 liters)
(–29 to +21°C) 1017238
(5 gal./18.9 liters)

Hydraulic Reservoir Hydraulic 10W-30 Motor Oil 990-603/04

(for high performance/ high Fluid API Service CE,CD,CC,SG,SF (1 quart/0.9 liter)
temperature applications) (12/ case)
990-603/03
(5 gal./18.9 liters)

Hydraulic Reservoir Hydraulic ISO VG32 1017238

(Cold Storage) * Fluid
(–0 to +50°F)
(–18 to +10°C)

Bearings and so forth Grease NLGI Grade 2 1012992/01

(10 cartridges per case)
1012992/02
(5 gal./18.9 liters)

Bearings and so forth Grease NLGI 2 990-652/001 (Spray)

(Cold Storage) with Teflon 990-652/002 (Cartridge)

NOTE: * Do not mix with any other type of

hydraulic fluid. Install decal
(P/N 1074515) on hydraulic unit.

A-2 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section A. Appendix

Thread Adhesives, Sealants, and Lubricants

Thread Adhesives, Sealants, and Lubricants

Table A-1. Thread Adhesives, Sealants, and Lubricants

Application Raymond P/N Loctite* Number/Color

Thread-locking 1/4 in. and below, 10 ml 990-403/01 222/Purple

Thread-locking 1/4 in. and below, 50 ml 990-403/02 222/Purple

Thread-locking 1/4 to 3/4 in. 990-536 242/Blue

Thread-locking 1/4 to 3/4 in. contamination tolerant 990-462 243/Blue

Thread-locking 1 in. and under 990-544 271/Red

Thread-locking 1 in. and under, contamination tolerant, 10 ml 990-463/01 603/Green

Thread-locking 1 in. and under, contamination tolerant, 50 ml 990-463/02 603/Green

Thread-locking 1 in. and over 990-571 277/Red

Primerless Thread-locking compound, 250 ml 990-669/01 2760

Primerless Thread-locking compound, 10 ml 990-669/02 2760

Thread-locking compound, solid 1056414 268/Red

Thread-locking Primer 990-538 707

Thread-locking Primer 990-533 T7471

990-666 7649 (19269)

1147803 7090

Thread-locking 1 1/2 in. and below, 0.02 oz. 1013829/01 2440

Thread-locking 1 1/2 in. and below, 10 ml 1013829/02 2440

Thread-locking 1 1/2 in. and below, 50 ml 1013829/03 2440

Gasket Sealant 990-411 51813

Hydraulic Sealant, 50 ml 990-552/01 569

Hydraulic Sealant, 250 ml 990-552/02 569

RTV Silicone Sealant 990-659 5900/Black

Other Manufacturer
designation

Molybdenum Anti-Seize Compound (Molykote) 990-638 /Silver

Corrosion Inhibitor Coating 990-644

Cold Storage silicone sealing compound 990-445

Alcohol-based cleaner 990-600/FOF

NOTE: *Loctite is a registered trademark of the Loctite Corporation. Brand endorsement is not
implied here, but listed only as a commonly identified product.

Publication: 1010183, Issued: 20 Mar 2014 A-3

Section A. Appendix Model 102XM Maintenance Manual

Component Specific Service/Torque Chart

Component Specific
Service/Torque Chart
Table A-2. Component Specific Service/Torque Chart

Thread-Locking Torque to:

Component Sub-Component(s)
Compound P/N /Notes

Brake air gap 0.008 in. (0.2 mm)

minimum

Brake friction disc 0.20 in. (5.5 mm)

minimum thickness

Brake mounting bolts (3) 50 in. lb. (5.6 Nm)

Drive Wheel mounting nuts (5) 55 ft. lbs. (75 Nm)

Hydraulic Reservoir screws mounting reservoir 49 to 60 in. lbs.

to adaptor housing (5.5 to 7 Nm)

Lift Motor end plate to adapter body 36 to 45 in. lb.

screws (4 to 7 Nm)

Lift Motor solenoid mounting screws 60 to 69 in. lb.

(6.8 to 7.9 Nm)

Lift Motor motor cable securing nut torque varies by 60 to 84 in. lb.
size (6.8 to 9.5 Nm)

Lift Pump bolts mounting pump to 40 to 45 in. lb.

adaptor body (2) (4.5 to 5 Nm)

Lift Pump inlet tube fitting to pump 245 to 275 in. lb.
housing (27 to 31 Nm)

Lower Solenoid Valve Body mounting into manifold 204 to 240 in. lb.
(23 to 27 Nm)

Nut on Solenoid Coil 48 to 60 in. lb.

(5 to 7 Nm)

Relief Valve Adjustment screw hex 144 to 180 in. lb.

cap (16 to 20 Nm)

Traction Power Amplifier terminals 12 ft. lb. (16.3 Nm)

Traction Motor cable terminal nuts torque varies by 100 to 120 in. lbs.
size (11.2 to 13.6 Nm)

Traction Motor cable securing nuts torque varies by 17.6 ft. lbs. (24 Nm)
size

Skid Bar to Bracket thread-locking 11.8 to 14 ft. lb.

compound (16 to 19 Nm)
P/N 990-536

A-4 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section A. Appendix

Component Specific Service/Torque Chart

Thread-Locking Torque to:

Component Sub-Component(s)
Compound P/N /Notes

Skid Bar Bracket to Bumper thread-locking 13.3 to 15.5 ft. lb.

compound (18 to 21 Nm)
P/N 990-536

Optional Caster to Bumper thread-locking 13.3 to 15.5 ft. lb.

compound (18 to 21 Nm)
P/N 990-536

Bumper to Truck thread-locking 18 to 24 ft. lb.

compound (24.4 to 32.5 Nm)
P/N 990-536

Publication: 1010183, Issued: 20 Mar 2014 A-5

Section A. Appendix Model 102XM Maintenance Manual

Torque Chart - Standard (Ferrous)

Torque Chart - Standard (Ferrous)

Table A-3. Torque Chart - Standard

Ferrous Bolts
(The grade rating is stamped on the head of the bolt.)

Grade
None
Marking

SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 7 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque Tightening Torque
Size Dry** Oiled* Dry** Oiled* Dry** Oiled* Dry** Oiled*
(in. (in. (in. (in. (in. (in. (in. (in.
(Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm)
lbs.) lbs.) lbs.) lbs.) lbs.) lbs.) lbs.) lbs.)
4-40 5 0.56 4 0.45 8 0.9 6 0.68 11 1.5 8 0.9 12 1.4 9 1.0
4-48 6 0.68 5 0.56 9 1.0 7 0.8 12 1.4 9 1.0 13 1.5 10 1.1
6-32 10 1.1 8 0.9 16 1.8 12 1.4 20 2.2 15 1.7 23 2.6 17 1.9
6-40 12 1.4 9 1.0 18 2.0 13 1.5 22 2.5 17 1.9 25 2.8 19 2.1
8-32 19 2.1 14 1.6 29 3.3 22 2.5 36 4.1 27 3.0 41 4.6 31 3.5
8-36 20 2.2 15 1.7 31 3.5 23 2.6 38 4.3 29 3.3 44 5.0 33 3.7
10-24 27 3.0 21 2.4 42 4.8 32 3.6 52 5.9 39 4.4 60 6.8 45 5.1
10-32 31 3.5 24 2.7 48 5.4 36 4.1 60 6.8 45 5.1 68 7.7 51 5.8
1/4-20 66 7.5 49 5.5 100 11.3 76 8.6 125 14.1 94 10.6 143 16.2 107 12.1
1/4-28 75 8.5 56 6.3 120 13.6 87 9.8 143 16.2 107 12.1 164 18.5 123 13.9
(ft. (ft. (ft. (ft. (ft. (ft. (ft. (ft.
(Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm)
lbs.) lbs.) lbs.) lbs.) lbs.) lbs.) lbs.) lbs.)
5/16-18 11 15.1 8 10.9 17 23.0 13 18 21 29 16 22 25 34 18 24
5/16-24 12 16.3 9 12.2 19 26 14 19 24 33 18 24 25 34 20 27
3/8-16 20 27 15 20 30 41 23 31 40 54 30 41 45 61 35 47
3/8-24 23 31 17 23 35 47 25 34 45 61 30 41 50 68 35 47
7/16-14 32 43 24 33 50 68 35 47 60 81 45 61 70 95 55 75
7/16-20 35 47 25 34 55 75 40 54 70 95 50 68 80 109 60 81
1/2-13 50 68 35 47 75 102 55 75 95 129 70 95 110 150 80 109
1/2-20 55 75 40 54 85 115 65 88 105 143 80 109 120 163 90 122
9/16-12 70 95 50 68 110 150 80 109 135 183 100 136 150 203 110 150
9/16-18 80 109 60 81 120 163 90 122 150 203 110 150 170 231 130 177
5/8-11 95 129 70 95 150 203 110 150 190 258 140 190 220 298 170 231
5/8-18 110 150 85 115 170 231 130 177 210 285 160 217 240 326 180 244
3/4-10 170 231 130 177 260 353 200 272 330 448 240 326 380 515 280 381
3/4-16 190 258 140 190 300 407 220 298 370 502 280 381 420 569 320 434
7/8-9 170 231 125 169 430 583 320 434 530 719 400 544 600 813 460 624
7/8-14 185 252 140 190 470 637 350 475 580 786 440 598 660 895 500 680
1-8 250 339 190 258 650 881 480 651 800 1085 600 813 900 1224 680 925
1-12 275 373 205 278 700 949 520 705 860 1166 660 895 1000 1360 740 1003
1 1/8-7 350 475 270 366 800 1085 600 813 1120 1519 840 1139 1280 1136 960 1302
1 1/8-12 400 544 300 407 880 1193 660 895 1260 1708 940 1274 1440 1952 1080 1464
1 1/4-7 500 680 375 509 1120 1523 840 1139 1580 2142 1200 1627 1820 2468 1360 1884
1 1/4-12 550 746 420 569 1240 1681 920 1247 1760 2386 1320 1790 2000 2720 1500 2034
1 3/8-6 650 881 490 664 1460 1980 1100 1491 2080 2820 1560 2115 2380 3227 1780 2413
1 3/8-12 750 1017 560 759 1680 2278 1260 1708 2380 3227 1780 2413 2720 3688 2040 2766
1 1/2-6 870 1180 650 881 1940 2630 1460 1980 2780 3769 2080 2820 3160 4298 2360 3200
1 1/2-12 980 1329 730 990 2200 2983 1640 2224 3100 4203 2340 3173 3560 4857 2660 3606
NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.
NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

A-6 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section A. Appendix

Torque Chart - Standard (Brass)

Torque Chart - Standard

(Brass)
Table A-4. Torque Chart - Standard Brass

Brass MS63 Standard Bolts, Coarse Thread

Torque (with bolts oiled*)
Size
Inch pounds Newton meters
0-80 0.5 0.05
1-64 0.9 0.10
1-72 1.0 0.11
2-56 1.5 0.17
2-64 1.6 0.18
3-48 2.3 0.26
3-56 2.5 0.28
4-40 3.3 0.37
4-48 3.6 0.40
5-40 4.8 0.54
5-44 5.3 0.60
6-32 6.1 0.69
6-40 6.8 0.77
8-32 11 1.24
8-36 11 1.24
10-24 14 1.58
10-32 17 1.92
12-24 23 2.59
12-28 25 2.82
1/4-20 35 3.96
1/4-28 40 4.52
5/16-18 73 8.25
5/16-24 81 9.15
3/8-16 130 14.69
3/8-24 147 16.61
NOTE: * Use “oiled” values for bolts with
thread-locking compound.

Publication: 1010183, Issued: 20 Mar 2014 A-7

Section A. Appendix Model 102XM Maintenance Manual

Torque Chart - Metric (Ferrous)

Torque Chart - Metric

(Ferrous)
Table A-5. Torque Chart - Ferrous Metric

Ferrous Metric Bolts, Coarse Thread

(The grade rating is stamped on the head of the bolt.)
Grade 4.8 Grade 8.8 Grade 10.9 Grade 12.9
Dry** Oiled* Dry** Oiled* Dry** Oiled* Dry** Oiled*
Size
(in. (in. (in. (in. (in. (in. (in. (in.
(Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm)
lbs.) lbs.) lbs.) lbs.) lbs.) lbs.) lbs.) lbs.)
M1.6-0.35 0.8 0.09 0.6 0.07 1.6 0.18 1.2 0.14 2.2 0.25 1.7 0.19 2.6 0.30 2.0 0.22
M2-0.40 1.7 0.19 1.3 0.14 3.3 0.37 2.5 0.28 4.6 0.52 3.4 0.39 5.3 0.60 4.0 0.45
M2.5-0.45 3.5 0.40 2.6 0.30 6.7 0.76 5.1 0.57 9.3 1.1 7.0 0.79 11 1.2 8.2 0.93
M3-0.5 6.2 0.70 4.7 0.53 12 1.4 9 1.0 17 1.9 12 1.4 19 2.2 15 1.7
M3.5-0.6 9.8 1.1 7.3 0.83 19 2.1 14 1.6 26 3.0 20 2.2 31 3.5 23 2.6
M4-0.7 14 1.6 11 1.5 28 3.2 21 2.4 39 4.4 29 3.3 45 5.1 34 3.8
M5-0.8 29 3.3 22 2.5 57 6.4 42 4.8 78 8.9 59 6.6 91 10.4 69 7.8
(ft. (ft. (ft. (ft. (ft. (ft. (ft. (ft.
(Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm) (Nm)
lbs.) lbs.) lbs.) lbs.) lbs.) lbs.) lbs.) lbs.)
M6-1 – – – – 8 10.9 6 8.2 11 15.1 8 11.3 13 17.6 10 13.2
M8-1.25 – – – – 19 26 15 20 27 37 20 27 31 43 24 32
M8-1 – – – – 21 29 16 22 29 39 22 30 34 6 25 34
M10-1.5 – – – – 38 52 29 39 53 72 40 54 62 85 47 63
M10-1.25 – – – – 41 56 30 41 56 76 42 57 66 90 49 67
M12-1.75 – – – – 65 88 50 68 90 122 70 95 110 150 80 109
M12-1.25 – – – – 75 102 55 75 100 136 75 102 120 163 90 122
M14-2 – – – – 105 143 80 109 150 204 110 150 175 238 130 177
M14-1.5 – – – – 115 156 85 116 160 218 120 163 190 258 140 190
M16-2 – – – – 165 224 125 170 230 313 170 231 270 367 200 272
M16-1.5 – – – – 175 238 130 177 245 333 185 252 280 381 215 292
M20-2.5 – – – – 325 442 240 326 450 612 340 462 520 707 400 544
M20-1.5 – – – – 360 490 270 367 500 680 375 510 580 789 440 598
M24-3 – – – – 560 762 420 571 780 1061 580 789 900 1224 680 925
M24-2 – – – – 610 830 460 626 850 1156 640 870 1000 1360 740 1006
M30-3.5 – – – – 1120 1523 840 1142 1550 2108 1160 1578 1800 2448 1350 1836
M30-2 – – – – 1240 1686 920 1251 1700 2312 1280 1741 2000 2720 1500 2040
M36-4 – – – – 1950 2652 1460 1986 2700 3671 2000 2720 3160 4298 2350 3196
M36-2 – – – – 2200 2992 1640 2230 3000 4080 2250 3060 3500 4760 2650 3604
NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.
NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

A-8 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section A. Appendix

Torque Chart - Metric (Brass)

Torque Chart - Metric Torque Chart -

(Brass) Thread-Forming Screws
Table A-6. Torque Chart - Brass Metric Table A-7. Torque Chart - Standard Thread-Forming
Screws
Brass MS63 Metric Bolts, Coarse Thread
Torque (with bolts oiled*) Standard Thread-Forming Screws
Diameter Torque
(in millimeters) Inch Newton
pounds meters Size Newton
Inch pounds
2 1.2 0.14 meters

2.5 2.5 0.29 4-40 10 1.1

3 4.4 0.5 5-40 16 1.8

3.5 7.0 0.79 6-32 20 2.3

4 10 1.2 8-32 36 4

5 19 2.2 10-24 51 5.76

6 34 3.9 10-32 59 6.7

8 79 9 12-24 81 9.1

10 150 17 1/4-20 123 13.9

5/16-18 253 28.6
NOTE: * Use “oiled” values for bolts with
thread-locking compound. 3/8-16 450 50.8
7/16-14 736 83.1
1/2-13 1000 113

Table A-8. Torque Chart - Metric Thread-Forming Screws

Metric Thread-Forming Screws

Torque
Diameter
(in millimeters) Newton
Inch pounds
meters
2.5 7 0.8
3 14 1.6
3.5 22 2.5
4 33 3.7
5 47 5.3
6 113 12.7
6.3 147 16.6
7 198 22.3
8 280 31.7
10 554 62.6
12 981 110.9

Publication: 1010183, Issued: 20 Mar 2014 A-9

Section A. Appendix Model 102XM Maintenance Manual

Torque Chart - Hydraulic Fittings

Torque Chart - Hydraulic

Fittings
Table A-9. Torque Chart - Hydraulic Fittings

JIC SAE Straight Thread O-Ring Steel Plugs

SAE
Thread (37° Flare Thread)
Dash Hollow Hex Head Plug HP50N Hex Head Plug P50N
Size
Size
ft. lbs. Nm ft. lbs. Nm ft. lbs. Nm

-2 5/16-24 3 ±1 4 ±1 3 ±0.5 4 ±0.6 7.5 ±0.5 10 ±0.6

-3 3/8-24 6 ±1 8 ±1 5 ±0.5 7 ±0.6 14 ±1 19 ±1

-4 7/16-20 12 ±1 16 ±1 11 ±1 15 ±1 18 ±1 24 ±1

-5 1/2-20 15 ±1 20 ±1 15 ±1 20 ±1 22 ±1 30 ±1

-6 9/16-18 21 ±1 28 ±1 18 ±1 24 ±1 27 ±2 37 ±3

-8 3/4-16 45 ±2 61 ±3 46 ±2 62 ±3 48 ±2 65 ±3

-10 7/8-14 60 ±5 81 ±7 75 ±5 102 ±7 90 ±5 122 ±7

-12 1 1/16-12 85 ±5 115 ±7 85 ±5 115 ±7 110 ±5 149 ±7

-14 1 3/16-12 105 ±5 142 ±7 130 ±6 176 ±8 145 ±6 197 ±8

-16 1 5/16-12 120 ±5 163 ±7 135 ±6 183 ±8 160 ±6 217 ±8

-20 1 5/8-12 170 ±10 230 ±14 225 ±12 305 ±16 225 ±12 305 ±16

-24 1 7/8-12 200 ±15 271 ±20 250 ±12 339 ±16 250 ±12 339 ±16

-32 2 1/2-12 270 ±20 366 ±27 325 ±15 441 ±20 325 ±15 441 ±20

A-10 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section A. Appendix

Torque Chart - Straight Thread Face Seal O-Rings

Torque Chart - Straight

Thread Face Seal
O-Rings
Table A-10. Torque Chart - Straight Thread Face Seal O-Rings

SAE Dash Tube Side

ft. lbs. Nm
Size Thread Size

-4 9/16-18 18 ±1 25

-6 11/16-18 27 ±2 40

-8 13/16-16 40 ±2 55

-10 1-14 63 ±3 80

-12 1 3/16-12 90 ±4 115

-14 1 5/16-32 95 130

-16 1 7/16-12 120 ±8 150

-20 1 11/16-12 140 ±8 190

-24 2-12 165 ±8 245

-32 2 1/2-12 360 490

Publication: 1010183, Issued: 20 Mar 2014 A-11

Section A. Appendix Model 102XM Maintenance Manual

Decimal Equivalent Chart

Decimal Equivalent Chart

Table A-11. Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 .397
1/32 .031 .03 .794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700

A-12 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Section A. Appendix

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
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

Publication: 1010183, Issued: 20 Mar 2014 A-13

Section A. Appendix Model 102XM Maintenance Manual

Standard/Metric Conversions

Standard/Metric Conversions
To Convert... Multiply, Add, or Subtract...
Area
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Distance
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Mass
Ounces to Grams Ounces x 28.35
Grams to Ounces Ounces x 0.035
Ounces to Kilograms Ounces x 0.028
Kilograms to Ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to Pounds Kilograms x 2.2
Pressure
Pounds per Square Inch (PSI) to kiloPascals PSI x 6.894
kiloPascals to Pounds per Square Inch (PSI) kiloPascals x 0.145
Speed
Miles per hour to Kilometers per hour Miles per hour x 1.609
Kilometers per hour to Miles per hour Kilometers per hour x 0.6214
Temperature
Fahrenheit to Celsius (°F minus 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) plus 32
Torque
Inch Pounds (in. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lb.) Newton Meters x 0.737
Volume
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26

A-14 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Index

Index
A Control Handle
Control Head
Acceleration . . . . . . . . . . . . . . . . . . . . . . . 8-2 Changing Horn Button/Switch . . . 7-13
Anti-Static Kit . . . . . . . . . . . . . . . . . . . . . 2-11 Changing Lift/Lower Button . . . . . 7-14
Arm Angle Switches . . . . . . . . . . . . . . . . . 7-49 Changing Push Button . . . . . . . . . 7-14
Adjustment . . . . . . . . . . . . . . . . . . . . 7-49 Disassembly . . . . . . . . . . . . . . . . . 7-13
Metal Bridge . . . . . . . . . . . . . . . . . . . 7-49 Display and Programming . . . . . . . . . . . 3-6
Plastic Bridge . . . . . . . . . . . . . . . . . . 7-50 Stem . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Reassembly . . . . . . . . . . . . . . . . . . 7-17
Removal . . . . . . . . . . . . . . . . . . . . 7-16
B Control Handle Assembly . . . . . . . . . . . . . 7-43
Conversions, Standard/Metric . . . . . . . . .A-14
Battery Cover, Tractor . . . . . . . . . . . . . . . . . . 7-8, 7-9
Adding Water . . . . . . . . . . . . . . . . . . . 7-35 Creep Speed . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Charging . . . . . . . . . . . . . . . . . . . . . . 7-34 Current Limiting . . . . . . . . . . . . . . . . . . . . . 8-2
Exterior Cleaning . . . . . . . . . . . . . . . . 7-33
Maintenance-Free . . . . . . . . . . . . . . . 7-33
D
Safety . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Specific Gravity . . . . . . . . . . . . . . . . . 7-35
Storage . . . . . . . . . . . . . . . . . . . . . . . 7-36 Decimal Equivalent Chart . . . . . . . . . . . . .A-12
Voltage Check . . . . . . . . . . . . . . . . . . 7-36 Definitions
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Acceleration . . . . . . . . . . . . . . . . . . . . . 8-2
Disc Location . . . . . . . . . . . . . . . . . . . 7-20 Arm Angle Switches . . . . . . . . . . . . . . . 8-2
Friction Disc Replacement . . . . . . . . . 7-21 CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Gap Adjustment . . . . . . . . . . . . . . . . 7-20 Click-to-Creep . . . . . . . . . . . . . . . . . . . . 8-2
Brushes Continuity . . . . . . . . . . . . . . . . . . . . . . 8-2
Inspection . . . . . . . . . . . . . . . . . . . . . 7-54 Controller Area Network . . . . . . . . . . . . 8-2
Lift Motor, Replacement . . . . . . . . . . . 7-59 Creep Speed . . . . . . . . . . . . . . . . . . . . . 8-2
Replacement . . . . . . . . . . . . . . . . . . . 7-54 Current Limiting . . . . . . . . . . . . . . . . . . 8-2
Bumper Electronic Tiller Arm Card . . . . . . . . . . . 8-4
Removal . . . . . . . . . . . . . . . . . . . . . . . 7-9 Emergency Reverse . . . . . . . . . . . . . . . . 8-3
ETAC . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Fault Codes . . . . . . . . . . . . . . . . . . . . . 8-3
C High Pedal Disable . . . . . . . . . . . . . . . . 8-3
HPD . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Cables, Power . . . . . . . . . . . . . . . . . . . . . 7-37 Open Circuit . . . . . . . . . . . . . . . . . . . . . 8-3
Carrier Frame Linkage . . . . . . . . . . . . . . 7-75 Overvoltage Cutoff . . . . . . . . . . . . . . . . 8-3
Circuit Breaker . . . . . . . . . . . . . . . . . . . . 7-42 PIN-Key Code . . . . . . . . . . . . . . . . . . . . 8-3
Inspect . . . . . . . . . . . . . . . . . . . . . . . 7-42 Pulse Width Modulation . . . . . . . . . . . . 8-3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42 PWM . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Codes Regenerative Braking . . . . . . . . . . . . . . 8-3
Caution . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Short Circuit . . . . . . . . . . . . . . . . . . . . . 8-3
Error . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Speed Limiting . . . . . . . . . . . . . . . . . . . 8-4
Cold Storage Conditioning . . . . . . . . . . . . 7-80 SRO . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Contactors . . . . . . . . . . . . . . . . . . . . . . . 7-45 Static Return to Off . . . . . . . . . . . . . . . . 8-4
Inspection . . . . . . . . . . . . . . . . . . . . . . 4-7
Repair . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Sealed, Repair . . . . . . . . . . . . . . . . . . 7-45

Publication: 1010183, Issued: 20 Mar 2014 I-1

Index Model 102XM Maintenance Manual

Thermal Cutback . . . . . . . . . . . . . . . . 8-4 G

Tractor . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Truck Off Delay . . . . . . . . . . . . . . . . . . 8-4 Grease Fittings . . . . . . . . . . . . . . . . . . . . . . 4-8
Undervoltage Cutout . . . . . . . . . . . . . . 8-4
VM . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Digital Inputs, PA . . . . . . . . . . . . . . . . . . 3-16 H
Digital Inputs, VM . . . . . . . . . . . . . . . . . . 3-17
Digital Outputs . . . . . . . . . . . . . . . . . . . . 3-16 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
Dimensions, Lift Truck . . . . . . . . . . . . . . . 3-5 Hydraulic
Display and Programming Fluid . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Error Codes . . . . . . . . . . . . . . . . . . . . . 3-6 Hydraulic Components
Hourmeter . . . . . . . . . . . . . . . . . . . . . 3-6 Cylinder
Part Numbers . . . . . . . . . . . . . . . . . . 3-14 Assembly . . . . . . . . . . . . . . . . . . . 7-70
Downstop Disassembly . . . . . . . . . . . . . . . . . 7-70
Adjustment . . . . . . . . . . . . . . . . . . . . 7-76 Inspection . . . . . . . . . . . . . . . . . . . 7-70
Drive Housing Lubrication . . . . . . . . . . . 7-29 Installation . . . . . . . . . . . . . . . . . . 7-70
Drive Unit Removal . . . . . . . . . . . . . . . . . . . . 7-69
Brake, Electromagnetic . . . . . . . . . . . 7-20 Fluid
Drive Wheel . . . . . . . . . . . . . . . . . . . . 7-23 Changing . . . . . . . . . . . . . . . . . . . 7-63
Lubrication . . . . . . . . . . . . . . . . . . . . 7-29 Level . . . . . . . . . . . . . . . . . . . . . . . 7-63
Traction Motor General Guidelines . . . . . . . . . . . . . . . 7-62
Brush Replacement . . . . . . . . . . . 7-57 Hydraulic Pump
Transmission Assembly . . . . . . . . . . . 7-25 Removal/Installation . . . . . . . . . . 7-67
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . 7-23 Hydraulic Reservoir
Installation . . . . . . . . . . . . . . . . . . 7-65
Removal . . . . . . . . . . . . . . . . . . . . 7-65
E
Hydraulic Unit
Installation . . . . . . . . . . . . . . . . . . 7-64
Electrical Symbols, List of . . . . . . . . . . . . 5-12 Relief Valve Adjustment . . . . . . . . 7-68
Electrical Troubleshooting . . . . . . . . . . . . . 5-4 Removal . . . . . . . . . . . . . . . . . . . . 7-64
Electromagnetic Brake . . . . . . . . . . . . . . 7-20 Relieve Valve
Electrostatic Discharge . . . . . . . . . . . . . . 2-11 Pressure Setting Adjustment . . . . . 7-68
Emergency Reverse . . . . . . . . . . . . . . . . . . 8-3 Pressure Setting Check . . . . . . . . . 7-68
Equivalent Chart, Decimal . . . . . . . . . . . A-12 Solenoid
Error Codes . . . . . . . . . . . . . . . . . . . . . . . 3-6 Installation . . . . . . . . . . . . . . . . . . 7-72
History . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Removal . . . . . . . . . . . . . . . . . . . . 7-72
ESD, See Electrostatic Discharge Hydraulic Troubleshooting . . . . . . . . . . . . 5-11
Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . 7-64
F
I
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . 8-3
Firmware Identification, Model . . . . . . . . . . . . . . . . . . 3-3
FlashWare . . . . . . . . . . . . . . . . . . . . . 3-35 IETM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
FlashWare Inspection
Connecting . . . . . . . . . . . . . . . . . . . . 3-35 Contactor Tip . . . . . . . . . . . . . . . . . . . . 4-7
Installing PC . . . . . . . . . . . . . . . . . . . 3-35 Lower Link . . . . . . . . . . . . . . . . . . . . . 7-76
Overview . . . . . . . . . . . . . . . . . . . . . . 3-35 Pivot Block . . . . . . . . . . . . . . . . . . . . . 7-76
Requirements . . . . . . . . . . . . . . . . . . 3-35 Switches . . . . . . . . . . . . . . . . . . . . . . . 7-48
Starting . . . . . . . . . . . . . . . . . . . . . . . 3-36 Interactive Electronic Technical Manuals . . 1-3
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Inspection . . . . . . . . . . . . . . . . . . . . . 7-41
Test . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

I-2 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Index

J O

Jacking Safety . . . . . . . . . . . . . . . . . . . . . . 2-9 Operation

Directional/Speed Control . . . . . . . . . . 8-6
K Lift/Lower . . . . . . . . . . . . . . . . . . . . . . . 8-8
Motor Controller . . . . . . . . . . . . . . . . . . 8-6
Truck Starting . . . . . . . . . . . . . . . . . . . 8-5
Key Code . . . . . . . . . . . . . . . . . . 3-6, 3-10, 8-3
Overvoltage Cutoff . . . . . . . . . . . . . . . . . . . 8-3
Key Switch
Inspection . . . . . . . . . . . . . . . . . . . . . 7-53
Key Switch (Optional) . . . . . . . . . . . . . . . 7-53 P

L Page Revision Record . . . . . . . . . . . . . . . . . . xi

Parameter Settings
Parameter 1 . . . . . . . . . . . . . . . . . . . . 3-11
Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . 7-59
Parameter 10 . . . . . . . . . . . . . . . . . . . 3-12
Lift-Limit Switch . . . . . . . . . . . . . . . . . . . 7-53
Parameter 14 . . . . . . . . . . . . . . . . . . . 3-12
Adjustment . . . . . . . . . . . . . . . . . . . . 7-53
Parameter 15 . . . . . . . . . . . . . . . . . . . 3-12
List of Electrical Symbols . . . . . . . . . . . . 5-12
Parameter 16 . . . . . . . . . . . . . . . . . . . 3-12
Load Wheels
Parameter 2 . . . . . . . . . . . . . . . . . . . . 3-11
Carrier Frame Linkage . . . . . . . . . . . . 7-75
Parameter 20 . . . . . . . . . . . . . . . . . . . 3-12
Pull Rod Removal/Replacement . . . . . 7-74
Parameter 21 . . . . . . . . . . . . . . . . . . . 3-13
Removal/Replacement . . . . . . . . . . . . 7-74
Parameter 25 . . . . . . . . . . . . . . . . . . . 3-13
Loctite®
Parameter 3 . . . . . . . . . . . . . . . . . . . . 3-11
See Thread Adhesives
Parameter 39 . . . . . . . . . . . . . . . . . . . 3-14
Lubrication Equivalency Chart . . . . . . . . . A-2
Parameter 4 . . . . . . . . . . . . . . . . . . . . 3-11
Lubrication, Drive Housing . . . . . . . . . . . 7-29
Parameter 5 . . . . . . . . . . . . . . . . . . . . 3-11
PIN-Key Code . . . . . . . . . . . . . . .3-6, 3-10, 8-3
M Power Amplifier . . . . . . . . . . . . . . . . . . . . . 8-6
Digital Outputs . . . . . . . . . . . . . . . . . . 3-16
Maintenance Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Guidelines . . . . . . . . . . . . . . . . . . . . . . 4-2 Thermal Cutback . . . . . . . . . . . . . . . . . 8-4
Maintenance Schedule Undertemperature . . . . . . . . . . . . . . . . 8-4
250 HD . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Power Cables . . . . . . . . . . . . . . . . . . . . . . 7-37
500 HD . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Product Improvement Notices Included . . . . xiii
2000 HD . . . . . . . . . . . . . . . . . . . . . . . 4-6 Programmable Maintenance Tool . . . . . . . 3-19
Manual Revision Record . . . . . . . . . . . . . . . xi Clear Fault History . . . . . . . . . . . . . . . 3-20
Master Control Relay . . . . . . . . . . . . . . . . 7-47 Modes
Model Identification . . . . . . . . . . . . . . . . . . 3-3 Faults . . . . . . . . . . . . . . . . . . . . . . 3-20
Motors Information . . . . . . . . . . . . . . . . . . 3-21
General . . . . . . . . . . . . . . . . . . . . . . . 7-54 Monitor . . . . . . . . . . . . . . . . . . . . . 3-20
Inspection . . . . . . . . . . . . . . . . . . . . . . 5-7 Programmer . . . . . . . . . . . . . . . . . 3-21
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59 Pump, Hydraulic . . . . . . . . . . . . . . . . . . . 7-67
Servicing Commutators . . . . . . . . . . . . 5-7
Traction . . . . . . . . . . . . . . . . . . . 7-54, 7-57 R

N Ramp Shape . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Relay, Master Control . . . . . . . . . . . . . . . . 7-47
Neutral Braking . . . . . . . . . . . . . . . . . . . . 8-3

Publication: 1010183, Issued: 20 Mar 2014 I-3

Index Model 102XM Maintenance Manual

S T

Safety Terminal Nuts

Battery . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Definitions . . . . . . . . . . . . . . . . . . . . . 2-2 Test
General . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Main Control Relay . . . . . . . . . . . . . . . 7-47
Jacking . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Switch . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Static . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Tests
Towing . . . . . . . . . . . . . . . . . . . . . . . 2-10 Electric Motor . . . . . . . . . . . . . . . . . . . . 5-7
Welding . . . . . . . . . . . . . . . . . . . . . . . 2-12 Grounded Motor . . . . . . . . . . . . . . . . . 5-10
Sealants, Specifications . . . . . . . . . . . . . . A-3 Open Motor Circuit . . . . . . . . . . . . . . . . 5-9
Sequencing Delay . . . . . . . . . . . . . . . . . . . 8-3 Short-Circuited Armature . . . . . . . . . . 5-10
Serial Number Short-Circuited Winding . . . . . . . . . . . 5-10
Location on Specification Plate . . . . . . 3-5 Shorts to Frame . . . . . . . . . . . . . . 5-4, 5-5
Service Bulletins Included . . . . . . . . . . . . . . xii Theory of Operation . . . . . . . . . . . . . . . . . . 8-5
Service Key . . . . . . . . . . . . 3-8, 3-9, 3-15, 3-22 Lift System . . . . . . . . . . . . . . . . . . . . . . 8-8
Service/Torque Chart, Component Specific A-4 Lower System . . . . . . . . . . . . . . . . . . . . 8-8
Shorts to Frame Test . . . . . . . . . . . . . . . . 5-4 Starting the Truck . . . . . . . . . . . . . . . . 8-5
Skid Shoe Blocks Traction System Components . . . . . . . . 8-6
Adjustment . . . . . . . . . . . . . . . . . . . . 7-78 Thread Adhesives, Specifications . . . . . . . . A-3
Software Thread-Forming Screws, Torque Chart . . . . A-9
FlashWare . . . . . . . . . . . . . . . . . . . . . 3-35 Tools, Special . . . . . . . . . . . . . . . . . . . . . . 3-18
Soldering Procedures . . . . . . . . . . . . . . . 7-40 Torque Chart . . . . . . . . . . . . . . . . . . . . . . . A-6
Solenoid, Hydraulic . . . . . . . . . . . . . . . . . 7-72 Brass, Metric . . . . . . . . . . . . . . . . . . . . A-9
Special Tools . . . . . . . . . . . . . . . . . . 3-18, 3-19 Brass, Standard . . . . . . . . . . . . . . . . . . A-7
Programmable Maintenance Tool . . . . 3-19 Component Specific . . . . . . . . . . . . . . . A-4
Service Key . . . . . . . . . . . . . . . . . . . . 3-22 Ferrous, Metric . . . . . . . . . . . . . . . A-6, A-8
Specifications, Lift Truck . . . . . . . . . . . . . 3-5 Ferrous, Standard . . . . . . . . . . . . . . . . A-6
Specifications, Vehicle . . . . . . . . . . . . . . . 3-4 Hydraulic Fittings . . . . . . . . . . . . . . . . A-10
Speed Limiting . . . . . . . . . . . . . . . . . . . . . 8-4 Standard . . . . . . . . . . . . . . . . . . . . . . . A-6
Standard/Metric Conversions . . . . . . . . . A-14 Straight Thread Face Seal O-Rings . . . A-11
Static Discharge . . . . . . . . . . . . . . . . . . . 2-11 Thread-Forming Screws, Metric . . . . . . A-9
Static Safety . . . . . . . . . . . . . . . . . . . . . . 2-11 Thread-Forming Screws, Standard . . . . A-9
Static Wrist Strap . . . . . . . . . . . . . . . . . . 2-11 Towing Safety . . . . . . . . . . . . . . . . . . . . . . 2-10
Static-Sensitive Components . . . . . . . . . . 2-11 Traction Motor
Strap, Static . . . . . . . . . . . . . . . . . . . . . . 2-11 Brush Inspection/Replacement . . . . . 7-54
Switch Adjustment . . . . . . . . . . . . . . . . . . A-4 Brush Spring Tension . . . . . . . . . . . . . 7-55
Switch Gap . . . . . . . . . . . . . . . . . . . . . . . . A-4 Commutator . . . . . . . . . . . . . . . . . . . . . 5-7
Switches Tractor Cover . . . . . . . . . . . . . . . . . . . 7-8, 7-9
Arm Angle . . . . . . . . . . . . . . . . . . . . . 7-49 Installation . . . . . . . . . . . . . . . . . . 7-8, 7-9
Arm Angle (Metal Bridge) . . . . . . . . . . 7-49 Removal . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Arm Angle (Plastic Bridge) . . . . . . . . . 7-50 Troubleshooting
General . . . . . . . . . . . . . . . . . . . . . . . 7-48 Electrical . . . . . . . . . . . . . . . . . . . . . . . 5-4
Key Switch (Optional) . . . . . . . . . . . . 7-53 Hydraulic . . . . . . . . . . . . . . . . . . . . . . 5-11
Lift-Limit . . . . . . . . . . . . . . . . . . . . . . 7-53 List of Charts/Tables . . . . . . . . . . . . . . 5-2
Main ON/OFF . . . . . . . . . . . . . . . . . . 7-48 Shorts to Frame Test . . . . . . . . . . . . . . 5-4
Test/Inspection . . . . . . . . . . . . . . . . . 7-48 Symptom Tables . . . . . . . . 5-13, 5-15, 5-19
Symptom Tables Truck Model Identification . . . . . . . . . . . . . 3-3
Electrical System . . . . . . . . . . . . . . . . 5-13 Truck Specifications . . . . . . . . . . . . . . . . . . 3-4
Lift/Lower System . . . . . . . . . . . . . . . 5-15
Travel (Forward/Reverse) System . . . 5-19

I-4 Publication: 1010183, Issued: 20 Mar 2014

Model 102XM Maintenance Manual Index

TruckCom . . . . . . . . . . . . . . . . . . . . . . . . 3-23 U
Connecting . . . . . . . . . . . . . . . . 3-23, 3-26
Diagnostics Undervoltage Cutback . . . . . . . . . . . . . . . . 8-4
Access . . . . . . . . . . . . . . . . . . . . . 3-31
Drive Controller Tab . . . . . . . . . . . 3-33
Signal Colors . . . . . . . . . . . . . . . . 3-31 V
Tiller Arm Tab . . . . . . . . . . . . . . . 3-32
Disconnecting . . . . . . . . . . . . . . . . . . 3-26 Vehicle Manager
Downloading Digital Inputs . . . . . . . . . . . . . . . . . . . 3-17
Emergency with Key . . . . . . . . . . . 3-28 Vehicle Specifications . . . . . . . . . . . . . . . . . 3-4
Emergency with Keypad . . . . . . . . 3-28
Normal with Key . . . . . . . . . . . . . 3-27 W
Normal with Keypad . . . . . . . . . . . 3-27
Software Function . . . . . . . . . . . . 3-27 Welding Safety . . . . . . . . . . . . . . . . . . . . . 2-12
General . . . . . . . . . . . . . . . . . . . . . . . 3-23 Wheels, Load . . . . . . . . . . . . . . . . . . . . . . 7-74
Icons . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Wiring Harness . . . . . . . . . . . . . . . . . . . . . 7-39
Information Window . . . . . . . . . . . . . 3-25 Inspection . . . . . . . . . . . . . . . . . . . . . . 7-39
Main Screen . . . . . . . . . . . . . . . . . . . 3-24 Wrist Strap . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Menu Bar . . . . . . . . . . . . . . . . . . . . . 3-25
Menu Functions . . . . . . . . . . . . . . . . 3-34
Delete Error Log . . . . . . . . . . . . . . 3-34
Download from File . . . . . . . . . . . 3-34
Exit . . . . . . . . . . . . . . . . . . . . . . . 3-34
Help . . . . . . . . . . . . . . . . . . . . . . . 3-34
Read Error Log . . . . . . . . . . . . . . . 3-34
Reset CAN Adapter . . . . . . . . . . . . 3-34
Reset Hour Meter . . . . . . . . . . . . . 3-34
Save to File . . . . . . . . . . . . . . . . . 3-34
Nodes . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Parameters
Changing . . . . . . . . . . . . . . . . . . . 3-29
Hour Meter Values . . . . . . . . . . . . 3-30
PIN Code Values . . . . . . . . . . . . . 3-29
Status Bar . . . . . . . . . . . . . . . . . . . . . 3-26
Tool Buttons . . . . . . . . . . . . . . . . . . . 3-25
Truck Reports . . . . . . . . . . . . . . . . . . 3-28

Publication: 1010183, Issued: 20 Mar 2014 I-5

Index Model 102XM Maintenance Manual

I-6 Publication: 1010183, Issued: 20 Mar 2014

 !1010183C!
1010183C

Printed by the Digital Print Center,

The Raymond Corporation, Greene, NY
 Schematics

Model Serial Numbers

This publication applies to the all subsequent releases of this product until
102XM 102-03-00500 and Up otherwise indicated in new editions or bulletins. Changes occur periodically
to the information in this publication.

If you need assistance with your lift truck, or to order additional copies of
this document, contact your local authorized Raymond Sales and Service
Center. To locate your local authorized Raymond Sales and Service Center,
go to www.raymondcorp.com.

Publication: 1123035B Issued: 20 Mar 2014 Use with Maintenance Manual 1010183C

©2014 The Raymond Corporation.

Model 102XM Lift Truck Schematics
Section A. Appendix

Figure 1. Electrical Schematic (Single Rocker Switch) - Sheet 1 of 3

RPIN PLT-07-R005_Page_5.tif

Publication: 1123035B, Issued: 20 Mar 2014 2

Model 102XM Lift Truck Schematics
Figure 2. Electrical Schematic (Dual Rocker Switch) - Sheet 2 of 3
D20012084_D1.svg

Publication: 1123035B, Issued: 20 Mar 2014 3

Model 102XM Lift Truck Schematics
Figure 3. Electrical Schematic - Sheet 3 of 3
D20012084_D2.svg

Publication: 1123035B, Issued: 20 Mar 2014 4

Model 102XM Lift Truck Schematics
Figure 4. Hydraulic Schematic
HYD_SCH.cgm

Motor

Check
Filter Valve

Solenoid
Pump Valve

Lift
Cylinder
Pressure
Relief Valve
(3000 PSI)

Flow Control
(1.3 GPM)
Reservoir

Publication: 1123035B, Issued: 20 Mar 2014 5